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

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Steering Linkage The steering linkage assemblies consist of the following: F-250, F-350, 4×2 Tie rod end (outer, RH) Tie rod end (inner) Castellated nut, M14-1.5 Cotter pin Adjusting sleeve Steering gear sector shaft arm Lockwasher, 7/8 Nut, 7/8-10 Steering sector shaft arm drag link Adjusting sleeve Tie rod end (outer, LH) Nut, M12 x 1.75 (off-road or heavy service option package only) Damper (off-road or heavy service option package only) Damper bracket (off-road or heavy service option package only) Bolt, M12 x 1.75 (off-road or heavy service option package only) U-Bolt, M10-1.5 (off-road or heavy service option package only) Bolt, M12 – 1.75 (off-road or heavy service option package only) Castellated nut, M14-1.5 Cotter pin Nut, M12-1.75 (F-350 DRW only) Bolt, M12-1.75 x 70 (F-350 DRW only) Bolt, M12-1.75 x 35 (F-350 DRW only) Damper bracket (F-350 DRW only) Nut, M12-1.75 (F-350 DRW only) Steering gear sector shaft arm Lockwasher, 7/8 Nut, 7/8-10 Tie rod end (outer, LH) Adjusting sleeve Tie rod end (inner) Damper bracket (F-350 DRW only) U-bolt (F-350 DRW only) Damper (F-350 DRW only) Steering sector shaft arm drag link Adjusting sleeve Tie rod end (outer, RH)

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Power Steering Gear Special tools, testers and auxiliary items required Hose clamps up to 25 mm dia. 3094 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 Notes for repair work on power steering gear All work on the power steering must be carried out with utmost cleanliness. Thoroughly clean all connections and the surrounding area before disconnecting. If repairs will not be carried out immediately, place removed parts onto a clean surface and cover. Only use lint-free cloths. Only unpack replacement parts immediately prior to installation. Only use parts in their original packing. Removing Remove bolts – 1 – . Remove cover – A – . Remove bolt – 1 – from universal joint. Remove universal joint from steering gear. Clamp off hose from reservoir using hose clamps up to 25 mm dia. 3094 . Clamp off hose on power steering pump using hose clamps up to 25 mm dia. 3094 . Remove sound-deadening pan. Place drip tray underneath. . Press off tie rod from steering knuckle. A – Tie rod puller (standard), e.g. Kukko 128/2 Remove hose lines at steering gear and plug using a plastic bag and tape. Seal threaded holes on power steering gear using plastic screw plugs – 1 – and – 2 – . Remove bolts – 1 – and – 2 – . With TDI Engines Remove bracket for front exhaust pipe at subframe – arrows – and disengage. Continuation for All Support subframe using engine/transmission jack V.A.G 1383 A . Loosen bolts – 1 – . Remove bolts – 2 – and – 3 – . Lower subframe using engine/transmission jack V.A.G 1383 A . Remove bolts – 1 – for power steering gear. Remove power steering gear toward right. Installing Note: . Use new O-rings for hose/line connections. Coat seal on steering gear with lubricant, e.g. lubricating soap, before installing steering gear. After placing steering gear on to universal joint shaft, make sure that seal on steering gear makes contact on assembly plate without kinks and opening to footwell is correctly sealed. Ingress of water and/or noises may result otherwise. Make sure sealing surfaces are clean.

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90 Nm + 45 ° ( 1 / 8 ) additional turn. loosening and tightening Remove any paint residue and/or corrosion in the threads of outer joint before screwing on nut. 3 – Phillips-head screw 4 – Brake disc Notes for repairing 5 – Brake caliper Do not remove brake hose when working on front wheel suspension Hang with wire or similar means Replace brake pads 6 – Metal countersunk screw 7 – Wheel hub Pressing out Pressing in Remove bearing inner race 8 – Rotor for speed sensor Only on vehicles with ABS Front brakes – brake caliper Girling, servicing Brake pads, removing and installing 9 – Hex bolt, 10 Nm 10 – Cover plate 11 – Securing ring Check for proper seating 12 – Wheel bearing Pressing out Replace, destroyed during ejection Pressing in 13 – Self-locking hex nut, 35 Nm 14 – Wheel bearing housing 15 – Ribbed bolt, 125 Nm 16 – Drive axle Removing and installing Servicing 17 – Multipoint socket head bolt, 45 Nm 18 – Hex bolt Camber setting Drive axle with triple rotor joint, removing and installing Drive axle, servicing Camber of front wheels, adjusting Mark installation position before loosening 19 – Hex bolt 20 – Bracket 21 – Stop 22 – Self-locking hex nut, 60 Nm unbolt and bolt in 23 – Suspension strut Disassembling and assembling 24 – Self-locking hex nut, 95 Nm 25 – Tie rod Removing and installing Front suspension strut – Basic/Plus suspensions, servicing Tie rod – power steering gear, TRW and ZF, removing and installing

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 3. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper support bracket and brake caliper aside. 4. Disconnect the front anti-lock brake sensor (ABS) wire assembly. Disconnect the ABS electrical connector. Unclip the ABS harness routing clips. 5. Remove the tie-rod castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 6. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 7. Using a suitable jack, support the front suspension lower arm. 8. Remove the lower ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 9. Using the special tool, separate the front wheel knuckle from the suspension lower arm. Then, loosely reinstall the castellated nut. 10. Remove the upper ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 11. CAUTION: Do not damage the ball joint boot when installing the special tool. Using the special tool, separate the front wheel knuckle from the front suspension upper arm. 12. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel knuckle. 13. Remove the snap ring from the ball joint. Discard the snap ring. 14. Using a suitable tool, remove the ball joint.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 3. CAUTION: Do not reuse the torque prevailing design hub nut and washer assembly. Remove and discard the hub nut and washer assembly. 4. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper and support bracket aside. 5. Remove the brake disc. 6. CAUTION: Do not use a hammer to separate the outboard front wheel halfshaft joint from the wheel hub. Damage to the outboard CV joint stub shaft threads and internal CV joint components may result. Using the special tool, separate the outboard front wheel halfshaft joint from the wheel hub. Remove the special tool. 7. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame. 1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame. 8. Using a suitable jack, support the front suspension lower arm. 9. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft. Support the front axle shaft with wire. 10. Remove the tie-rod end castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 11. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 12. Remove the lower ball joint castellated nut.