Filed Under (Toyota) by admin on 04-06-2011
Some customers may complain about a “squeak” or “creak” noise when depressing or releasing the clutch pedal. The clutch master cylinder clevis assembly has been improved to eliminate this condition. Repair Procedure 1. Record all radio presets before starting. 2. Disconnect the negative (–) battery terminal cable. 3. Remove the clutch pedal sub–assembly. A. Remove the front door opening trim LH (scuff plate). B. Remove the cowl side trim board. C. Remove the instrument panel finish panel lower No. 1. D. Remove the driver’s side Junction Block. E. Remove the turnover (compression) spring. F. Remove the bolt attached to the instrument panel reinforcement assembly. G. Remove the clutch pedal sub–assembly. a. Remove the bolt and nut. b. Remove the clutch pedal from the clutch pedal support. 4. Remove the clutch pedal spring holder from the clutch pedal support. 5. Remove the clutch pedal pad. 6. Remove the two (2) clutch pedal bushes from the clutch pedal. 7. Remove the clutch pedal shaft collar. 8. Using needle–nose pliers, remove the No. 1 cushion from the clutch pedal. 9. Install the clutch pedal No. 1 cushion on the NEW clutch pedal sub–assembly. NOTE: Install parts on the NEW clutch pedal sub–assembly BEFORE installing in the vehicle. 10. Install the clutch pedal shaft collar. A. Apply MP grease to the clutch pedal shaft collar. B. Install the clutch pedal shaft collar onto the clutch pedal. 11. Install the clutch pedal bushes. A. Apply MP grease to the two (2) NEW bushes. B. Install the two (2) bushes onto the clutch pedal. 12. Install the clutch pedal pad. 13. Install the clutch pedal spring holder. A. Apply MP grease to the contact surface of the clutch pedal spring holder. B. Install the clutch pedal spring holder. 14. Remove the clevis sub–assembly. A. Measure length “A” of the clutch master cylinder. a. Measure length “A” between the lock nut and the thread end with a ruler. b. Record length “A”. B. Remove the clevis sub–assembly from the master cylinder. a. Loosen the lock nut. b. Rotate and remove the clevis sub–assembly. 15. Install the NEW clevis sub–assembly. A. Rotate the lock nut to match length “A”. B. Rotate and install the NEW clevis sub–assembly to contact the lock nut. C. Tighten the lock nut and torque to specification. Torque: 11.8 NSm (120 kgfScm, 8.7 ftSlbf) D. Apply MP grease to the ball end of the clevis sub–assembly where it will contact the clutch pedal. 16. Install the NEW clutch pedal sub–assembly. A. Install the clutch pedal onto the clutch support with the bolt and nut. Torque: 34 NSm (347 kgfScm, 25 ftSlbf) HINT: Install the bolt from the left side of the vehicle. B. Apply MP grease to the clutch pedal sub–assembly where the clevis sub–assembly contacts the clutch pedal. NOTE: Failure to apply grease to the clevis and clutch pedal sub–assemblies could cause the noise to return. C. Tighten the bolt to the instrument panel reinforcement assembly. Torque: 8 NSm (82 kgfScm, 6 ftSlbf) 17. Install the turnover (compression) spring. A. Apply MP grease to the contact surface of the spring holder, clutch pedal, and spring. B. Install the spring onto the clutch pedal and spring holder.
Filed Under (Lincoln) by admin on 25-03-2011
1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If the brake fluid is spilled onto a painted or plastic surface, wash it immediately with water. NOTE: Make sure of absolute cleanliness when filling the brake fluid reservoir. NOTE: Do not re-use brake fluid. Fill the brake fluid reservoir with High Performance DOT3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specifcation ESA-M6C25-A, DOT3. 2. Raise and support the vehicle. For additional information, refer toSection 100-02. 3. Remove the dust cover. 4. Remove the bleed nipple cover. 5. Bleed the clutch system. Attach a proprietary bleed jar to the bleed nipple and open the bleed nipple one turn. Depress the clutch pedal repeatedly until the emerging fluid is free of bubbles; always make sure that there is sufficient fluid (5 mm [0.2 in] above the MAX) in the reservoir. After bleeding, tighten the bleed nipple. Install the bleed nipple cover. Install the dust cover. After bleeding, lower the vehicl and depress the clutch 10 times and check that it is functioning correctly. 6. NOTE: Make sure of absolute cleanliness when filling the brake fluid reservoir. Check the brake fluid level. The fluid level should be between the MIN and MAX marks. If the level drops below the MIN mark, the brake warning indicator will light up. As necessary, fill the brake fluid reservoir with High Performance DOT3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specifcation ESA-M6C25-A, DOT3.
Filed Under (Dodge) by admin on 17-03-2011
The oil level control is located on the electrohydraulic unit (4) and consists of the float (5) which is integrated into the electrohydraulic unit. The float is positioned to plug the opening (6) between the oil gallery (2) and gearset chamber (1) so that the rotating gearsets do not splash about in oil as the oil level rises. The oil level control reduces power loss and prevents oil from being thrown out of the transmission housing at high oil temperatures. See Fig. 182. OPERATION FLUID LEVEL CONTROL With low oil levels, the lubricating oil which flows constantly out of the gearset, flows back to oil gallery (2) though the opening (6) If the oil level rises, the oil presses the float (5) against the housing opening (6). The float (5) therefore separates the oil gallery (2) from the gearset chamber (1). The lubricating oil which continues to flow out of the gearsets is thrown against the housing wall, incorporated by the rotating parts and flows back into the oil gallery (2) through the upper opening (arrow). See Fig. 183. DIAGNOSIS AND TESTING CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. Heavy duty operation with a vehicle not properly equipped for this type of operation.
Filed Under (Ford) by admin on 19-02-2011
NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes must be cleaned and backflushed using a suitable torque converter/fluid cooler cleaner. A new Oil-To-Air (OTA) transmission fluid cooler must also be installed. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service. NOTE: After the transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls after any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service. The cleaning of foreign material from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission. A new Oil-To-Air (OTA) transmission fluid cooler must be installed under the following condition. For additional information, refer to Section 307-02. Evidence of broken transmission components or transmission fluid contamination found due to the following transmission or converter failure modes: Major metallic failure Multiple clutches or clutch plate failure Sufficient component wear which results in metallic contamination 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Section 419-03. Failure to follow the instructions may result in serious personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 3. NOTE: Only if transmission disassembly or replacement is required, drain the transmission fluid. For additional information, refer to Fluid Pan, Gasket and Filter in this section. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. After transmission fluid has drained remove the bolts and the pan and drain the remaining transmission fluid that is in the pan. 4. Install the transmission fluid pan and the old transmission fluid pan gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 5. NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle pinion flange so they can be installed in their original positions. Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.
Filed Under (Ford) by admin on 18-02-2011
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. If servicing the radiator lower fan shroud or the radiator, drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. 3. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. If servicing the radiator lower fan shroud or the radiator, fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section. Item 9: Lower Degas Bottle Hose Removal Note 1. Remove the lower degas bottle hose from the clip on the radiator lower fan shroud. Item 10: A/C Tube Removal Note 1. On 4.6L engines, detach the A/C tube from the retainers. Item 11: Transmission Cooler and A/C Tubes Removal Note 1. Disconnect the transmission cooler tubes. Remove the safety retainers from the transmission cooler tubes. Using the special tool, disconnect the quick coupler. If equipped, loosen and remove the screw clamp from the hose. 2. Remove the A/C tube brackets from the engine front cover. Item 12: Radiator Fan Shroud Screw Removal Note 1. Not all vehicles will have these radiator fan shroud screws. If vehicle is equipped with these screws, please discard them. Item 15: Cooling Fan Removal Note 1. CAUTION: Cardboard must be placed against the radiator when removing the cooling fan. Failure to follow these procedures can result in damage to the vehicle. Place a piece of cardboard against the radiator to prevent damage while removing the cooling fan. 2. Using the special tools, remove the fan blade and the clutch assembly. Item 17: Radiator Lower Fan Shroud Removal Note 1. Remove the power steering tube from the clip on the radiator lower fan shroud. Item 19: Radiator Bracket Bolt Removal Note 1. If necessary, remove the radiator brackets. Item 21: A/C Condenser Support Bracket Bolt Removal Note 1. If necessary, remove the condenser brackets. Item 22: Radiator Removal Note 1. NOTE: It will be necessary to lift the radiator assembly up off the mounts and set it on the frame in order to separate the A/C condenser from the radiator. NOTE: RH side shown, LH side similar. Remove the radiator up off the mounts and set it on the frame. 2. Remove the left inner air deflector from the A/C condenser.