Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Release the fuel pressure. For additional information, refer to Section 310-00. 3. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 4. If removing the fuel tank or fuel pump module, use the special tool and siphon the fuel through the fuel filler hose into a suitable container. 5. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. 7. Turn the ignition key to the ON position to pressurize the fuel system. 8. Visually inspect the fuel system for leaks. Item 3: Fuel Filler Pipe Pin-Type Retainer Removal Note 1. Remove the LH rear wheel well inner splash shield. Item 7: Fuel Filler Pipe Removal Note 1. CAUTION: Some fuel will remain in the fuel filler pipe after draining the fuel tank. Carefully drain the filler pipe into an appropriate container. Separate the fuel vapor fresh air hose from the fuel filler pipe mounting bracket. Items 9, 10 and 18: Fuel Supply and Vapor Tube Quick Connect Fittings Removal Note 1. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube. NOTE: If the fuel tube or retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retainer clip legs. Once the retainer clip legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. Disconnect the fuel tube quick release coupling. Push the connector towards the tube to release pressure. Press the fuel tube quick release coupling button and pull the fuel tube to disconnect.

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NOTE: Make sure the front wheels (1007) are in the straight-ahead position. Remove the battery cables. 1. Remove the battery ground cable (14301). 2. Remove the battery to starter relay cable (14300) and wait one minute for the backup power supply to be depleted. 2. Remove the driver side air bag module (043B13). 1. Remove the two back cover plugs. 2. Remove the screws. 3. Disconnect the horn electrical connector. 4. Disconnect the air bag sliding contact electrical connector. 5. Remove the driver side air bag module. 3. Remove the steering wheel bolt. 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use 2-Jaw Puller to remove the steering wheel (3600). 5. Remove the air bag sliding contact (14A664); refer to Section 501-20B . 6. Remove the multi-function switch (13K359). 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the multi-function switch. 7. Remove the instrument panel steering column opening cover reinforcement. 1. Remove the nuts. 2. Remove the instrument panel steering column opening cover reinforcement. 8. Disconnect the ignition switch electrical connector. 1. Remove the bolt. 2. Disconnect the electrical connector. 9. On automatic transmission vehicles, remove the transmission range indicator from the steering column.

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1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 2. NOTE: Caliper is removed for clarity. Position aside the front disc brake caliper and anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate and position aside. 3. NOTE: Carry out this step for F-250 and F-350 4×4 SRW vehicles. Remove the rotor. 4. NOTE: Carry out this step for DRW vehicles. NOTE: If excessive force must be used during brake rotor removal, the brake rotors should be checked for lateral runout prior to installation. For additional information, refer to Section 206-00. Remove the eight hub extender nuts, the hub plate and the rotor. 1. Remove the eight hub plate nuts. 2. Remove the hub plate. 3. Remove the rotor. CAUTION: Due to the fit of the splines, the hub lock will be difficult to remove. Lifting or lightly prying (with a small bar) on the axle U-joint will ease removal. When prying on the cap/hub flange, work around the flange to uniformly withdraw the hub lock. 5. CAUTION: The service replacement kit includes two O-ring seals. One for testing the hub lock assembly and one for reassembly into the wheel hub. DO NOT REUSE O-RING SEALS. CAUTION: Always check the vacuum leak rate of the wheel end assembly when repairing or diagnosing the axle, wheel end or hub lock performance. Loosen each retainer screw one to two turns. ? Gently pry on the hub lock cap edge to release gasket adhesion. ? Remove and discard the retainer screws. ? While lifting/jiggling the axle U-joint, pull or uniformly pry the hub lock from the wheel hub.

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Removal NOTE: If, for any reason, the rear hub (1109) is removed from the spindle, the old hub seal must be removed and a new hub seal installed. 1. Set the parking brake and loosen the eight axle shaft retaining bolts. 2. Raise the vehicle to the desired working height, keeping the axle parallel with the floor. 3. Release parking brake and back off the rear brake adjustment, if necessary. 4. Remove the wheel (1007). 5. Remove brake drum (1126). Push-on (sheet metal) drum retainer nuts may be discarded. Push-on retainer nuts are used for shipping purposes only and have no vehicle function. If retainers are not flush against the drum, the retainers can prevent the wheel from being flat against the drum, which could contribute to vibration. 6. Place a drain pan under the axle shaft (4234) and rear hub. Remove the eight 7/16-inch axle shaft bolts and remove the axle shaft. Axle Shaft Removal 7. CAUTION: The right hub nuts are right-hand thread; the left hub nuts are left-hand thread. Each hub nut is stamped RH for the right hub nut or LH for the left hub nut. Install Locknut Wrench T85T-4252-AH so that the drive tangs of the tool engage the four slots in the hub nut. 8. CAUTION: A new hub nut must be installed if used hub nut comes apart during removal or installation. CAUTION: Under no circumstances are power impact tools to be used when performing these operations. NOTE: The hub nut will ratchet during this operation. Remove hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread). 9. Install Step Plate Adapter D80L-630-7 (Part of Step Plate Adapter Set D80L-630-A) or equivalent. 10. Install 2-Jaw Puller D80L-1002-L or equivalent and loosen rear hub to the point of removal. 11. CAUTION: Do not drop outer hub bearing when removing. Remove rear hub assembly.

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Removal CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the brake disc. For additional information, refer to Section 206-04. 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ? Using mechanic’s wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut. 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.