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

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PROBABLE CAUSE The torque converter is faulty. CORRECTIVE ACTION Replace the torque converter, or the torque converter and the transmission, and update the PCM with the HDS. NOTE: You must update the PCM to complete the repair.REPAIR PROCEDURE B Follow the IN-WARRANTY EXCHANGE steps in service bulletin 90-009, Automatic Transmission In- Warranty Exchange Program, to order a remanufactured A/T, replace the failed A/T, and return the failed A/T core. 1. Remove the transmission: • Refer to page 14-203 of the 2003–04 MDX Service Manual, or • Online, enter keyword A/T REM, and select A/T Removal from the list. 2. Clean the transmission cooler. Refer to service bulletin 89-015, ATF Cooler Cleaner. 3. Install a remanufactured transmission: • Refer to page 14-215 of the 2003–04 MDX Service Manual, or • Online, enter keyword A/T INSTALL, and select A/T Installation from the list. 4. Update the PGM-FI software using HDS version 1.018.016 or later (see SOFTWARE INFORMATION). Refer to service bulletin 01-026, Updating the ECM/PCM. 5. Do the idle learn procedure: • Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are turned off. • Start the engine and let it run until it reaches its normal operating temperature (cooling fan cycles twice). • Let the engine idle with the throttle fully closed for 10 minutes.

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1. Back out the tensioner bolt four (4) full turns and position the tensioner so the locating tab is at approximately the 4 o’clock position. Line up the hex key slot in the tensioner adjusting washer with the pointer that is located behind the pulley (Figure 1). 2. Working counterclockwise from the crank sprocket, install the liming belt. 3. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover (Figure 2). 4. Position the hex key slot in the tensioner adjusting washer to the 4 o’clock position (Figure 2). 5. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key (Figure 2). 6. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab. (The pointer will move in a clockwise direction during adjustment) (Figure 3). 7. While holding the adjusting washer in position, torque the attaching bolt to 25 +/- 3 N.m (18 +/- 2 lb-ft) (Figure 4). NOTE IF THE POINTER DOES NOT REMAIN CENTERED OVER THE INDEX LINE DURING FINAL TIGHTENING, LOOSEN THE BOLT AND REPEAT THE PROCEDURE BEGINNING WITH STEP 4. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 499000

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ISSUE Some 2002 Explorer/Mountaineer vehicles built prior to 3/4/2002 with 5R55W transmission, may exhibit no 3rd gear or slipping 2-3 shift with diagnostic trouble codes (DTCs) P0733 and P0745 present. This may be due to a broken intermediate band. SERVICE PROCEDURE 1. Loosen the intermediate band locknut on the band adjustment screw. 2. Using the special service tool (307-S022), tighten the suspect band adjustment screw to 10 lb-ft (14 N•m). a. If the band adjustment torque cannot be achieved, both bands will need to be replaced. Proceed to PROCEDURE “B”. b. If the proper torque is achieved, the band is OK and does not need to be replaced. Proceed to Step 3 of PROCEDURE “A”. 3. Lubricate the locknut seal with petroleum jelly prior to installation. a. Remove the band locknut and discard. b. Install a NEW band locknut. c. Using the special service tool (307-S022), tighten the band adjustment screw to 10 lb-ft (14 N•m). d. Back off the screw exactly two (2) turns and hold that position. e. Tighten the intermediate band locknut. f. Hold the band adjustment screw stationary. g. Tighten the band locknut to 40 lb-ft (54 N•m). h. Continue with normal diagnosis and repair for the condition as outlined in the Workshop Manual.

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COOLING UNIT REMOVAL Zoom Sized for Print 1. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY 2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 3. DISCONNECT SUCTION TUBE AND LIQUID TUBE FROM COOLING UNIT OUTLET FITTING 4. DISCONNECT LIQUID TUBE FROM COOLING UNIT INLET FITTING HINT: Cap the open fittings immediately to keep moisture out of the system.5. 6. 7. 8. REMOVE GROMMETS FROM INLET AND OUTLET FITTINGS REMOVE GLOVE BOX DISCONNECT CONNECTOR REMOVE COOLING UNIT Remove the 4 screws and a nut. Zoom Sized for Print COOLING UNIT INSTALLATION 1. 2. 3. 4. 5. INSTALL COOLING UNIT Install the cooling unit with the 4 screws and the nut. CONNECT CONNECTORS INSTALL GLOVE BOX INSTALL GROMMETS ON INLET AND OUTLET FITTING CONNECT LIQUID TUBE TO COOLING UNIT INLET FITTING Torque: 14 N.m (140 kgf.cm, 10 ft.lbf) CONNECT SUCTION TUBE TO COOLING UNIT OUTLET FITTING Torque: 32 N.m (325 kgf.cm, 24 ft.lbf) IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR Add 40-50 cc (1.4-1.7 fl.oz.) Compressor oil: ND-OIL 8 or equivalent CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY EVACUATE AIR FROM REFRIGERATION SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND INSPECT FOR GAS LEAKAGE Specified amount: 700 ±50 g (24.69 ±1.76 oz.) 6. 7. 8. 9. 10.

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Front Pad Removal Before replacing the pads, inspect the master cylinder to ensure that it has not been topped off before retracting the pistons into the caliper bores. The front brakes are a floating dual-piston caliper type, the pistons are phenolic. The caliper bridge bolts have a guide pin and bolt that attach the caliper to the bracket. Removing the bottom bolt allows the caliper to be pivoted out of the bracket. Using a special piston retractor designed to push evenly on the dual pistons is highly recommended. The pads are retained in the bracket with anti-rattle clips. To release the pad from the clip, there are tabs at the ends of pad that are depressed to release the pad. The pads have noise dampening material attached to the back of the pads. Front Pad Install Inspect the dust boots for damage and replace if necessary. Inspect the guide pins and replace and lubricate if necessary. The boot is to be seated in the grooves of the caliper bracket and guide pin. Install new anti-rattle clips and pads, rotate the caliper and align the flats on the guide pin to the mounting ear of the caliper. Torque the guide pin bolts to 64 Nm (30 ft/lbs). The caliper bracket bolts on this vehicle use high strength thread locker to hold it in place (it is the “red stuff”). Make sure to clean the old thread locker material off the threads with denatured alcohol before putting new thread locker on. The bolts should be tightened to a whopping 129 ft/lbs! Rear Pads Inspect the dust boots for damage and replace the caliper if necessary. Inspect the guide pins and replace and lubricate if necessary. The boot is to be seated in the grooves of the caliper bracket and guide pin. Install new anti-rattle clips and pads rotate the caliper and align the flats on the guide pin to the mounting ear of the caliper. Torque the guide pin bolts to 64 Nm (30 ft/lbs). Like in the front, the rear caliper brackets use thread locker. Make sure to clean threads. Then torque the bolts to 148 ft/lbs. Rotor and Hub Inspection Specifications: Front Brakes