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

download
Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Condition Some customers may comment on a shudder condition at approximately 64-80 km/h (40-50 mph) when the TCC engages. Cause This condition may be caused by water in the automatic transmission fluid (ATF). Water may enter the transmission by dripping from the cowl area onto the handle of the transmission fluid level indicator. Indications of water in the ATF may include: • Visible rust on the transmission fluid level indicator. • Visible water in the oil pan. • A milky white substance inside the pan area. • Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. • Rust on internal transmission iron/steel components. Correction First, repair the transmission and second, replace the transmission fill tube, seal and level indicator to prevent repeat water contamination of the ATF. Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission – 4L60-E/4L65-E. Important: If water or coolant is found in the transmission, the following components MUST be replaced. • Replace all of the rubber type seals. • Replace all of the composition-faced clutch plate assemblies including the band. • Replace all of the nylon parts (Thrust Washers). • Replace the torque converter. • Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. • Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30- 052C or newer – Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow . Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Element Replacement (SI Document ID# 1364496). 2. Remove the transmission fluid level indicator from the filler tube.

download
Checking Transmission Fluid Level and Condition Checking fluid level and condition (color and odor) at regular intervals will provide early diagnosis information about the transmission. This information may be used to correct a condition that, if not detected early, could result in major transmission repairs. IMPORTANT: When new, automatic transmission fluid is red in color. As the vehicle is driven, the transmission fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with burnt odor may indicate excessive fluid deterioration and signal a need for fluid change. Fluid Level When adding or changing fluid, use only DEXRON ®-lll. Refer to Maintenance and Lubrication in General Information section for maintenance information and servicing interval. CAUTION: DO NOT OVERFILL. Overfilling will cause foaming, loss of fluid, abnor- mal shifting and possible damage to the transmis- sion. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Check fluid level with engine running at idle. NOTE: Be sure that transmission fluid temperature is below 30°C (86°F). 3. Move the selector lever through all gear ranges. 4. Move the selector lever to “Park”. 5. Let engine idle for 3 minutes and open the overfill screw (1). 6. Add released transmission fluid until it flows out over the overfill screw opening. 7. Let engine idle until a fluid temperature between 32° C (90°F) and 57°C (135°F) is reached, then close the overfill screw (1). Torque: 38 N*m (28 Ib ft) NOTE: Check transmission fluid temperature with scan tool. Minimum fluid level – 57°C (135°F) Maximum fluid level – 32°C (90°F)

download
1994-1997 Ford Probe, Mazda MX3 with 4 cyl. & A/T 1994-2000 Mazda 626 with 4 cyl. & A/T 1998-2000 Mazda 626 with 6 cyl. & A/T 1995-2000 Ford Contour/Mercury Mystique with 6 cyl. & A/T 1999-2001 Mercury Cougar with A/T SUBJECT Vehicles with the Ford CD4E automatic transmission. CONDITION The driver’s side front CV axle has a 6-½ inch male inboard stub that fits into the transmission’s side gear. On the stub next to the housing seal surface is a carrier support surface that fits into the final drive sun gear inside the transmission (see figure 1). This sprocket assembly is chain driven with the reverse/overdrive sprocket by the planetary gear sets (see figure 2). The final drive sprocket assembly rides on the axle stub carrier support surface using a pressed, center bored bushing. This bushing wears the carrier support surface causing damage to the axle and eventually the transmission. SOLUTION If the carrier support surface of the axle being replaced appears rough and worn, then several possible failures need to be checked before replacing the axle or premature failure of the axle or possible damage to the transmission could occur. If the transmission’s internal oiling solenoid that lubricates this bushing fails, then the 2nd and 3rd gearshifts will not function. Although the Aftermarket lists this bushing, no tool exists to replace it. Ford only offer the bushing in a complete sprocket assembly making its replacement a very costly repair. The most common contributor to premature wear of this bushing is the vehicle not being within proper alignment specs. Without a four-wheel alignment, even though the front wheels may be centered to the rack, the rear thrust is pushing the front wheels causing stress on the front CV joints. The thrust forces acting on the front wheels while driving changes ALL the alignment specs resulting in the front wheels being in a constant turning action. This will wear the side gears and transmission seals as well as stressing this bushing. Another possible sign that alignment is affecting these items is a worn or torn inboard boot. Do not forget that worn motor mounts will also affect alignment thrust forces.

download
APPLICABLE MODEL(S)/VINS 1995-2007 B-Series (A/T only) 1997-2003 Protege (A/T only) 1997-2005 Miata (A/T only) 1997-2002 626 (A/T only) 1997-2002 Millenia (A/T only) 1997-2006 MPV (A/T only) 2001-2006 Tribute (A/T only) 2003-2007 Mazda6 (A/T only) 2004-2007 Mazda3 (A/T only) 2004-2007 RX-8 (A/T only) 2006-2007 Mazda5 (A/T only) 2006-2007 MX-5 (A/T only) 2007 CX-7 (A/T only) DESCRIPTION Automatic Transmission (A/T) oil cooler/lines must be power flushed completely before an overhauled or replacement A/T is installed. One of the causes of repeat A/T failures is an internal automatic transmission fluid (ATF) restriction at the inlet side of the oil cooler. This restriction is usually caused by an accumulation of metal particles and debris (from a previous A/T failure) on the internal mesh type baffle of the oil cooler. Power flush- ing will remove the restriction by back flushing the cooler/lines followed by forward flushing. This will in turn ensure full ATF flow for the transmission when it is operating.NOTE: Repeat repairs caused by improper or lack of cooler line flushing will not be covered under warranty, and are subject to review and debit by Mazda Recommended Power Flushing Equipment

download
Transmission Fluid Level Check NOTE: This drain and fill procedure is referenced from TSB # 02-20-3 and applies to 5R55N, 5R55S, and 5R55W Automatic Transmissions. STE467-A ST1269-A Rubber Tip Air No?.zle 100-D009 (D93L-7fiO(1-A) Vacuum Pump Kil 416-D002{D95L-7559-A) Fluid Transporter/Evacuator/ Inj actor ST233Z-A Worldwide Diagnostic System (WDS) 418-F224 New Generation Star (NGS) Tester 418-F205 or equivalent scan tool ST2581-A Adapter, Fluid Level and Fill Plug 307-437 Part 2 Of 2 Special Tool(s) Fluid Fill Reference Item Description ] Fluid level 2 Fluid level tube 3 Fluid level and fill plug (small) (in-vehicle) 4 Fluid drain plug (large) NOTE: Left side of case is shown. 1. Using the scan tool (WDS), monitor the Transmission Fluid Temperature (TFT) using PID TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27°C – 49°C (80°F – 120°F)