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

download
Some 2004 – 2009 model year Highlander, 2001 – 2005 model year RAV4, and 2004 – 2010 model year Sienna AWD (4WD) vehicles may display a transmission ?uid or gear oil seepage from a vent on the right side of the transfer case. The seepage is from the transfer RH (right-hand) bearing retainer No. 2 oil seal. Production improvements have been implemented to prevent this condition from occurring. Follow the repair procedure in this bulletin to replace the RH bearing retainer No. 2 oil seal assembly. Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD) Repair Procedure: Removal 1. Con?rm source of gear oil/transmission ?uid seepage is from vent on RH bearing retainer. 2. Remove the engine assembly with transaxle. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual: • 2004 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy: Replacement” • 2005 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy: Replacement” • 2006 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical: Engine Assembly: Removal” • 2007 Highlander: Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical: Engine Assembly: Removal” • 2008 / 2009 Highlander: Engine/Hybrid System – Engine Mechanical – “ 2GR-FE Engine Mechanical: Engine Assembly: Removal” 3. Remove the automatic transmission w/transfer. Refer to TIS, applicable model and model year Repair Manual: • 2004 Highlander: Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy (U151E/U151F) / (U241E/U140F): Replacement” • 2005 Highlander: Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy (U151E/U151F) / (U241E/U140F): Replacement” • 2006 Highlander: Drivetrain – Automatic Transmission/Transaxle – “U140F / U151F Automatic Transaxle: Automatic Transaxle Assembly: Removal” 4. Remove the transfer case No. 1 plug and remove the gasket from the plug. 5. Remove the transfer drain plug and remove the gasket from the drain plug. 6. Remove the transfer assembly. A. Remove the 2 bolts and 6 nuts. B. Using a plastic hammer, drive out the transfer assembly from the transaxle assembly. NOTICE • Disconnect the transfer assembly from the transaxle assembly without tilting. • When moving the transfer assembly, do NOT hold the assembly by the oil seals.

download
Valve Bodies and Intermediate Band Servo NOTE: If a transmission has been disassembled to replace worn or damaged parts and the valve body sticks repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as Rotunda Torque Converter/Oil Cooler Cleaner 014-00028 or equivalent. Removal If solenoid valve body is going to be replaced: Remove solenoid body connector heat shield and loosen both bolts using an 8mm socket. Remove slotted heat shield. CAUTION: Do not attempt to pry tab with pry bar or screwdriver. Remove the heat shield from the transmission before attempting to remove the connector. Remove solenoid body connector by pushing on the center tab and pulling on the wire harness. Check electrical connectors for terminal condition, corrosion and contamination. Repair or replace as required. 1. Position a drain pan under transmission. 2. Remove all transmission pan bolts except the front ones using a 10mm socket. Loosen only the front bolts at this time. 3. Pry the rear of the pan down and allow the fluid to drain. 4. Remove front pan bolts using a 10mm socket. Remove transmission pan. 5. Remove pump inlet filter and seal assembly by carefully pulling and rotating the filter as necessary. If seal remains in bore, carefully remove using O-Ring Tool T71P-19703-C. NOTE: Discard pump inlet filter and seal. CAUTION: Use care not to scratch or damage aluminum pump bore. 6. Remove 11 accumulator body bolts using an 8mm socket and two nuts using a 10mm socket. Remove accumulator body assembly. NOTE: If separator plate is to be left on the transmission, use one of the reinforcing plate bolts in the hole shown to prevent front of plate from sagging and displacing balls. 7. Remove 14 main control body bolts using an 8mm socket and two nuts using a 10mm socket. Remove main control body. NOTE: Do not remove the two bolts as shown on illustration. This will keep the upper and lower control bodies attached as an assembly. 8. Remove nine solenoid body bolts using a T30 Torx® bit and one nut using a 10mm socket. Push down on solenoid body receptacle to remove solenoid body. 9. Remove solenoid screen by rotating and pulling it out. 10. Remove reinforcing plate bolts using an 8mm socket. Remove plate. 11. Lower separator plate and gasket carefully so that check balls, EPC ball and spring are retained. 12. Remove intermediate accumulator regulator filter and spring assembly. Clean or replace filter as required. 13. Depress retaining plate, remove retaining ring, retaining plate, servo piston and rod assembly and servo spring. Installation

download
Removal 1. Raise the vehicle on a hoist. 2. Remove the front wheel and tire assembly. 3. CAUTION: To avoid damage to the 6mm drive hole in the front stabilizer bar link ball stud, do not use an Allen wrench to break loose or tighten to final torque the front stabilizer bar link-to-front shock absorber nut. Remove the stabilizer bar link retaining nut and disconnect the link from the strut. 4. CAUTION: Do not allow the halfshaft to move outboard. Over extension of the CV joint may result in the separation of internal parts, causing failure of the joint. Remove the strut assembly-to-steering knuckle pinch bolt. If required, slightly spread the steering knuckle to ease the removal of the strut. Pry down on the lower control arm and roll the strut base out of the knuckle. Do not pry on the halfshaft, as damage may result. Wire the steering knuckle up to prevent the halfshaft from moving outboard. 5. Partially lower the vehicle. 6. Support the strut assembly and remove the top three mount-to-strut tower nuts. Remove the strut assembly from the vehicle. 7. CAUTION: The strut assembly is under spring tension. Attempting to disassemble the strut without properly compressing the spring can result in injury. Using a suitable spring compressing tool, slightly compress the strut spring to relieve initial tension. Loosen the upper rod nut. Continue to compress the spring until the tension is relieved. Remove the upper rod nut. 8. Remove all upper mounting parts, coil spring, and coil spring isolators from the strut and save them for reassembly. Carefully note the position of each part during removal to ensure proper reassembly. Inspect each part for wear and damage as it is removed. Installation 1. CAUTION: The bearing and seal assembly is press-fit onto the upper mount. The mount washers must be installed in the correct orientation. NOTE: Be sure to check the spring insulator for damage before assembly. If the outer metal splash shield is bent or damaged, it must be carefully bent back, so it does not touch the locator on the bearing and seal assembly. NOTE: New gas struts are shipped with the rod in a locked down position. To extend the new strut, remove the external tie down and/or rotate the upper end of the rod, counterclockwise. Install the coil spring insulator, coil spring, and upper mounting parts to the new strut assembly. Make sure the spring is correctly seated in both spring seats.

download
All vehicles 1. Raise the vehicle on a hoist. 2. If the vehicle is equipped with an inline transmission fluid filter, remove and discard the filter. Vehicles Equipped With A Fluid Pan Drain Plug 3. Remove the drain plug and allow the fluid to drain. 4. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. Remove the transmission fluid pan and the gasket. Vehicles Not Equipped With A Fluid Pan Drain Plug 2001 Ford Truck Expedition 4WD V8-5.4L SOHC VIN L 5. NOTE: Do not discard the fluid pan gasket unless damaged. This is a reusable gasket. Remove the transmission fluid pan and gasket. 1 Loosen, but do not remove the bolts. 2 Remove the front and side bolts. 3 Lower the front of the fluid pan and allow the fluid to drain. 4 Remove the remaining fluid pan bolts and the fluid pan. All vehicles 6. CAUTION: When installing a new transmission fluid filter and seal assembly, the torque converter should be drained. Transmission cooler, cooler lines, and cooler bypass valve must be thoroughly flushed to remove any contamination. NOTE: After removal, discard the filter and seal assembly. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. 7. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak and damage to the case will result. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.