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

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WARNING: THE ELECTRIC COOLING FAN MAY COME ON AT ANY TIME WHEN THE IGNITION SWITCH IS IN THE ON POSITION. If the coolant has not been changed in the last 36 months, or 48,000 km (30,000 miles), or if the inspection reveals hoses, gaskets, or other components requiring service or replacement, the coolant must be drained and discharged, or saved for reuse, depending on its condition. For a vehicle with a rear heater, set the rear blower switch to 4 and the rear temperature control knob to the full WARM position. 1. For vehicles equipped with manual A/C-heater, turn the ignition switch to the ON position and set the front temperature control panel selectors in the following positions: The front blower switch to 4. The front temperature control knob to the full WARM position. The rear control switch to the 4 position. The mode selector switches to any mode except OFF. 2. For vehicles equipped with electronic automatic temperature control (EATC), turn the ignition switch to the ON position and perform the following procedures: Turn the blower motor control to HI. Press the TEMP button to the maximum temperature setting. Turn the rear control switch to the 4 position. Turn the mode selector switches to any mode except OFF. 3. Turn the ignition switch (11572) OFF. 4. Remove the RH engine and transmission splash shield (6776). 5. NOTE: Do not use a galvanized drain pan if the coolant is going to be reused. Position a drain pan under the radiator (8005). 6. Open the radiator draincock (8115) at the bottom of the radiator inlet tank (8079). 7. CAUTION: Do not allow coolant to contact the drive belts (8620) or they will be damaged. Remove the radiator cap (8100) from the filler neck. If the system is hot and pressurized, carefully release the pressure before fully opening the radiator cap. 8. Use an Allen wrench to loosen the radiator air relief plug three turns. Do not remove the radiator air relief plug.

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1. Open hood. 2. Disconnect battery ground cable (14301). Refer to Section 14-01. 3. From inside vehicle, remove nuts retaining steering column tube boot (3C611) to cowl panel. 4. Remove bolt retaining steering column intermediate shaft coupling (3A525) to steering column lower yoke (3N725) . 5. Position steering column tube boot out of the way. Remove pinch bolt retaining steering column intermediate shaft coupling to power rack and pinion steering gear and remove steering column intermediate shaft coupling . 6. Raise vehicle on a twin post hoist and remove front wheel and tire assemblies. 7. Remove exhaust system flex tube-to-dual converter Y-pipe attachment. Disconnect heated oxygen sensor wiring harness. Remove dual converter Y pipe (5F250) from vehicle. Dual Converter Y Pipe Removal 8. Support vehicle with jack stands under rear edge of front sub-frame (5C145). 9. Remove tie rod cotter pins and nuts, and remove tie rod end (3A130) from RH front wheel knuckle (3K185) and LH front wheel knuckle (3K186). 10. Remove tie rod end from front wheel spindle tie rod (3280) . Mark position of jam nut to maintain alignment. 11. Remove nuts from steering gear-to-front sub-frame retaining bolts. 12. Remove rear sub-frame-to-body retaining bolts. 13. Raise twin post hoist carefully until rear sub-frame (5R003) separates from body approximately 102 mm (4 inches). 14. Remove heat shield push-pin retainers from power steering hose bracket (3C510). Remove steering shaft U-joint shield (3F540). 15. Remove screw and power steering left turn pressure hose (3A714) from power steering hose bracket . Remove two screws and power steering hose bracket. 16. Remove LH stabilizer bar link (5K484). 17. Disconnect power steering pressure switch electrical connector. 18. Rotate power rack and pinion steering gear to clear bolts from front sub-frame and pull left to ease line fitting removal. 19. Place a drain pan under vehicle and remove hydraulic power steering pressure hose and power steering return hose from fittings on power rack and pinion steering gear. 20. Remove power rack and pinion steering gear assembly through LH wheel well. Installation 1. Install new Teflon® O-rings on both line connector assemblies as described under Quick Connect Power Steering Fitting—Seal Replacement. 2. Place steering gear retaining bolts in steering gear housing (3548). 3. Install power rack and pinion steering gear through LH wheel well. 4. Install power steering hose bracket and two screws. Tighten to 9-12 Nm (80-106 lb-in). 5. Install hydraulic power steering pressure hose and power steering return hose to fittings on power rack and pinion steering gear. Tighten hoses to 33-41 Nm (25-30 lb-ft). 6. Install power steering pressure hose and and screw. Tighten to 9-12 Nm (80-106 lb-in). 7. Connect power steering pressure switch electrical connector. 8. Position power rack and pinion steering gear into front sub-frame. 9. Install tie rod ends onto front wheel spindle tie rods . 10. Install push-pin retainers at top of heat shield. 11. Install tie rod end to RHfront wheel knuckle and LH front wheel knuckle. Install nuts and tighten to 47-63 Nm (35-46 lb-ft). Install new cotter pins. 12. Install LH stabilizer bar link. Tighten to 76.5-103.5 Nm (57-76 lb-ft).

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-02 4×4 vehicles 3. Remove the transfer case. For additional information, refer to Section 308-07A. 4. To maintain initial driveshaft balance, index-mark the front flange and pinion flange. ? Remove the four bolts and remove the front driveshaft. 4×2 vehicles 5. Remove the rear driveshaft. For additional information, refer to Section 205-01. All vehicles 6. NOTE: Drain the transmission fluid if the transmission is disassembled, or installation of a new transmission is necessary. Place a drain pan under the transmission fluid pan. 7. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the fluid to drain. After the fluid has drained, remove the bolts. Remove the transmission fluid pan and transmission fluid pan gasket. 9. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 10. Install the bolts. 11. Remove the starter motor solenoid terminal cover. 12. NOTE: The 4.6L engine is shown, the 4.2L and 5.4L engines are similar. Disconnect the starter motor electrical connectors. 4.2L engines 13. Remove the bolt, stud bolt and starter. 4.6L and 5.4L engines 14. Remove the starter motor. 1. Remove the stud bolt. 2. Remove the two bolts. 3. Remove the starter.

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CAUTION: The three-way catalytic converter (5E212) is located beside the transfer case . Be careful when working around the three-way catalytic converter because of the extreme high temperatures generated by the three-way catalytic converter . 1. Raise the vehicle on a hoist and position suitable safety stands under vehicle. 2. Remove skid plate from frame (5005) , if equipped. 3. Remove the damper from the transfer case , if equipped. NOTE: Drain transfer case only if transfer case disassembly is required. 4. Place a drain pan under the transfer case . Remove the drain plug and drain the fluid from the transfer case . CAUTION: Do not pull directly on the wires or pull outwardly on the locking tabs. 5. Remove the wire connector from the feed wire harness at the rear of the transfer case . First squeeze the locking tabs, then pull the connectors apart. Remove the connector for the motor from the mounting bracket. NOTE: For detailed instruction on front and rear driveshaft removal and installation, refer to Section 05-01. 6. Disconnect the front driveshaft from the case yoke (7B214) and wire the driveshaft out of the way. 7. Disconnect the rear driveshaft from the case yoke and wire the driveshaft out of the way. 8. Disconnect the speedometer drive gear (17285) from the transfer case rear case (7005) . 9. Disconnect the transfer case breather tube from the mounting bracket. 10. Support the transfer case with a suitable high lift transmission jack, such as Rotunda Number 077-00019 or equivalent.

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SYMPTOM ATF leaks from the right side of the transmission. PROBABLE CAUSE The accumulator cover is cracked. CORRECTIVE ACTION Replace the accumulator cover. REPAIR PROCEDURE 1. Raise the vehicle on a hoist. 2. 2002 only: Loosen the bracket that secures the ATF cooler return line, and disconnect the line from the transmission. 3. Clean the accumulator housing. 4. Using the accumulator cover installation tool and a Phillips screwdriver to hold the tool, tap on the accumulator cover to unseat the cover from the snap ring. 5. Remove the snap ring from the accumulator housing. SNAP RING 6. Screw the accumulator cover removal tool clockwise into the accumulator cover. ACCUMULATOR COVER REMOVAL TOOL 7. Using a 22 mm wrench, continue turning the tool clockwise until the accumulator cover turns in the housing. 8. Position a drain pan under the transmission. 9. Using the 22 mm wrench as a lever and the transmission case as the fulcrum, pry the accumulator cover out of the housing. NOTE: For maximum leverage, do not fully seat the 22 mm wrench against the removal tool. Line up the end of the wrench with the center of the tool. 10. Clean the accumulator housing. 11. Lubricate the accumulator housing and the accumulator cover with clean ATF. NOTE: The accumulator cover is rubber coated and does not require an O-ring or sealant. 12. Install the new cover using the accumulator cover installation tool.