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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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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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2004 Pontiac Montana Trim Panel Replacement – Side Front Door

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Filed Under (Pontiac) by admin on 26-10-2010

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Removal Procedure 1. Open the door. 2. Remove the front door trim plate. Refer to Door Trim Plate Replacement () . 3. Remove the front door manual window regulator handle if equipped. Refer to Window Regulator Handle Replacement – Door Remove the armrest screws. Route the electrical harness through the front door trim panel opening. Use J 38778 in order to remove the front door trim panel from the door. Use J 38778 in order to pry the front door trim panel from the door frame at the window seal. 8. Remove the front door trim panel from the door. 4. 5. 6. 7. Installation Procedure 1. Install the front door trim panel to the front door. 2. Place the window seal portion of the panel over the door frame. 3. Route the electrical harness through the front door trim panel opening and into place. 4. Align the front door trim panel retainers to the holes in the door metal. 5. Firmly press the front door trim panel to the door metal in order to seat the retainers. Notice: Refer to Fastener Notice in Cautions and Notices. 6. Install the armrest screws. Tighten the screws to 3 N.m (26 lb in). 7. Install the front door manual window regulator handle if equipped. Refer to Window Regulator Handle Replacement – Door 8. Install the door trim plate. Refer to Door Trim Plate Replacement () . 9. Close the door.

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1996 Lincoln Town Car Power Window Regulator REMOVAL AND INSTALLATION

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Filed Under (Lincoln) by admin on 31-03-2011

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Window Regulator, Power Front Door—Town Car Removal 1. CAUTION: When servicing front door power window regulator minus motor (23208), regulator cable tension must not be altered. Cable tension is preset at production. Improper adjustment may result in premature front door power window regulator failure or erratic operation. CAUTION: Be careful not to drill through the window regulator behind inner door panel. Additional repairs may be necessary. If front door window glass (21410) is in the down position and is inoperable, a through f must be taken; if front door window glass is operational, proceed to Step 2. a. Remove front door trim panel (23942) and front door trim shield (237A04). Refer to Section 01-05. b. Disconnect battery ground cable (14301). Refer to Section 14-01. c. CAUTION: Be careful not to strike or scratch front door window glass. Remove three 1/4 inch rivets retaining window regulator electric drive (23394) to inner panel. d. Working through front access hole in inner panel, remove three screws from window regulator electric drive. e. Separate window regulator electric drive from front door power window regulator minus motor. Raise front door window glass by hand and secure using tape. f. Proceed to Step 2. 2. Remove front door window glass as outlined. 3. Disconnect window regulator electric drive wiring connector. 4. Remove two upper front door power window regulator retaining nuts. 5. NOTE: Use care not to enlarge sheet metal holes in the door inner panel. Remove two 1/4-inch rivets retaining front door power window regulator minus motor to inner door panel. 6. Remove front door power window regulator minus motor from front door (20124). Installation 1. Lubricate front door power window regulator minus motor with Teflon® Lubricant E7FZ-19590-A or equivalent meeting Ford specification ESB-M1C111-A as outlined. 2. Install front door power window regulator minus motor into access hole in inner panel. 3. Position front door power window regulator minus motor using upper front door power window regulator studs and tabs on window regulator electric drive mounting bracket. 4. Install rivets retaining front door power window regulator minus motor to door inner panel (1/4-20 x 1/2 inch screw and 1/4-20 nut and washer assemblies or equivalent metric fasteners may be used as alternates). 5. Install two upper front door power window regulator retaining nuts. 6. Install Front Door Window Glass as outlined. 7. Adjust Front Door Window Glass as outlined. 8. Install front door trim shield and front door trim panel. Refer to Section 01-05. Front Door—Crown Victoria, Grand Marquis Removal 1. If front door window glass is in the down position and is inoperable, the following steps must be taken; if front door window glass is operational, go to Step 2. a. Remove front door trim panel and front door trim shield. Refer to Section 01-05. b. Disconnect battery ground cable. Refer to Section 14-01. c. Disconnect window regulator electric drive wires. d. CAUTION: Be careful not to strike or scratch front door window glass because it could break. Remove window regulator electric drive retaining screws through holes. e. Remove window regulator electric drive from front door power window regulator minus motor.

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1994 Lincoln Town Car Door Window Glass Front Removal Installation

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Filed Under (Lincoln) by admin on 11-03-2011

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Front Removal 1. Remove front door trim panel (23942) and front door trim shield (237A04). Refer to Section 01-05. 2. Loosen front door glass run front retainer retaining screw and position front door glass run front retainer (21572) forward. 3. Lower front door window glass (21410) to gain access to two front door window channel bracket (23288) rivets and remove the center pins from rivets using a drift punch. Using a 1/4-inch diameter drill, drill out remainder of rivets. CAUTION: Do not attempt to pry out the rivets as damage to the front door window glass could result. NOTE: Prior to removing the rivet center pins, it is recommended that a suitable block support be placed between the door outer panel and the front door window channel bracket to stabilize the front door window glass during rivet removal. 4. Remove front door window glass . Installation 1. Insert front door window glass into front door (20124) between front door belt line outside weatherstrip (21452) and inner panel. 2. Position front door window glass into door frame and lower front door window glass to align with front door window channel bracket . 3. Install two 1/4-inch rivets using Rotunda Blind Fastener Installation Tool 107-00600 or equivalent (use of 1/4-20 X 1-inch screw and washer assemblies and 1/4-inch-20 nut and washer assemblies is optional). Equivalent metric fasteners may also be used. NOTE: Torque must not exceed 9-14 Nm (7-10 lb-ft). 4. Adjust front door window glass as outlined. 5. Install front door trim shield and front door trim panel. Refer to Section 01-05. Rear Removal 1. Remove rear door trim panel (27406) and watershield. Refer to Section 01-05. 2. Remove rear door glass run front lower retainer (25796) as outlined. CAUTION: Do not attempt to pry out the rivets as damage to the rear door window glass (25712) could result. Prior to removing rivet center pins, it is recommended that a suitable block support be placed between door outer panel and rear door window channel bracket to stabilize rear door window glass during rivet removal. 3. Lower rear door window glass to gain access to the two rear door window channel bracket retaining rivets and remove center pins from rivets using a drift punch. Using a 6.35mm (1/4-inch) diameter drill, drill out the remainder of the rivets. 4. Remove rear door window glass.

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