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

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Special tooling required Mot. 1732 Tool for removing and re?tting the alternator pulley Tightening torquesm the alternator decou- pling pulley I – PARTS AND CONSUMABLES FOR THE REPAIRS Parts always to be replaced: – the alternator belt, – the tensioning roller, – the mechanic tension wheel mounting bolts. II – PRECAUTIONS DURING REPAIR It is essential to replace an alternator decoupling pulley with a decoupling pulley. III – EQUIPMENT REQUIRED – Torque wrench capable of tightening a left-hand thread. IV – REMOVAL Remove the vehicle alternator (see 16A, Starting – charging, Alternator 110276 110268 Position adapter (2) from the tool kit (Mot. 1732) (corresponding to the alternator rotor recess) in the hexagon socket (1). 110267 Position the hexagon socket (1) from the tool box (Mot. 1732) in the alternator pulley. 110269 Position the adapter holder (3) in socket (2). 110270 Hold the hexagon socket (1) using an open-jawed spanner (4). Loosen the decoupling pulley (5) using a ratchet, (6) (turning it in the clockwise direction.). Remove the decoupling pulley. V – REFITTING Position: – the hexagon socket in the alternator (1), – the adapter (2) (corresponding to the alternator ro- tor mark), – the adapter holder (3) on the adapter(2). Note: Check that the torque wrench is capable of tigh- tening in an anticlockwise direction. 110266 Screw the new decoupling pulley onto the alternator rotor. Tighten to torque the alternator decoupling pulley (80 Nm) using a torque wrench(7). Refit the vehicle alternator (see 16A, Starting – charging, Alternator).

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The recommended wheel bearing lubricant is lithium-base High-Temperature Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A. CAUTION: Sodium-base grease is not compatible with lithium-base grease. Do not intermix. Clean all old lubricant grease prior to lubricating front/rear wheel bearing. Use of incompatible bearing lubricant could result in premature lubricant breakdown. NOTE: If bearing adjustment does not eliminate looseness or rough and noisy operation, clean, inspect and repack the hub and wheel bearings with specified wheel grease. If wheel bearing cup or the cone and roller assemblies are worn or damaged, they should be replaced. Manual Locking Hub, Ranger Disassembly 1. Raise the vehicle and install Rotunda Car/Truck Stands 077-00018 or equivalent. 2. Remove the wheel and tire assembly. 3. Remove the retainer washers and remove the hub assembly. Refer to Manual Locking or Automatic Locking Hubs under Front Wheel Bearing Adjustment in this section for removal. 4. Remove the disc brake caliper (2B120) as described in Section 06-03. 5. Remove the hub and rotor. Remove the outer wheel bearing cone. 6. Remove the wheel hub grease seal (1190) from the rotor with Seal Remover TOOL-1175-AC or equivalent and Impact Slide Hammer T50T-100-A. Discard wheel hub grease seal and replace upon assembly. 7. Remove excluder seal. 8. Remove the inner wheel bearing. 9. NOTE: If new wheel bearing cups are installed, install new cone and roller assemblies. Inspect the wheel bearing cups for pits or cracks. If necessary, remove them with Internal Puller D80L-943-A or equivalent and Impact Slide Hammer T50T-100- A. Assembly 1. Lubricate the wheel bearings with High Temperature Constant Velocity Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A. Clean all grease from the hub. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages. 2. If wheel bearing cups are to be installed, position wheel bearing cups in rotor and drive in place with Bearing Cup Replacer T80T-4000-P and Driver Handle T80T-4000-W. 3. Position excluder seal on spindle and drive into position using Spindle Seal Replacer T95T-3132-D. 4. Position the inner wheel bearing in the inner wheel bearing cup in the rotor. Install the wheel hub grease seal by driving in place with Seal Replacer T80T-4000-T and Driver Handle T80T-4000-W. 5. Carefully install the rotor onto the front wheel spindle (3105). Refer to Section 06-03. 6. Install outer wheel bearing into rotor. 7. Refer to Automatic Locking Hubs under Front Wheel Bearing Adjustment in this section for remainder of installation.

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1. Loosen the strut tower nuts by at least five turns. See Fig. 4 . Loosen the wheel hub retaining nut. Raise and support vehicle. Remove front wheel, brake caliper and rotor. Remove ABS wheel speed sensor (if equipped). Remove tie rod end cotter pin and nut. Using Tie Rod End Separator (211-001), remove tie rod end. See Fig. 13 . 2. Remove lower control arm nut and pinch bolt. See Fig. 15 . Separate lower control arm from steering knuckle. Remove wheel hub retaining nut. Using a suitable puller, separate wheel hub from halfshaft. See Fig. 6 . Remove strut assembly-to-steering knuckle bolt. See Fig. 3 . Remove steering knuckle. Disassembly & Reassembly 1. Using Bearing Pulling Attachment (205-D064), press wheel hub from wheel knuckle. See Fig. 7 . Remove retainer ring from wheel knuckle. See Fig. 8 . Using a suitable drift, remove front wheel bearing from wheel knuckle. See Fig. 9 . CAUTION: Avoid any impact on the wheel speed sensor ring. Make sure the wheel speed sensor ring is clean. Avoid any contact between the wheel speed sensor ring and a magnetic surface. Make sure the wheel bearing is installed into the wheel knuckle with the wheel speed sensor ring, colored black, at the wheel speed sensor end of the wheel knuckle. 2. To reassemble, reverse disassembly procedure.

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Fig. Exploded view of a Hitachi style distributor Fig. Exploded view of a TEC style distributor Fig. Distributor mounting bolt torque Fig. Position of the ignition wires on the distributor cap Fig. Matchmark the position of the distributor before removal Fig. Using a closed end wrench, remove the distributor mounting bolts Fig. Remove the distributor Fig. Location of the distributor mounting bolts holes Fig. Use a small pick to remove the O-ring from the distributor Fig. Always replace the O-ring before re-installing the distributor Fig. Distributor adjusting bolt location The radio may contain a coded theft protection circuit. Always make note of the code before disconnecting the battery. 1. Disconnect the negative battery cable. 2. Access the crankshaft pulley bolt through the left side inner fender liner. Use a socket, long extension and a suitable ratchet to rotate the engine. Rotate the engine counterclockwise until the white Top Dead Center (TDC) mark on the pulley aligns with the pointer on the engine cover. 3. Label and the ignition wires but do not remove them. 4. Remove the distributor cap and note the location of the ignition rotor. If the ignition rotor is not pointing toward the terminal of the distributor cap for cylinder No. 1, rotate the crankshaft one complete revolution counterclockwise, and align the white (TDC) mark on the pulley with the pointer on the engine cover.

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1. Set the parking brake. 2. Loosen the retaining bolts. 3. Raise the vehicle to the desired working height, keeping the axle parallel with the floor; for additional information, refer to Section 100-02. 4. Release the parking brake. 5. Remove the wheel(s); for additional information, refer to Section 204-04. 6. Remove the brake caliper and rotor on the single rear wheel axle; for additional information, refer to Section 206-04. 7. Remove the retaining bolts and axle shaft. 8. CAUTION: The hub nuts are right-hand thread (right hub) and left-hand thread (left hub). Each hub nut is stamped RH or LH. Install the Ford Axle Locknut Socket so that the drive tangs of the tool engage the four slots in the hub nut. 9. CAUTION: Discard the hub nut if the hub nut comes apart during removal. CAUTION: Under no circumstances are power tools to be used when performing these operations. NOTE: The hub nut will ratchet during this operation. Remove the hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread). 10. Install the Step Plate. 11. Install the 2-Jaw Puller and loosen the rear hub to the point of removal. 12. CAUTION: Do not drop the outer hub bearing when removing the hub. Remove the rear hub assembly.