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

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JATCO Gearbox – KV6 – NAS models Remove 1. 2. 3. 4. Position the vehicle on a twin-post lift. Tie bonnet back in upright position. Disconnect battery earth lead. Remove engine acoustic cover. 5. 6. 7. 8. Release HO2S multiplug from support bracket on LH camshaft cover, disconnect multiplug. Raise vehicle on lift. Remove rear beam. Remove RH catalytic converter. 9. Remove 2 nuts securing front pipe to manifold. 10. Release and disconnect post catalyst HO2S multiplug. 11. Release post catalyst HO2S harness from clips. 12. Remove bolt securing front pipe to bracket and remove front pipe. Discard gasket. 13. Remove 3 screws securing LH splash shield and remove shield. 14. Release HO2S lead from clip on cylinder block. Remove 4 nuts securing exhaust manifold to cylinder head, remove manifold and discard gasket. 15. Drain fluid from IRD. 16. Drain gearbox fluid. 17. FitLRT-54-026 to the RH drive shaft inboard joint. 18. Using a suitable lever, release drive shaft from IRD. 19. With assistance, pull hub outwards and release drive shaft from IRD. CAUTION: Care must be taken not to damage oil seal when removing drive shaft from IRD. CAUTION: To avoid damage to gaiter or joint, do not allow shaft to hang on joint. 20. Remove LRT-54-026 from RH drive shaft inboard joint. 21. Remove and discard drive shaft circlip. 22. Remove bolt securing lower engine steady to sump mounting bracket. 23. Remove lower engine steady noting that ‘TOP’ mark on engine steady faces uppermost. 24. Reference mark front propeller shaft for reassembly. 25. Remove 6 nuts and bolts securing propeller shaft to IRD drive flange. 26. Release propeller shaft from IRD drive flange and tie shaft aside. CAUTION: Care must be taken to support the Tripode joint when removed from the IRD unit. To avoid damage to gaiter or steel can, the joint should not be allowed to fully extend or be dropped. 27. Disconnect breather hose from IRD housing. 28. Position container to collect coolant spillage.

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Transmission Replacement Tools Required J 42371 Hydraulic Clutch Line Separator Removal Procedure 1. 2. 3. 4. 5. 6. Shift the transmission into 3rd or 4th gear. Remove the shift lever assembly. Drain the transmission fluid. If vehicle is a 2 wheel drive (2WD), remove the propeller shaft. If vehicle is a 4 wheel drive (4WD), remove the transfer case. Using J 42371, push back on the white plastic sleeve on the quick connect in order to separates the hydraulic clutch line from the clutch actuator quick connect. 7. Disconnect the following engine wiring harness electrical connectors: Backup lamp switch (1) Vehicle speed sensor (VSS) (3) Oxygen sensor (4) 8. Remove the oxygen sensor (2) from the transmission bracket. 9. Remove the engine harness clips from the fuel feed/return line clip/bracket. Zoom Sized for Print 10. If equipped with 4WD, remove the vent hose clip from the bracket. 11. If equipped with 4WD, remove the vent hose clip (1) from the fuel feed/return hose bracket. Zoom Sized for Print 12. If equipped with 4WD, remove the fuel feed/return hose clip from the bracket. 13. Remove the starter. 14. Support the transmission using a suitable transmission jack. 15. Remove the transmission support. Zoom Sized for Print 16. Disconnect the vent hose from the transmission. 17. Remove the vent hose clip from the clutch housing. Zoom Sized for Print 18. Remove the transmission to clutch housing bolts. 19. Remove the transmission from the clutch housing.

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This bulletin provides the procedure for replacing the manual transmission gear shift lever assembly and transmission oil. • TGS REPLACEMENT 1. Place the vehicle so it may be raised on a hoist and release the parking brake. 2. Unbutton the shift lever boot hook (A) and open the shift lever boot. 3. Remove the shift lever knob by turning it counterclockwise. 4. Raise the vehicle off the ground and remove the heat shield by unfastening 6 mounting bolts (B). 5. Unfasten the two nuts (C) at the flange in front of the catalytic converter. NOTE: Torque specification: 28.9 ~ 43.4 lb-ft. 6. Unfasten the two nuts (D) that connect the center pipe to the muffler assembly. NOTE: Torque specification: 28.9 ~ 43.4 lb-ft. 7. Disengage the rubber exhaust hanger on the center pipe and remove the center pipe together with the secondary catalytic converter. 8. Draw a straight line across the front propeller shaft rubber coupling (a) and the transmission companion flange(b). This will be used to align when reinstalling. CAUTION: Use care not to exchange locations and directions of bolts and washers when reinstalling to prevent balance issues. 9. Remove the 3 propeller shaft mounting nuts (E) holding the rubber coupler to the transmission output flange. NOTE: Tightening torque : 90~110Nm (9.0~11.0 kgf.m/65~79.5Ib-ft) 10. Lower propeller shaft to gain access to the shift lever.

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1. 2. REMOVE ATF LEVEL GAUGE REMOVE ENGINE UNDER COVER Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 3. 3RZ–FE: DISCONNECT THROTTLE CABLE Loosen the nut and disconnect the cable. Separate the throttle cable from the clamp. (a) (b) 4. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No.1 fan shroud. 5. REMOVE TRANSMISSION SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER Remove the 2 bolts, 4 screws and rear console box. (a) (b) w/ One touch 2–4 selector: Remove the 3 screws and front console box with the transfer shift lever knob. (c) w/o One touch 2–4 selector: Remove the 2 screws and front console box with the transfer shift lever knob. Disconnect the connectors. (d) (e) Remove the nut and washer, and disconnect the shift control rod. (f) Disconnect the connector and remove the 8 screws and transmission shift lever assembly. (g) Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer. HINT: At the time of installation, apply MP grease to the transfer shift lever. 6. REMOVE OIL FILLER PIPE (a) 3RZ–FE: Remove the 2 bolts and oil filler pipe with the O–ring. HINT: At the time of installation, replace the used O–ring with a new one. (b) 5VZ–FE: Remove the bolt and oil filler pipe with the O–ring. HINT: At the time of installation, replace the used O–ring with a new one. 7. REMOVE FRONT AND REAR PROPELLER SHAFT (See page PR–11)

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Some customers may comment on a clunk, bump or squawk noise when the vehicle comes to a stop or when accelerating from a complete stop. Cause A slip/stick condition between the transfer case output shaft and the driveshaft slip yoke may cause this condition. Diagnostic Tips There are several resources in the electronic Service Information System which can provide the technician with information on diagnosis and repair of clunk conditions, and fix the customer’s vehicle right the first time without unnecessary parts replacement. Some of the documents available in SI include: • Symptoms – Propeller Shaft (SI Document ID #697266) • Knock or Clunk Noise (SI Document ID #697290) • Rear Drive Axle Noises (SI Document ID #700580) • Launch Shudder/Vibration on Acceleration (Replace Propeller Shaft and Install a New Pinion Flange/Seal), Bulletin #02-04-17-001 • Information on 2-3 Upshift or 3-2 Downshift Clunk Noise, Bulletin #01-07-30-042 • Driveline Clunk When Stopping (Reprogram Powertrain Control Module (PCM), Bulletin #03-07-30-028 Correction Replace the rear drive shaft slip yoke with a new nickel-plated slip yoke. See the parts table below. Follow the service procedure below. 1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID #349918). 2. Reference mark the propeller shaft to the pinion flange connection. Important: Do not pound on the propeller shaft yoke ears. Never pry or place any tool between a yoke and a universal joint. 3. Remove the bolts and the yoke retainers from the pinion flange. 4. Slide the propeller shaft forward and out of the rear pinion flange. 5. Lower the rear of the propeller shaft and pull the driveshaft out of the transfer case.