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

download
The axle housing assembly consists of a cast-aluminum center section, a removable cast-aluminum axle housing tube (3B210), and a differential housing cover (3N136). Both the axle housing tube and the differential housing cover use silicone sealant as a gasket. The hypoid-design gearset consists of an 8.8-inch ring gear (3A397) and a pinion gear (3N175). Two opposed tapered roller bearings support the drive pinion in the axle housing. A drive pinion collapsible spacer (4662), located on the pinion shaft, maintains pinion bearing preload. The pinion nut adjusts the preload. Differential bearing shims (4A451), located between the differential bearing cups (4221) and the axle housing, adjust the differential bearing preload and the ring gear backlash. The differential case (4205) is a one-piece design with two openings to allow for assembly of the internal components and lubricant flow. Two opposed tapered roller bearings (differential bearings [4221]) support the differential case in the axle housing. Removable differential bearing caps (4224) retain the differential assembly in the axle housing. Inside the differential case, the differential pinion shaft (4211) supports two differential pinion gears (4215). The pinion gears engage the differential side gears (4236), to which the left axle shaft (3A381) and the axle cluster gear shaft (7L253) are splined. The differential pinion shaft bolt retains the differential pinion shaft in the differential case. An embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification information. CAUTION: Actuate the front drive axle with the wheels in a straight ahead position, and at light throttle only. A front axle actuator motor assembly (7G360), controlled by an instrument panel-mounted switch, actuates the front drive axle.

download
Some customers of 2WD 2005 – 2007 model year Sequoia and 2005 – 2006 model year Tundra vehicles may complain about a clunk, thunk, or pop noise from the vehicle that is commonly heard when stopping, accelerating from a stop, or turning at low speeds. The source of the noise has been identi?ed as the joint between the rear transmission mount and the frame crossmember. The transmission mount has been redesigned to prevent this. Use the following repair procedure to address customer concerns. Repair Procedure 1. Place the vehicle on a lift and install ChassisEAR™ (or equivalent) on the following components to help isolate the source of the noise (see Figure 1): • On frame crossmember No. 3. • On rear transmission mount above rubber section of mount or on transmission extension housing assembly. Figure 1. 2. Test drive the vehicle and duplicate the noise. 3. With ChassisEAR™ installed, the noise should be very loud from the frame crossmember No. 3 pickup location and NOT heard on the rear transmission mount above the rubber section of the mount. Is the noise loudest when ChassisEAR™ has frame crossmember No. 3 selected? • YES — Go to step 4. • NO — This TSB does NOT apply. Continue using ChassisEAR™ to identify the source of the noise and diagnose per the Repair Manual. 4. Replace the rear transmission mount, frame crossmember No. 3, and 4 bolts retaining the transmission mount to frame crossmember No. 3. A. Place the vehicle on a lift. HINT Use a transmission jack and underhoist stand to lift and support the transmission assembly during the next 5 steps. B. Remove the 4 bolts retaining the transmission to the rear transmission mount. C. Remove the 4 bolts retaining the frame crossmember No. 3 to the frame assembly and remove the frame crossmember No. 3 assembly with rear transmission mount from the vehicle. NOTE Do NOT torque any of the bolts in steps D through F until ALL the bolts in steps D through F have been started. D. Install the NEW rear transmission mount (insulator, engine mounting rear) to the transmission extension housing using the 4 bolts. Torque: 65 N*m (660 kgf*cm, 48 ft*lbf) E. Install the NEW rear transmission mount (insulator, engine mounting rear) to the NEW frame crossmember No. 3 using the 4 NEW bolts. Torque: 30 N*m (300 kgf*cm, 22.1 ft*lbf) NOTE The torque value for these 4 bolts has been increased. Figure 5. 1 Engine Mounting Rear Insulator (P/N 12371-0F080) 2 Frame Crossmember No. 3 3 Bolt w/Washer (P/N 90119-08895) 4 Front of Vehicle

download
Principles of Operation Differential Electronic Module (DEM) and Active On-Demand Coupling The main role of the active on-demand coupling and the differential electronic module (DEM) is to regulate the all wheel drive (AWD) function by distributing torque between the front and rear axles. The system consists of a coupling that combines mechanical, hydraulic and electronic sections. The coupling unit is attached to the rear axle, between the differential gear and the driveshaft. The mechanical and hydraulic sections are driven by the driveshaft. Active on-demand coupling (AOC) has the following characteristics: Permanent AWD with electronic control of torque transfer front to rear 4X4 control module integrated into the DEM Similar to four wheel drive (4WD) operation No driveline wind-up during slow speed maneuvers or parking The system is not sensitive to size differences between the 4 road tires (when driving with a spare wheel, for example). The system is not sensitive to being towed with one axle raised. Inspection and Verification — Electronic Shift 1. Visually inspect for the following obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Axle shafts and universal joints Driveshaft and universal joints Rear differential Differential electronic module (DEM) Fluid leaks Matching tire size 2. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position. 3. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual. 4. Carry out the DATA LINK DIAGNOSTICS test. If the scan tool responds with: CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00. NO RESP/NOT EQUIP for DEM, GO to Pinpoint Test A. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the anti-lock brake system (ABS) module self-test. Carry out one key cycle after clearing codes. 5. If the DTCs retrieved are related to the concern, go to the 4X4 Control Module (DEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 6. NOTE: Not all DTCs cause the traction control indicator to illuminate. Refer to the table for specific DTCs. When the 4X4 control module (DEM) detects certain types of faults in the AWD system, a DTC is set and the traction control indicator will stay illuminated until the condition has been repaired and the DTCs are cleared using the scan tool. Carry out one key cycle after clearing codes. DTC P0562 System Voltage Low P0563 System Voltage High P0602 Powertrain Control Module (PCM) Programming Error P0606 ECM/PCM Processor Electrical Smart junction box (SJB) mini-fuse 19 (10A) Differential electronic module (DEM) Wiring harness Connector(s) Circuitry Description Traction Control Indicator State OFF OFF ON ON

download
NOTE: Unless noted, the procedures in this section apply to both the conventional differential and the Truetrac® differential, though most of the illustrations used in the procedures show the conventional differential. The Model S135 rear axle features the following: a hypoid design differential ring gear and pinion a two-bearing overhung pinion mounting full-floating axle shafts a steel differential housing a front mounted removable one-piece carrier housing a conventional differential assembly or a Truetrac® limited slip differential assembly The trademark shows the company logo, and identifies the location of the manufacturing facility. CAUTION: Never mate a differential ring gear and pinion together that does not have the same matched set numbers. Always install a new matched set if discarding either the differential ring gear or the pinion. A corresponding number marked on the differential ring gear and pinion identifies them as a matched set. The manufacturer’s date identifies the gear set’s date of fabrication. The tooth combination identifies the number of teeth on the pinion and the number of teeth on the differential ring gear. A tooth combination of 41-11, for example, would indicate that the pinion has 11 teeth and the ring gear has 41 teeth that results in a 3.73:1 ratio. Dana Model S135 Full-Floating Rear Axle, Disassembled View

download
1. Vehicle Preparation. (a) Open hood. (b) Place a fender cover over the driver’s side fender to protect the vehicle paint. 2. Check Kit Contents. (a) Check the Front Brake Upgrade kit for contents and damage. 3. Attach Brake Fluid Fill Adaptor. (a) Remove brake reservoir cap. (b) Fix adaptor in place. (1) Route chain all the way under the master cylinder as shown in (Fig. 3-1). (2) Tighten wing nut snug, do not over tighten. (c) Attach the locking vacuum line to the adaptor (Fig. 3-2). (d) Close the air valve on the adaptor. (1) Turn valve clockwise until closed (Fig. 3-3). (e) Press B-1 button then START (Fig. 3-4). (1) After alarm sounds press STOP button NOTE: You may continue to the next step while waiting for the alarm to sound. 4. Remove front wheels (a) Use a vehicle hoist to lift the vehicle using the vehicle jacking points. If a vehicle hoist is not available, use a hydraulic jack to lift the front of the vehicle and set it on jack stands. Use the owner’s manual to locate the proper vehicle jacking points. Caution: Always use jack stands to support the vehicle, never work on a vehicle using only the jack. (b) Use a 22mm deep socket and ½” air impact gun to remove all front wheel lug nuts. (c) Remove both front wheel/tire assemblies and save for reuse. 5. Disconnect & Remove the Front Brake Hose. (a) Place a drip tray directly below the inboard brake line connection. This connection is where the rubber hose attaches to the steel brake line as shown in (Fig. 5-1). Caution: Brake fluid will damage most painted surfaces. Immediately clean any spilled brake fluid from all painted surfaces. (b) Use a 10mm flare nut wrench to loosen the steel line fitting where it attaches to the rubber brake hose (Fig. 5-1). (c) Use a pair of needle-nose pliers to remove the brake line retaining clip (Fig 5-2). Retain this clip for re-use. (d) Repeat steps 5(b) & 5(c) for the connection on the lower end of the rubber brake hose (Fig. 5-3). Remove and discard the rubber brake hose but retain the clip. 6. Remove Factory Brake Caliper, & Rotor. (a) Using a 17mm socket, loosen and remove the two bolts from the original equipment (OE) caliper (Fig. 6-1). Discard these bolts as they will be replaced by longer bolts. (b) Remove and retain the steel brake line from the OE caliper. Discard the OE Caliper. (c) Remove the OE rotor from the hub and discard.