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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.

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1994 Jeep Wrangler SE TROUBLE SHOOTING STARTER MOTOR NOISE

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Filed Under (Jeep) by admin on 01-12-2010

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CONDITION POSSIBLE CAUSE CORRECTION Very High Frequency Excessive distance between Shim starter motor toward Flywheel/Drive Whine Before Engine pinion gear and Flywheel/Drive Plate. Starts; Engine Starts OK. Plate gear. Very High Frequency Insufficient distance between Shim starter motor away from Whine After Engine Starts starter motor pinion gear and Flywheel/Drive Plate. Inspect With Ignition Key Flywheel/ Drive Plate runout Flywheel/Drive Plate for damage; bent, Released. Engine Starts can cause noise to be unusual wear, and excessive runout. OK. intermittent. Replace Flywheel/Drive Plate as necessary. A Loud “Whoop” After Probable cause is defective Replace starter motor. Engine Starts While Starter overrunning clutch. Motor is Engaged “Rumble”, “Growl”, or Probable cause is bent or Replace starter motor. “Knock” as Starter Motor unbalanced starter motor Coasts to Stop After armature. Engine Starts.

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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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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2001 Toyota Sienna CE Trunk / Liftgate Service and Repair DISASSEMBLY

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Filed Under (Toyota) by admin on 11-07-2010

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1. REMOVE BACK DOOR ASSIST GRIP a. Using a screwdriver, open the covers. HINT: Tape the screwdriver tip before use. b. Remove the 2 screws and assist grip. 2. REMOVE BACK DOOR PULL STRAP a. Using a screwdriver, remove the strap cover. HINT: Tape the screwdriver tip 3. REMOVE CENTER GARNISH Using a screwdriver, remove the center garnish. HINT: Tape the screwdriver tip before use. 4. REMOVE SIDE GARNISH a. Using a screwdriver, remove the side garnish. HINT: Tape the screwdriver tip before use. b. Employ the same manner described above to the other side. 5. REMOVE DOOR TRIM BOARD a. Insert a screwdriver between the door and door trim board to pry the door trim board out. NOTE: Be careful not to damage the door and door trim board. HINT: Tape the screwdriver tip before use. b. Pull the door trim board to remove it. 6. REMOVE HIGH-MOUNTED STOP LIGHT a. Remove the 2 screws. b. Disconnect the connector. c. Remove the high-mounted stop light. 7. REMOVE WASHER NOZZLE 8. REMOVE REAR WIPER ARM Remove the nut, rear wiper arm. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 9. REMOVE WIPER MOTOR AND LINK ASSEMBLY a. Remove the 3 bolts from the wiper motor. b. Remove the 2 bolts and wiper motor and link assembly. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) c. Remove the grommet. 10. REMOVE COMBINATION LIGHTS 11. REMOVE LICENSE PLATE LIGHT ASSEMBLY a. Disconnect the back door control cable from the handle lever. b. Disconnect the connector. c. Remove the 3 nuts. d. Using a screwdriver, remove the license plate light assembly. HINT: Tape the screwdriver tip before use. e. Remove the handle lever from the license plate light cover. f. Remove the license plate light assembly from the license plate light cover. 12. REMOVE KEY CYLINDER

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