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

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1. Remove instrument panel cover and reinforcement from vehicle as described in this section. 2. Unscrew and remove tilt wheel handle and shank (3F609), if equipped. 3. Remove three screws and lower steering column shroud (3530). 4. Turn ignition switch lock cylinder (11582) to RUN position. 5. Using flat-tipped punch, push on button below ignition switch lock cylinder and pull out ignition switch lock cylinder. 6. Remove upper steering column shroud. 7. CAUTION: Be sure air bag sliding contact internal lock is engaged. Hub should not turn more then 45 degrees in either direction. Using door trim removal tool, remove air bag sliding contact electrical connectors from bend bracket. 8. CAUTION: Do not remove wire harness clips from wire bundle. Using door trim removal tool, disconnect two wire harness clips from steering column. 9. Remove key warning chime contact and anti-theft contact from ignition lock cylinder pocket of lock cylinder housing. Steering Wheel with Air Bag

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Removal NOTE: Mark the pinion yoke and driveshaft to make sure the yoke and driveshaft are correctly aligned during assembly. 1. Remove the nuts and U-bolts connecting the driveshaft to the yoke. Disconnect the driveshaft from the yoke. Wire the driveshaft out of the way, so it will not interfere in the carrier removal process. 2. Remove both spindles and the Left and Right Shaft and U-joint assemblies as described in the Removal and Installation portion of this Section under Spindle and Left and Right Shaft and U-joint Assemblies. 3. Support the carrier with a suitable jack and remove the bolts retaining the carrier to the support arm. Separate the carrier from the support arm and drain the lubricant from the carrier. Remove the carrier from the vehicle. 4. Place the carrier in a Holding Fixture, T57L-500-B with Adapters T90T-4000-A. 5. Rotate the slip yoke and shaft assembly so the open side of the snap ring is exposed. Remove the snap ring from the shaft. 6. Remove the slip yoke and shaft assembly from the carrier. 7. Remove the oil seal and caged needle bearings at the same time, using Slide Hammer, T50T-100-A and Collet, D80L-100-A or equivalents. Discard the seal and needle bearing.

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WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK. For disassembly, relocate the transmission to the top of a flat work bench. WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF OIL. 1. Remove torque converter (7902) . 2. Remove input shaft (7017) . The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly. NOTE: For transfer case disassembly and assembly see Section 07-07A, Section 07-07B and Section 07-07C. 3. If the vehicle has a transfer case (7A195) , use a 13mm socket to remove five bolts holding the transfer case to the extension housing (7A039) . Remove transfer case and set aside for reassembly. NOTE: The case oil pressure plug is a press fit into the extension housing and is not serviced separately. CAUTION: The parking pawl (7A441) , parking pawl return spring (7D070) , and parking pawl shaft (7D071) could fall out during removal of the extension housing . 4. Remove the extension housing seal using Front Seal Remover T74P-77248-A. NOTE: Remove extension housing bushing (7A034) only if service is required by inspection. 5. Remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-E. 6. Use 17mm socket to remove four M10 x 30mm screws (E800152-S72) and two studs (E800137-S72) holding the extension housing to the transmission case (7005) . 7. Remove the parking pawl , parking pawl return spring , and parking pawl shaft . 8. Use a 10mm socket to remove two M6 x 20mm screws holding governor to collector body. Remove the governor body, governor primary valve (7C054) , governor valve spring (7A302) , and governor weight (7D324) . The governor body counter weight (7F124) need not be removed.

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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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ENGINE – 4.0L OHV – CARBON KNOCK ON ACCELERATION NOISE – CARBON KNOCK ON ACCELERATION – VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1990-1997 AEROSTAR 1990-2000 EXPLORER, RANGER ISSUE Some vehicles equipped with the 4.0L OHV engine may exhibit an engine noise which may be perceived by the customer as a piston/connecting rod bearing knock. This carbon knock is heard only under load during the drive cycle. Carbon knock is a customer drive duty-cycle phenomenon that cannot be repaired with an engine exchange. This may be caused by carbon build-up within the combustion chamber. ACTION Verify condition. If normal diagnostics fail to correct the condition, de-carbon the combustion chamber to help quiet the carbon knock noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE Use Motorcraft Carburetor Tune-up Cleaner PM-3. Carbon removal: a. Disconnect canister purge line from throttle body. b. Attach a vacuum line to the canister purge port. c. At hot engine idle, allow the engine to ingest 1/2 to 2/3 of a can of Motorcraft Carburetor Tune-up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. d Shut engine off and allow it to soak for one hour. e. Start engine, allow engine to ingest the remainder of the Motorcraft Carburetor Tune-up Gleaner. f. Remove vacuum line and re-install canister purge line. g. Road test vehicle at 3500 RPM for 2-3 miles. h. Repeat above procedure two times for a total of three times. i. Change oil and filter.