1997 Ford Expedition Starter Motor REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 03-04-2011

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Starter Motor Removal WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle; refer to Section 100-02 . 3. Remove the starter motor solenoid terminal cover (11N087). 4. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Disconnect the starter motor electrical connections. 1. Remove the nuts. 2. Remove the battery cable. 3. Remove the starter solenoid wire. 5. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Remove the (A) starter motor ground cable nut and the (B) starter motor ground cable. 6. Remove the starter. 1. Remove the two bolts. 2. Remove the starter. Installation WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. 1. Install the starter motor. 1. Position the starter motor. 2. Install the two bolts. 2. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Connect the (A) starter motor ground cable and install the (B) starter motor ground cable nut. 3. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Connect the starter motor electrical connections. 1. Position the starter solenoid wire. 2. Position the battery cable. 3. Install the two nuts. 4. Install the starter motor solenoid terminal cover. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Connect the battery ground cable.

1998 Ford Mustang Steering Column Disassembly Assembly

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Filed Under (Ford) by admin on 03-04-2011

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1. Disconnect battery ground cable (14301) . Refer to Section 14-01. 2. Remove steering wheel (3600) as described. 3. Remove steering column from vehicle as described. 4. Remove steering column lower yoke (3N725) , steering column upper bearing spring (3520) , suspension height sensor control ring (3C131) and steering column bearing tolerance ring (3L539) . Lower Steering Column Assembly 5. Remove turn indicator cancel cam (13318) by pushing up with flat-bladed screwdriver. Note direction of flush surface. 6. Remove ignition switch (11572) . 7. Remove bearing retainer (3C610) and steering column upper bearing spring . 8. Remove steel steering column bearing tolerance ring and steering column bearing sleeve (3518) . 9. Remove plastic bearing retainer from ignition switch lock cylinder bore. 10. Remove metal steering column lock housing bearing (3E700) from ignition switch lock cylinder bore. 11. Note position of steering column lock gear (3E717) to actuator lock. Remove steering column lock gear . 12. Remove two pivot bolts. Use caution as steering column position spring (3D655) will release when bolts are removed. Remove steering column lock cylinder housing (3511) . 13. Remove steering column shaft assembly from steering column. 14. Remove steering column lock lever actuator (3E715) and steering actuator housing (3F723) . 15. Remove lower steering column bearing (3517) and steering column lower bearing retainer (3D681) . 16. Remove tilt position lever pivot pin using a drift. Remove RH steering column locking lever (3B661) (RH and LH), steering column lock left hand lever (3D653) and steering column locking lever springs (3B664) . Assembly 1. Install steering column shaft assembly into steering actuator housing . 2. Install lower steering column bearing and steering column mounting bracket (3E660) . Tighten screws to 7-11 Nm (62-97 lb-in). 3. Install suspension height sensor control ring , steering column bearing tolerance ring , steering column upper bearing spring and steering column lower yoke to steering column shaft assembly. Tighten pinch bolt to 25-35 Nm (19-25 lb-ft). Item 1 2 3 4 5 A 4. Position actuator cam in steering column lock cylinder housing and install cam pivot pin with small hammer. Tap pin in until flush with steering column lock cylinder housing . 5. Install one steering column locking lever spring and RH steering column locking lever into steering actuator housing using a drift to hold in place. 6. Install the LH steering column locking lever spring and steering column lock left hand lever with steering column lock actuator lever pin (3F530) . Tap steering column lock actuator lever pin into place while driving out drift. Part Number N803942 3L539 3C131 3520 3N725 — Description Pinch Bolt Steering Column Bearing Tolerance Ring Suspension Height Sensor Control Ring Steering Column Upper Bearing Spring Steering Column Lower Yoke Tighten to 25-35 Nm (19-25 Lb-Ft)

1998 Ford F-150/250 Generic Electronic (GEM) Module REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 01-04-2011

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Removal 1. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable (14301). 2. Remove the cover from the instrument panel fuse junction panel. 3. Remove the lower instrument panel steering column cover (044F08). 1. Remove the lower instrument panel steering column cover bolts. 2. Remove the lower instrument panel steering column cover. 4. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 5. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 6. Disconnect the (A) generic electronic module/central timer module (GEM/CTM) electrical connectors from the (B) GEM/CTM. 7. Remove the GEM/CTM screws and the GEM/CTM. Installation NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 1. To install, reverse the removal procedure. Check for proper operation.

2000 Ford F-150 Temperature Blend Door Actuator REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 01-04-2011

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Temperature Blend Door Actuator Removal All vehicles 1. Depower the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in Section 501-20B. 2. Remove the floor duct panel. Remove the pin-type retainers and release the expander clip. 3. Remove the RH instrument panel brake. 1. Remove the nut. 2. Remove the bolt. 3. Remove the brace. 4. Remove the LH instrument panel lower nut and position the brace aside. 5. Disconnect the restraints control module (RCM) electrical connector. 6. Remove the RCM and bracket assembly. 1. Remove the bracket retaining bolts. 2. Remove the RCM and bracket assembly. Vehicles equipped with rear airflow duct 7. Cut the rear seat airflow duct along both sides. Fold back carpet. Cut rear seat airflow duct. ? 8. Fold the air duct rearwards. All vehicles 9. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. 10. Remove the electronic blend door actuator. 1. Disconnect the connector. 2. Remove the screws. 3. Pull down to release the actuator shaft and remove the electronic blend door actuator. Installation All vehicles 1. Install the electronic blend door actuator. 1. Connect the actuator shaft. 2. Install the screws. 3. Connect the connector. 2. Install the floor duct. 1. Install the floor duct. 2. Install the two screws (one each side). Vehicles equipped with rear airflow duct 3. Zip-tie the rear airflow duct to floor duct. 4. Reposition the carpet. All vehicles WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. 5. Install the RCM and bracket assembly. 6. Connect the restraints control module (RCM) electrical connector. 7. Install the LH instrument panel lower nut. 8. Install the RH instrument panel brace. Install the brace. Install the nut. Install the bolt. 9. Install the floor duct panel. Install the pin-type retainers and release the expander clip. 10. Repower the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in Section 501-20B.

1993 Ford Bronco Valve Bodies and Intermediate Band Servo Removal Installation

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Filed Under (Ford) by admin on 01-04-2011

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Valve Bodies and Intermediate Band Servo NOTE: If a transmission has been disassembled to replace worn or damaged parts and the valve body sticks repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as Rotunda Torque Converter/Oil Cooler Cleaner 014-00028 or equivalent. Removal If solenoid valve body is going to be replaced: Remove solenoid body connector heat shield and loosen both bolts using an 8mm socket. Remove slotted heat shield. CAUTION: Do not attempt to pry tab with pry bar or screwdriver. Remove the heat shield from the transmission before attempting to remove the connector. Remove solenoid body connector by pushing on the center tab and pulling on the wire harness. Check electrical connectors for terminal condition, corrosion and contamination. Repair or replace as required. 1. Position a drain pan under transmission. 2. Remove all transmission pan bolts except the front ones using a 10mm socket. Loosen only the front bolts at this time. 3. Pry the rear of the pan down and allow the fluid to drain. 4. Remove front pan bolts using a 10mm socket. Remove transmission pan. 5. Remove pump inlet filter and seal assembly by carefully pulling and rotating the filter as necessary. If seal remains in bore, carefully remove using O-Ring Tool T71P-19703-C. NOTE: Discard pump inlet filter and seal. CAUTION: Use care not to scratch or damage aluminum pump bore. 6. Remove 11 accumulator body bolts using an 8mm socket and two nuts using a 10mm socket. Remove accumulator body assembly. NOTE: If separator plate is to be left on the transmission, use one of the reinforcing plate bolts in the hole shown to prevent front of plate from sagging and displacing balls. 7. Remove 14 main control body bolts using an 8mm socket and two nuts using a 10mm socket. Remove main control body. NOTE: Do not remove the two bolts as shown on illustration. This will keep the upper and lower control bodies attached as an assembly. 8. Remove nine solenoid body bolts using a T30 Torx® bit and one nut using a 10mm socket. Push down on solenoid body receptacle to remove solenoid body. 9. Remove solenoid screen by rotating and pulling it out. 10. Remove reinforcing plate bolts using an 8mm socket. Remove plate. 11. Lower separator plate and gasket carefully so that check balls, EPC ball and spring are retained. 12. Remove intermediate accumulator regulator filter and spring assembly. Clean or replace filter as required. 13. Depress retaining plate, remove retaining ring, retaining plate, servo piston and rod assembly and servo spring. Installation