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

download
Removal 1. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. If necessary, using a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 3. Inspect the brake pads for wear or contamination. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper. Do not install a damaged anchor housing spring. Remove the anchor housing spring. 5. NOTE: Verify if the anchor housing spring has 1 end with 2 tabs. If yes, the LH side anchor housing spring must be installed with the 2-tabbed end in the upper brake caliper cavity. For the LH brake caliper, release the lower portion of the anchor housing spring. Apply force at the center of the anchor housing spring and pull outward at the bottom of the anchor housing spring to remove it from the lower brake caliper cavity. 6. Rotate the spring upward then remove it from the brake caliper. 7. NOTE: On the RH side, the anchor housing spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The illustration below shows the anchor housing spring end with 2 tabs. For RH brake caliper, release the upper portion of the anchor housing spring. Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 8. Rotate the spring downward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose. Remove the brake caliper. 1. Remove the zero-drag spring. 2. Remove and discard the brake caliper-to-anchor plate bolts, guide pins and boots. 10. Remove the brake pads from the brake caliper. 11. NOTE: Use a wood block or used brake pad to protect the brake caliper piston boots. Compress the brake caliper pistons. 12. Measure the brake disc thickness. Install a new brake disc if it is not within specification. For additional information, refer to Brake Disc in this section.

download
ISSUE A “soft” unresponsive clutch pedal may be felt or the driver may be unable to release the clutch. This is caused by air entrapped in the clutch hydraulic system. ACTION Use the information in this TSB article in addition to the appropriate bleeding procedure. This article includes detail as well as extra service tips for easier hydraulic clutch bleeding. The clutch hydraulic system for the 1993 model year is new and more difficult to bleed than the previous hydraulic system. Therefore, a different bleeding procedure is required for these vehicles. RANGER, EXPLORER, AEROSTAR The most difficult systems to bleed are on the Ranger, Explorer, Aerostars. NOTE: When installing dry clutch cylinder or tube service parts, do the bench bleed procedure first. BENCH BLEED The compact vehicles are more difficult to bleed because the downward angle of the master cylinder makes it difficult for air to escape up into the reservoir. Therefore, if the master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed) air can escape much more efficiently. Refer to Fig. 1 . BENCH BLEEDING PROCEDURE (CONCENTRIC SLAVE CYLINDER) 1. Remove master cylinder, line and reservoir from vehicle and assemble with replacement parts required based on initial concern. 2. Hold the master cylinder vertically with the reservoir feed hose in the highest position on the body. See Fig. 1 . 3. Fill the reservoir and extend above the master cylinder and assure the quick connect on the clutch line is below the master cylinder. (Lightly clamp reservoir in a vise). 4. Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve. See Fig. 1 . 5. Stroke and hold master cylinder pushrod. 6. Close quick connect valve. 7. Release master cylinder pushrod. 8. Fill reservoir. 9. Repeat Steps 4 through 8 four more times. 10. With the master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, proceed as follows: a. Push the pushrod into the body several times quickly to expel any remaining air. b. If it is a remote reservoir, pinch the supply hose with your fingers two or three times to help move air into reservoir. 11. When the movement of the pushrod is .130″ (4mm) or less when stroked in Step 10, reinstall the master cylinder into the vehicle and couple it to the slave cylinder.

download
The system relay is energized when the ignition is ON. The system relay supplies voltage to the solenoid valves and the pump motor. This voltage is referred to as the system voltage. The electronic brake control module (EBCM) controls each solenoid valve by grounding the solenoid. The EBCM controls the pump motor by grounding the control circuit. The pump serves 2 purposes: Transfers brake fluid from the brake calipers to the master cylinder reservoir during pressure decrease events. Transfers brake fluid from the master cylinder reservoir to the brake calipers during pressure increase events. Conditions for Running the DTC The ignition voltage is greater than 10.5 volts. The system relay is commanded ON. Conditions for Setting the DTC The system voltage is less than 8 volts for 0.23 seconds. Action Taken When the DTC Sets If equipped, the following actions occur: The EBCM disables the DRP/ABS/TCS/VSES for the duration of the ignition cycle. The ABS indicator turns ON. The Traction Off indicator turns ON. The DIC displays the Service Stability System message. The EBCM will also set DTC C1248. The red Brake warning indicator turns ON.

download
REMOVE OR DISCONNECT 1. Retainer and electrical connector from fluid level sensor. 2. Drain brake fluid front mister cylinder reservoir. 3. Reservoir hose from master cylinder. Plug hose to prevent fluid loss and contamination. 4. Brake pipes from master cylinder. Plug open pipes to prevent fluid loss and contamination. 5. Two attaching nuts. 6. Master cylinder. 7. Reservoir, if it is to he used on replacement master cylinder. INSTALL OR CONNECT Reservoir onto master cylinder, as needed. Master cylinder on to power booster. Attaching nuts. Tighten to 27 Nm (20 lb. ft.). Brake pipes. Tighten brake pipe fittings to 15 Nm (11 lb. ft.). Reservoir hose onto master cylinder. Fill master cylinder reservoir to full level mark using only Delco Supreme 11 Brake Fluid, or equivalent DOT 3 brake fluid. 7. Electrical connector to fluid level sensor, secure with retainer. 8. Bleed hydraulic system. 9. Recheck fluid level in reservoir. 1. 2. 3. 4. 5. 6.

download
CAUTION: Use only DOT 3 brake fluid from a sealed container. NOTE: ABS bleeding requires conventional bleeding methods (manual or pressure) plus ABS bleeding method (using scan tool). See MANUAL BLEEDING or PRESSURE BLEEDING plus ABS BLEEDING . Bleed system using either conventional bleeding method, then using ABS bleeding method. Repeat conventional bleeding method. Observe following precautions during brake bleeding procedure. DO NOT allow master cylinder to run out of fluid when bleeding brakes. Check fluid level frequently and add fluid as necessary. DO NOT pump brake pedal during bleeding procedure unless directed to do so. Bleed only one brake system component at a time. Use a bleed hose on each wheel cylinder and caliper bleed screw. Be sure to tighten each bleed screw when bleeding is complete. If master cylinder has been overhauled or a new cylinder is to be installed, bench bleed master cylinder before installation. MANUAL BLEEDING 1. Fill master cylinder. Install clear vinyl bleed hose onto left rear bleed screw. Place other end of hose in clean transparent container. 2. Partially fill a container with clean brake fluid. Submerge end of hose in fluid. Pump pedal 3-4 times and hold. Open bleed screw at least one turn. 3. Close bleed screw. Release pedal. Repeat procedure until flow of brake fluid is clear and free of bubbles. Proceed to next bleed screw of brake bleeding sequence. See BLEEDING SEQUENCE table.