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

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RELEASE CYLINDER Removal To prevent loss of brake fluid during clutch slave cylinder removal, the disconnected steel hydraulic line must be plugged or directed into a suitable container. 1. Disconnect flexible hose from steel hydraulic line. NOTICE: Twisting may damage the flex hose. 2. Remove hydraulic line retainer clip. 3. Remove two bolts. Disassembly 1. Remove flexible hose, boot, and push rod. 2. Remove piston and cap assembly and return spring. 3. Remove bleeder cap, bleeder screw, and steel ball. 4. Use brake fluid to clean inner parts. Inspection After cleaning, inspect the following parts: 1. Release cylinder bore and piston for wear. 2. Weak return spring. Assembly 1. Coat the piston and cups with clean brake fluid. 2. Insert steel ball in cylinder bleeder hole and secure with bleeder screw. 3. Push bleeder cap over bleeder screw end. 4. Insert return spring and piston and cup assembly into cylinder bore. 5. With boot installed on push rod, insert rod into cylinder bore and snap boot in place. 6. Connect flexible hose to the cylinder body. Tighten flexible hose nut to 16 ft. lbs. (22 Nm). Installation 1. With cylinder push rod in clutch arm detent, attach cylinder to the transmission case with two bolts. Tighten bolts to 17 ft. lbs. (23 Nm).

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CONDITION 4 wheel drive mode inoperative (diagnosed either during or after replacing knuckles and hub seals) due to insufficient vacuum being applied to the hubs. CAUSE In some cases moisture has entered the vacuum system, and vacuum lines have become corroded, plugged, or have developed a leak. CORRECTIVE ACTION Verify that with 4 wheel drive mode selected, vacuum is present at the T-fitting downstream from the solenoid (see photo). If not, diagnose and repair as required, otherwise use the following procedure to replace the vacuum lines: Note: Procedure applies to right side line; left side needs no further info. Disconnect and remove battery and battery tray. Leaving ground cables attached, remove clamp bracket from battery tray bottom and move out of the way. Remove plastic air resonator and disconnect throttle cable (plus A/T control cable if equipped). Disconnect MAF and IAC connectors, and 6 mm bolt holding DLC and MAF brackets to air cleaner housing. Disconnect air intake tube from throttle body, and MAF sensor from air

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NOTICE: To avoid paint damage, painted surfaces surrounding the master cylinder should be covered. 1. Using a line wrench, disconnect steel hydraulic line. The brake hydraulic system reservoir provides brake fluid for the clutch control system. To prevent loss of brake fluid during clutch master cylinder removal, the disconnected hydraulic fluid transfer hose must be plugged or directed into a suitable container. 2. Disconnect brake fluid transfer hose. 3. From engine compartment, remove lower mounting nut. 4. From passenger compartment, remove upper nut from clutch master cylinder mounting stud. 5. Remove clutch master cylinder and gasket. DISASSEMBLY 1. Press down on the piston and remove the stop wire with needle-nose pliers. 2. With stop wire removed, use compressed air to remove the piston and secondary cup assembly, primary cup and return spring. 3. Use brake fluid to clean inner parts.

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Removal 1. Disconnect negative battery cable. 2. Remove the upper two bolts from the intake manifold bracket. 3. Raise vehicle and support. 4. 5. 6. 7. 8. Remove the two bolts on the clutch release cylinder and push aside (M/T). Remove the lower two intake manifold bracket bolts. Remove intake manifold bracket. Remove the two upper starter bolts. Remove the lower starter bolt. 9. 10. 11. 12. Pull the starter from the clutch (M/T) / torque converter (A/T) housing and prop in place. Lower the vehicle. From above, disconnect the S-terminal connector. Remove nut and lock washer on B-terminal. 13. 14. 15. 16. Disconnect B-terminal. Raise and support vehicle. Push transmission wire harness aside. Remove starter. Installation 1. Place starter in engine well. 2. Lower vehicle. 3. Connect B-terminal wire. 4. Install washer and nut on B-terminal and tighten. 5. Connect S-terminal. 6. 7. 8. 9. 10. Lower intake manifold bracket into position and insert the two upper bolts. Raise and support vehicle. Place starter in position. Insert the two upper starter bolts. Insert lower starter bolt. NOTE:: The starter may require adjustment after installation. If required, rotate the starter slightly to provide proper clearance. 11. Tighten the three starter bolts. Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 12. Insert lower bracket bolts and tighten. Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 13. Position clutch release cylinder and install bolts (M/T). Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 14. Lower vehicle.

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ON-VEHICLE SERVICE If noise or vibration is present in the vehicle driveline, the driveshaft may be out of round due to damage. This inspection will help determine if the driveshaft and its attaching driveline components are “true” or turning with an absolute minimum amount of lateral movement. SPLINE BACKLASH Check for spline backlash by shaking driveshaft back and forth. LOOSE UNIVERSALS Check for loose universal yoke bolts and nuts. Tighten if necessary. DRIVESHAFT DEFLECTION 1. Place transmission in neutral. 2. Raise and support vehicle. 3. Install a dial indicator to the vehicle undercarriage and place the indicator plunger on the driveshaft. 4. Measure both shafts in three separate locations: At the center and 3 in (76.2 mm) from each yoke weld. Slowly turn one of the wheels to turn the driveshaft and record the highest indicator reading in all three locations. REMOVAL 1. Raise and support vehicle. 2. Place index marks (reference marks) on the driveshafts and their matching transfer case and differential input/output shafts.