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

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Removal All vehicles 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 (2B292). 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. 5. Remove the hub lock. 1. Remove the retainer ring. 2. Pull outward and remove the hub lock. 6. Remove the axle shaft thrust washers. 1. Remove the snap ring. 2. Remove the three thrust washers. Vehicles equipped with ABS 7. CAUTION: Do not remove the ABS sensor from the bearing. Disconnect the ABS wheel sensor harness. 1. Disconnect the connector. 2. Disconnect the harness routing clips. All vehicles 8. NOTE: The wheel hub and bearing is a slip fit design and should not require a puller to remove it. Remove the wheel hub and bearing. 1. Remove the four lock nuts. 2. Remove the wheel hub and bearing.

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NOTE: This procedure covers the removal and installation of the LH and RH front wheel driveshaft and joints. However, in the case of 1.8L engines, a halfshaft (3A329) is placed between the transaxle and the (outboard) front wheel driveshaft and joint (3B436) . For removal and installation procedures of either the two-piece RH front wheel driveshaft and joint assembly or the RH front wheel driveshaft and joint outboard half only, refer to the appropriate procedures in this section. Removal 1. Raise and support the vehicle. 2. Remove the lug nuts (1012) and the front wheel and tire assembly. 3. Remove the front fender splash shield bolts and the front fender splash shields (16103) . 4. Use a small cape chisel to carefully raise the staked portion of the front axle wheel hub retainer (3B477) . 5. Remove the front axle wheel hub retainer and discard it. 6. Remove the cotter pin and the tie rod end nut from the tie rod end (3A130) . Discard the cotter pin. 7. Use an appropriate tie rod end remover to separate the tie rod end from the front wheel knuckle (3K186) . 8. Remove the ball joint bolt and the ball joint bolt nut. 9. Carefully pry down on the front suspension lower arm (3078) to separate the front suspension lower arm ball joint (3050) from the front wheel knuckle . 10. Pull outward on the front wheel knuckle (3K185) . Carefully pull the front wheel driveshaft and joint from the front wheel knuckle and position it aside. 11. NOTE: Removal of the LH front wheel driveshaft and joint (3B437) requires removal of the rear engine support (6A023) to allow access with a pry bar. If the LH front wheel driveshaft and joint is being removed, continue with step 11. If the RH front wheel driveshaft and joint is being removed, continue with step 15. Support the transaxle with a transaxle jack or equivalent. 12. Remove the four transaxle mount-to-rear engine support nuts. 13. Remove the two rear engine support nuts at the rear of the rear engine support . 14. While supporting the rear of the rear engine support remove the two rear engine support bolts. Remove the rear engine support .

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All vehicles 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. NOTE: The rear wheels and brake drums/calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. Vehicles with drum brakes 3. Remove the rear brake drums. For additional information, refer to Section 206-02. Vehicles with disc brakes 4. Remove the rear disc brake caliper. For additional information, refer to Section 206-04.  Wire the rear disc brake caliper aside. 5. Remove the rear brake disc. 6. Mark the driveshaft flange and pinion flange for correct alignment during installation. 7. Remove the four driveshaft bolts. 8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Ne ver hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange. Position the driveshaft out of the way. 9. Install an inch-pound torque wrench on the pinion nut and record the torque required to maintain rotation of the pin ion through several revolutions. 10. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Using the special tool, hold the pinion flange and remove the pinion nut. 11. Mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 12. Using the special tool, remove the pinion flange. Installation All vehicles 1. Lubricate the pinion flange splines with rear axle lubricant. 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft.

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CAUTION: Since the engine is not free wheeling if the crankshaft (6303) or the camshafts (6250) are moved in any manner during removal and installation the crankshaft and camshafts must be resynchronized. These steps are located in Engine Assembly Steps 36 to 48. 1. Remove the engine front cover (6019); refer to Engine Front Cover — 5.4L in this section. 2. Remove the crankshaft sensor ring from the crankshaft. 3. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Position the crankshaft with the Crankshaft Holding Tool as shown. 4. Install and fully tighten the Camshaft Holding Tools on both camshafts. 5. Remove the timing chain tensioning system from both timing chain/belts (6268). 1. Remove the bolts. 2. Remove the timing chain tensioners (6L266). 3. Remove the timing chain tensioner arms (6L253). 6. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. CAUTION: Do not remove the Camshaft Holding Tool. Remove the LH and RH timing chains and the crankshaft sprockets (6306). ? Remove the Crankshaft Holding Tool. ? Remove the RH timing chain from the camshaft sprocket. ? Remove the RH timing chain and outer crankshaft sprocket from the crankshaft. ? Repeat for the LH timing chain and crankshaft sprocket. 7. Remove both timing chain guides (6K297). ? Remove the bolts. ? Remove both timing chain guides. 1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Compress the tensioner plunger, using an edge of a vise. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

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Water Pump — 3.0L (2V) Removal 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 2. Loosen the water pump pulley. 3. Remove the accessory drive belt. For additional information, refer to Section 303-05. 4. Remove the degas bottle. For additional information, refer to Degas Bottle in this section. 5. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 6. Disconnect the generator B+ cable and the voltage regulator electrical connector. 7. Remove the nut, the bolt and the generator brace. 8. Remove the generator mounting bolt and the generator. 9. Remove the bolt and the nut, and position the roll restrictor bracket out of the way. 10. Remove the bolt and the accessory drive belt tensioner. 11. Remove the nut, the bolt and the support bracket. 12. Remove the bolts and the water pump pulley. 13. Disconnect the water pump inlet hose and the crankshaft position sensor electrical connector. 14. Remove the bolts and the water pump, and clean the sealing surfaces. Installation 1. Install the water pump. Tighten bolts in the sequence shown: Tighten numbers 1–7 to 25 Nm (18 lb-ft). Tighten numbers 8–12 to 10 Nm (89 lb-in). 2. Connect the crankshaft position sensor electrical connector and the water pump inlet hose. 3. Install the support bracket, the nut and the bolt.