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

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1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air. 2. Inspect the transmission case for the following: 1. Stripped bolt hole threads. 2. Gasket and mating surfaces for burrs or nicks. 3. Obstructions to vent and fluid passages. Cracks or warpage. 3. Inspect the extension housing for cracks, burrs or warpage. 4. Inspect case bearing for damage. Replace as needed. 5. Remove the case bearing. 1. Install the Bearing Cup Puller with Slide Hammer into case bearing. 2. Remove the case bearing. Use an oil stone to remove any nicks or burrs in the bearing case bore. 6. Install a new case bearing. 1. Assemble and install the Drive Handle and Bearing Installer. 2. Position new case bearing onto bearing installer tool. 7. Tap case bearing into case bearing bore. 8. Install the A4LD Holding Fixure Adapter. 1. Position the A4LD Holding Fixture Adapter on the rear of the transmission case. 2. Install the A4LD Holding Fixture Adapter bolts. 9. Attach the fixture arm of the Bench Mounted Holding Fixture to the A4LD Holding Fixture Adapter. 10. Install transmission into Bench Mounted Holding Fixture. Rotate the transmission so that the fluid pan rail is facing up. -MOUNTED HOLDING FIXTURE IS SECURE. 11. Using Shift Lever Seal Replacer, install the manual control lever shaft seal. Lubricate the manual control lever shaft seal with petroleum jelly. 12. Assemble the manual valve inner lever and parking lever actuating rod as shown. 13. Install the manual control lever shaft. 14. NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Install the manual control lever shaft spring pin. Tap the manual control lever shaft spring pin into the transmission case. 15. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft. 16. Install the manual valve inner lever nut on the manual control lever shaft and tighten. 17. Install the output shaft thrust washer (No. 11). Coat the output shaft thrust washer with petroleum jelly. 18. Install the park gear.

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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

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Removal All vehicles 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 2. NOTE: Caliper is removed for clarity. Position aside the front disc brake caliper and anchor plate (2B292). 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate and position aside. 3. NOTE: Carry out this step for F-250 and F-350 4×4 SRW vehicles. Remove the rotor. 4. NOTE: Carry out this step for DRW vehicles. NOTE: If excessive force must be used during brake rotor removal, the brake rotors should be checked for lateral runout prior to installation. For additional information, refer to Section 206-00. Remove the eight hub extender nuts, the hub plate and the rotor. 1. Remove the eight hub plate nuts. 2. Remove the hub plate. 3. Remove the rotor. 5. Remove the hub lock. 1. Remove the retainer ring. 2. Pull outward and remove the hub lock. 6. Remove the axle shaft thrust washers. 1. Remove the snap ring. 2. Remove the three thrust washers. Vehicles equipped with ABS 7. CAUTION: Do not remove the ABS sensor from the bearing. Disconnect the ABS wheel sensor harness. 1. Disconnect the connector. 2. Disconnect the harness routing clips. All vehicles 8. NOTE: The wheel hub and bearing is a slip fit design and should not require a puller to remove it. Remove the wheel hub and bearing. 1. Remove the four lock nuts. 2. Remove the wheel hub and bearing.

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Some owners of the above models equipped with a Hydra-Matic 4T65-E transaxle with a Julian Date prior to 0045 may comment on a whine noise in PARK and/or NEUTRAL or a Service Engine Soon or Service Vehicle Soon lamp that is illuminated. Upon investigation, a DTC P0741 or P0742 may be found. Cause The above condition may be due to drive sprocket support bearing fluting and/or bearing failure. Correction Replace the drive sprocket support bearing. Inspect the channel plate and drive sprocket for any abnormal wear, Turbine shaft for cut seals and/or nicks, and chain for excessive play due to failed bearings. Important: When installing the new bearing, the part number MUST be visible (facing upward). Before installing the drive sprocket, lubricate the bearing assembly with J 36850 assembly lubricant. Refer to the 4T65-E Unit Repair Section for the installation procedure.

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revise the Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement procedure in the Variable Effort Steering (1998-2001 model years) or Steering Wheel and Column (2002-2003 model years) and add the Steering Wheel Position Sensor Centering procedure in the Steering Wheel and Column sub-sections of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Steering Wheel Position Sensor or Steering Shaft Lower Bearing Replacement Removal Procedure Caution: Refer to SIR Caution in Cautions and Notices. 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in SIR. 2. Remove the steering column from the vehicle. Refer to Steering Column Replacement. 3. Remove the following from the steering shaft: 3.1. steering shaft seal (7) 3.2. sensor retainer (6) 3.3. steering wheel position sensor (5), refer to Steering Wheel Position Sensor Centering. 3.4. 2 lower spring retainers (4) 3.5. lower bearing spring (3) 3.6. lower bearing seat (2) 3.7. adapter and bearing assembly (1) Installation Procedure