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1994 Ford Mustang A/C Evaporator Housing Removal and Installation

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

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1. Disconnect battery ground cable (14301) . 2. Remove two console armrest mounting access covers (047A62) at rear of console panel (045A36) (snaps out) to gain access to armrest retaining bolts. 3. Remove four armrest-to-floor bracket retaining bolts and remove armrest assembly (snaps out of console). 4. Remove console panel gear shift plate (044G24) (snaps out). On vehicles equipped with manual transmissions, shift boot is attached to bottom of finish panel. Remove shift knob and slide boot and console panel gear shift plate up shift lever to remove. 5. To remove top finish panel position emergency brake lever in the UP position. Remove four retaining screws and lift top finish panel up. Disconnect necessary wire connectors. 6. Remove two console-to-rear floor bracket retaining screws. 7. Insert a small screwdriver into two notches at bottom of front upper finish panel and snap out. 8. If the vehicle has a radio chassis (18806) , the radio chassis must be removed. Refer to Section 15-01. If the vehicle doesn’t have a radio chassis , use a small screwdriver and pry radio cover finish panel out of console. 9. Flex glove compartment bin tabs inward. Drop down glove compartment (06010) assembly. Remove two console-to-instrument panel retaining screws. 10. Remove four console bracket retaining screws. Remove console panel from vehicle. 11. Remove three bolts retaining steering column opening cover (3A673) and reinforcement panel. Remove cover. 12. Remove steering column opening reinforcement by removing two bolts. 13. Remove two bolts retaining steering column opening reinforcement and remove reinforcement. 14. Remove six steering column retaining nuts (two retaining the hood release mechanism and four retaining column to lower brake pedal support). Lower steering column to floor. 15. Remove upper and lower steering column shrouds (3530) and disconnect wiring from turn signal and windshield wiper switch (13K359) . 16. Remove steering column through bolt and nut on engine compartment side of cowl panel. Remove steering column from vehicle. 17. Remove brake pedal support nut. 18. Snap out instrument panel defroster opening grille (044E82) . 19. Remove screws from speaker covers. Snap out speaker covers. 20. Remove front screws retaining RH and LH scuff plates at cowl side trim panels. 21. Remove RH and LH cowl side trim panels. 22. Disconnect wiring at RH cowl side. 23. Remove cowl side retaining bolts (one each side). 24. Remove five cowl top screws attachments. 25. Gently pull instrument panel (04320) away from RH side of cowl panel. Disconnect speedometer cable, air conditioning controls and wire connectors. 26. Place a drain pan or suitable container under the heater water hose connections at the cowl panel. 27. Disconnect heater water hoses (18472) from heater core tubes and plug heater water hoses with suitable 5/8-inch and 3/4-inch plugs. Cap heater core tubes to prevent coolant loss from heater core (18476) during removal of heater case. 28. Remove screw retaining A/C evaporator case support bracket (19A639) to cowl top panel. 29. Disconnect vacuum supply supply hose (black) from A/C vacuum supply in engine compartment. 30. Working under the hood (16612) , remove nut retaining heater case to cowl panel. 31. Inside passenger compartment, remove screw retaining A/C evaporator case mounting bracket (19A865) to cowl top panel. 32. Remove one screw retaining A/C evaporator case mounting bracket below heater case to cowl panel. 33. Carefully pull heater case from cowl panel and remove heater case assembly from vehicle. 34. To install, reverse Removal procedure. Check operation of all components. 35. After repairs have been completed, check the coolant level in the radiator (8005) and in the radiator coolant recovery reservoir (8A080) . Fill as required with the recommended coolant mixture.

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1993 Mitsubishi Montero TRANSFER CASE DISASSEMBLY

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Filed Under (Mitsubishi) by admin on 30-12-2010

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Disassembly (Ram-50) 1) Remove both 4WD indicator switches and steel balls. Remove speedometer gear assembly. Remove output shaft cover, gasket, wave spring and spacer. See Fig. 3. Remove rear cover, rear cover gasket and spacer from chain cover. Drive roll pin out of high-low shift fork. 2) Remove 2 seal plugs. Remove 2 poppet springs and steel balls. Shift transfer case to “4WD” and pull high-low shift rail out, in rear cover direction. Remove interlock plunger. Remove pulse generator (if equipped), front output shaft cover and pulse rotor (if equipped). Remove snap ring from rear bearing on output shaft. Remove chain cover, oil guide and side cover. Remove countershaft locking plate. Remove countershaft. 3) Remove countergear, 2 thrust washers, 2 needle bearings and spacer through side cover opening. Remove snap ring, spring retainers and spring from 2WD-4WD shift rail. Remove front output shaft, rear output shaft and chain as assembly. 4) Remove 2WD-4WD shift fork and distance piece. Drive out 2WD-4WD shift rail spring pin. Remove 2WD-4WD shift rail and lug. Remove high-low shift fork and high-low synchronizer sleeve. Remove needle bearing and snap ring from input gear. Remove input gear assembly. 5) If either control shaft or input gear oil seals are to be replaced, drive out roll pin from transmission control change shifter. Separate transfer case from adapter. See Fig. 3. Disassembly (Montero) 1) Remove dynamic damper, 5 detection switches and 3 steel balls. Remove poppet plug, spring and steel ball. Remove speedometer gear assembly. Remove output shaft rear cover, spacers, dust seal guard and oil seals. Front output shaft cover, wave spring and spacer (if equipped). 2) Remove high-low shift rail plug and high-low shift fork spring pin. Shift transfer case to “4WD”. Remove rear cover and high- low shift rail. Remove interlock plunger. Remove rear output shaft (viscous coupling) assembly and center differential assembly. Remove 2WD-4WD synchronizer assembly, chain and front output shaft from transmission as a unit. With White paint make match marks in grooves of 2WD-4WD synchronizer in 3 places. With White paint make match marks on spline projections of 2WD-4WD synchronizer sleeve in 3 places. Refer to match marks during reassembly. 3) Remove snap ring, spring seat, spring, 2WD-4WD shift fork and 2WD-4WD synchronizer sleeve. Remove differential lock hub, oil dam cover and bearing retainer. Remove side cover and gasket. Remove transfer counter gear shaft, transfer counter gear, thrust washer, needle bearings and spacer. Remove transfer drive shaft assembly. Remove high-low shift fork assembly and clutch sleeve. Remove transfer input gear assembly. 4) Remove 2WD-4WD shift lug spring pin, spring, spring retainer 2WD-4WD shift lug and shift rail. Remove input gear oil seal, baffle plate, dust seal guard and front output shaft oil seal. See Fig. 4.

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1998 Ford Expedition/Navigator Engine REMOVAL

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Filed Under (Ford) by admin on 06-04-2011

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Special Tool(s) Engine Lift Bar 303-F047 (014-00073) Heater Hose Disconnect Tool 5/8 Inch 412-042 (T85T-18539-AH) Removal 1. Evaluate the A/C system. For additional information, refer to Section 412-00. 2. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01. 3. Remove the hood (16612). 4. Remove the engine air cleaner. For additional information, refer to Section 303-12. 5. Remove the radiator. For additional information, refer to Section 303-03. 6. Disconnect the climate control vacuum feed connector. 7. Position aside the power steering reservoir. For additional information, refer to Section 211-02. 8. Remove the intake manifold. For additional information, refer to Intake Manifold—Variable Resonance Induction System in this section. 9. Remove the splash shield covering the engine main harness connectors. 10. Disconnect the two starter cable leads from the starter relay. 11. Disconnect the two 42-pin connectors and the single pin connector. 12. Disconnect the 16-pin connector and the single pin connector. 13. Remove the bolts and the junction block bracket. 14. Remove the heater water hoses from the heater core. 15. On 4.6L engines, disconnect the following electrical connectors. LH ignition coil connector (A). Camshaft position (CMP) sensor electrical connector (B). Radio capacitor electrical connector (C). 16. On 4.6L engines, disconnect the following electrical connectors. RH ignition coil connector (A). Radio capacitor electrical connector (B). 17. On 4.6L engines, remove the ignition coils and ignition coil mounting brackets. 1. Remove the RH bolts. 2. Remove the RH ignition coil and bracket. 3. Remove the LH bolt. 4. Remove the LH nuts. 5. remove the LH ignition coil and bracket. 18. Remove the lower radiator hose and retaining bracket from the engine. 19. Remove the transmission oil filler tube if equipped. For additional information, refer to Section 307-01A (4R70W), or Section 307-01B (4R100). 20. Raise and support the vehicle. For additional information, refer to Section 100-02. 21. Remove the drain plug and drain the engine oil. 22. Disconnect the A/C compressor electrical connection if equipped. 23. Disconnect the crankshaft position (CKP) sensor. 24. Remove the starter motor (11001). For additional information, refer to Section 303-06. 25. Remove the A/C compressor if equipped. For additional information, refer to Section 412-03A. 26. Remove the transmission fluid cooler hose (7B093) from the block-mounted clip, if equipped. 27. Position the shift cable and bracket aside. 1. Disconnect the shift cable. 2. Remove the fasteners and position the bracket and shift cable aside. 28. Remove the bolts and the flexplate inspection cover. 29. Remove the cylinder block opening cover. 30. Remove the torque converter-to-flexplate nuts. Discard the nuts. 31. NOTE: The upper two transmission-to-engine bolts will be removed later. Remove the lower five transmission-to-engine bolts. 32. On 4×4 vehicles, loosen the bolt and position the oil cooler aside.

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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).

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2002 Ford Taurus Transaxle Removal

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Filed Under (Ford) by admin on 05-02-2011

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1. Remove the battery. For additional information, refer to Section 414-01. 2. Disconnect the mass air flow (MAF) sensor. 3. Disconnect the breather tubes. 4. Remove the engine air cleaner. 5. Remove the air filter assembly. 6. Remove the battery tray. 7. Disconnect the connectors. 8. Remove the electrical connector and the wiring harness from the bracket. 9. Remove the manual control lever cable. 1. Remove the nut. 2. Remove the shift actuator cable fitting from the shift cable and bracket. 10. Disconnect the power steering sensor connector. 11. Disconnect the power steering harness and output shaft speed (OSS) sensor connector. 12. Disconnect the wiring harness from the shift cable bracket. 13. Disconnect the turbine shaft speed (TSS) sensor. 14. Remove the bolt from the coolant pipe bracket. 15. Remove the nut from the coolant pipe bracket. 16. Remove the bolts. 17. Remove the nut for the cooling tube. 18. Install the engine lifting bracket. 19. Remove the upper cowl assembly. 1. Remove the wiper. 2. Remove the clips. 3. Remove the upper cowl assembly. 20. Remove the lower cowl assembly. Remove the three screws. Remove the clip. 21. Remove the rear support brace. 1. Remove the bolt. 2. Remove the nut. 3. Remove the rear support brace.

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