1992 Ford Bronco Transmission Model S5-42 ZF Disassembly

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Filed Under (Ford) by admin on 07-03-2011

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Disassembly NOTE: For 4×4 and F-Super Duty vehicles, skip to Step 5. 1. Attach the transmission to the Bench Mounted Holding Fixture T57L-500-B or equivalent. Place the transmission in a vertical position with the front case pointing downward. 2. Using a chisel, bend back the locking shoulder of the output flange retaining locknut (4×2 models only). 3. Attach Companion Flange Holding Tool T78P-4851-A or equivalent to the transmission output flange. 4. Loosen the hex nut that holds the output flange to the mainshaft with Thin-Walled Socket T87T-7025-AH or equivalent. Remove the flange holding tool after loosening the nut. CAUTION: Do not remove the hex nut or output flange at this time. 5. Remove 15 of the 17 8mm hex head screws that hold the front and rear cases together. Leave two screws at opposite sides of the case installed. 6. Remove any power take-off equipment installed on the transmission. 7. Remove the eight 8mm hex bolts that attach the shift tower assembly to the front case. Remove the complete gearshift lever and tower as an assembly. Rotate transmission on holding fixture so that the front case is pointing upward. 8. Remove the interlock plate and compression spring which serves as a reverse gear interlock. CAUTION: Make sure that parts do not inadvertently fall into transmission. 9. Place a drift punch against the detent bolt sealing cap. Hold the drift at an angle. Position the point of the drift punch so it is off-center on the cap. Drive the cap inward until spring pressure against its underside forces the cap out of its hole. Repeat this procedure for the other two detent bolt sealing caps in the front case. WARNING: CAP IS UNDER SPRING PRESSURE. ALWAYS WEAR PROTECTIVE EYEGLASSES WHEN PERFORMING THIS PROCEDURE TO ENSURE THAT CAP DOES NOT STRIKE EYES WHEN IT IS FORCED OUT BY SPRING PRESSURE. NOTE: Discard removed caps and replace with new sealing caps. 10. Remove the springs that are now protruding from the sealing cap holes. 11. Drive out the sealing caps for the two reverse idler shaft cap screws. Remove the reverse idler shaft cap screws. 12. If required, remove the back-up lamp switch, located above and slightly forward of the transmission nameplate. Remove the back-up lamp switch sealing ring.

2006 Ford Freestar Clockspring REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 07-03-2011

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Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the ignition switch in ON. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of this section. 2. NOTICE: Make sure the road wheels are in the straight-ahead position. Remove the steering wheel. For additional information, refer to Section 211-04. 3. Remove the 3 steering column opening cover lower screws. 4. Pull out at the top of the trim panel, releasing the clips and pivot the trim panel down and remove. 5. Remove the 2 steering column reinforcement screws. 6. Remove the lower steering column reinforcement cover. 7. Remove the tilt column handle. 8. Remove the 3 lower steering column shroud screws. 9. Remove the lower steering column shroud. 10. Remove the ignition lock cylinder. 1. Turn the ignition lock cylinder to the RUN position. 2. While pushing in on the tab, pull out on the ignition lock cylinder and remove. 11. Remove the lower instrument cluster finish panel. 12. Remove the upper steering column shroud. 13. Remove the passive anti-theft system (PATS) transceiver screw. 14. Remove the PATS transceiver. 15. If installing the same clockspring, apply 2 strips of masking tape across the clockspring to prevent accidental rotation when the clockspring is removed. 16. Remove the key-in-ignition warning switch. 17. Disconnect the clockspring electrical connectors and detach them from the bracket.

2006 Ford Explorer Transmission Fluid Refill procedure

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Filed Under (Ford) by admin on 07-03-2011

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Transmission Fluid Refill NOTICE: This procedure contains the air purge steps required to purge air from the cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. NOTICE: The vehicle should not be driven if the fluid level is low as internal failure could result. NOTICE: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTICE: The use of any other transmission fluid than specified, can result in the transmission failing to operate in a normal manner or transmission failure. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. Adding 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission is an initial fill enabling you to start the engine. The cold level range shown in the procedure allows the vehicle to be driven. The vehicle should be driven to allow the transmission fluid temperature to reach 85ºC-88ºC (185ºF-190ºF) in order to purge the air from the transmission cooling system. Fill the transmission fluid to the fill range on the fluid level indicator at the normal operating range 80ºC-85ºC (175ºF-185ºF). 1. NOTE: The transmission will need 3.3L (3.5 qt) of clean automatic transmission fluid added to the transmission as an initial fill if: the transmission has been overhauled. a new mechatronic assembly has been installed. the transmission fluid pan or fluid filter have been removed. Using the special tool, add 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission through the fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in this procedure. 2. Check the transmission fluid level cold. 1. The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90° F-11 0° F). Using the scan tool and the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 rpm).

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2001 Ford Expedition Heater Core Removal and Installation

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Filed Under (Ford) by admin on 07-03-2011

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If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. For additional information, refer to Section 412-00. 1. Drain the radiator. For additional information, refer to Section 303-03. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. If equipped with the 5.4L 4V engine, remove the junction block splash shield. 4. If equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay. 5. If equipped with the 5.4L 4V engine, remove the junction block bracket. 1. Disengage the wire harness connector. 2. Remove the bolts. 3. Remove the junction block bracket. 6. Disconnect the heater core hose couplings. For additional information, refer to Section 412-00. 7. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. 8. Disconnect the vacuum line.

1997 Ford F-250/350/Super Duty Engine Front Cover Removal

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Filed Under (Ford) by admin on 06-03-2011

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Crankshaft front seal replacement is recommended whenever the engine front cover (6019) has been removed. 1. Disconnect battery ground cable (14301). Drain crankcase. 2. Drain cooling system. Refer to Section 03-03. 3. Remove drive belts (8620). Refer to Section 03-05. 4. Remove bolts attaching fan shroud (8146) to radiator (8005). 5. Remove fan blade (8600) from fan clutch (8A616) and remove fan shroud. 6. Remove fan clutch and water pump pulley (8509) from water pump (8501). 7. Disconnect upper radiator hose (8260) and lower radiator hose (8286) at engine (6007). Disconnect transmission oil cooler lines at radiator. 8. Remove upper radiator support bracket and remove radiator. 9. Remove generator pivot and attaching bolts. Remove generator (GEN) (10300) from generator mounting bracket (10153) and generator adjusting arm (10145). 10. Remove two bolts attaching generator adjusting arm to water pump and generator mounting bracket and remove generator adjusting arm. 11. Remove air pump pivot and attaching bolts. Remove secondary air injection pump (AIR pump) (9A486) from generator mounting bracket. 12. Remove four bolts attaching generator mounting bracket to cylinder head (6049), cylinder blocks (6010) and water pump, and remove generator mounting bracket. 13. Remove power steering pump pulley (3A733) from power steering pump (3A674). 14. Remove power steering lines from power steering pump. Remove four bolts attaching power steering pump to A/C compressor mounting bracket (2882) and remove power steering pump from A/C compressor mounting bracket. 15. Remove four bolts attaching A/C compressor (19703) to A/C compressor mounting bracket. Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Remove A/C compressor mounting bracket from engine. 16. Remove the crankshaft pulley (6312) from the crankshaft vibration damper (6316). 17. Remove bolt and washer attaching crankshaft vibration damper. Remove crankshaft vibration damper using Crankshaft Damper Remover T58P-6316-D or Rotunda Gear and Pulley Puller 014-00293 or equivalent. Remove Woodruff key and crankshaft damper spacer from crankshaft (6303).