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

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Removal 1. NOTE: Make sure the parking brake control (2780) is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit (2853). 2. Insert a suitable retainer. 2. Raise and support the vehicle; for additional information, refer to Section 100-02. 3. Remove the tire and wheel assembly; for additional information, refer to Section 204-04. 4. CAUTION: Do not let the rear disc brake caliper hang from caliper hose, use wire to hang it aside. Remove the rear brake disc caliper (2552). 1. Remove the rear brake disc caliper bolts. 2. Remove the rear brake disc caliper and position aside. 5. NOTE: Be sure to remove square cut O-rings from hub before removing rear brake disc (2C026). Remove the rear brake disc. 6. Remove the brake shoe retracting spring (2296). 7. Remove the brake shoe adjusting screw spring (2049). 8. Remove the brake adjuster screw (2041). 9. Remove the rear brake shoe hold-down springs (2068). 10. Remove the rear brake shoes and linings (2200) along with the inboard brake shoe retracting spring. 11. Inspect the components for excessive wear or damage and install new components as required. Installation 1. NOTE: Lubricate the brake shoe contact point before installation of rear brake shoes using Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA- 10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. Install the rear brake shoes and linings along with the inboard brake shoe retracting spring. 2. Install the brake shoe hold-down springs.

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1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. CAUTION: Do not use heat to loosen a seized lug nut (1012). Heat can damage the wheel and the wheel bearings. Remove the rear wheels and tires; loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen, but do not remove, the lug nuts. 3. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. Raise and support the vehicle; refer to Section 100-02 . 4. Remove the tire and wheel assembly. 1. Remove the lug nuts. 2. Remove the tire and wheel assembly. 5. Disconnect the (A) parking brake intermediate cable from the (B) parking brake rear cable and conduit, LH. 6. Separate the (A) RH parking brake rear cable and conduit from the (B) LH parking brake rear cable and conduit at the (C) parking brake cable equalizer. 7. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket (2530). 1. Compress the parking brake cable clip. 2. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. 8. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit clip. 9. Remove the (A) RH parking brake rear cable and conduit from the (B) rear parking brake cable retainer (2A709). 10. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 11. Remove the parking brake cable retainer clip (2A826). 1. Remove the parking brake cable retainer clip bolt. 2. Remove the parking brake cable retainer clip. 12. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle housing.

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Water Pump Replacement (L61) Tools Required J 43651 Water Pump Holding Tool Removal Procedure 1. Drain the coolant. 2. Remove the thermostat housing pipe-to-cylinder bolt near the front of the engine. 3. Remove the exhaust manifold heat shield and bolts. 4. Remove the water pump access plate from the front cover. 5. Remove the right hand wheel nuts and wheel assembly. 6. Remove the right hand inner push-pins and splash shield. 7. Disconnect the engine coolant temperature sensor electrical connector. Important: A drain plug has been provided at the bottom of the water pump assembly for additional coolant drainage from the engine block and water pump. 8. Drain the coolant from the plug at the bottom of the water pump. 9. Remove the thermostat housing bolts. 10. Move the thermostat housing toward the left hand side of the vehicle while twisting the water feed pipe from the rear of the water pump assembly. Leave the coolant hoses and thermostat housing cover connected. 11. Remove the water feed pipe. Important: The water pump holding tool supports the sprocket and chain during water pump service. The tool must be used or the balance shaft must be re-timed. 13. Install the J 43651 into position. 14. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket. 15. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly. 16. Remove the 3 inner water pump sprocket to water pump blots.

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CAUTION: Refer to Brake Dust Caution in Cautions and Notices. 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4. Remove the rear tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 5. Install a hand tightened lug nut to retain the rotor to the hub. 6. Compress the caliper piston enough for clearance. Use a C-clamp (3). NOTE: NOTE: Use care to avoid damaging pin boot when rotating caliper. Support the brake caliper with heavy mechanic’s wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

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Removal 1. Raise and support vehicle. Remove wheel assembly. Remove caliper from rotor. Remove locking hub. See AUTOMATIC LOCKING HUBS or MANUAL LOCKING HUBS under REMOVAL & INSTALLATION. 2. Remove wheel bearings, lock nuts, hub and rotor. Remove spindle-to-steering knuckle nuts. Tap spindle with plastic hammer to free spindle from steering knuckle. See Fig. 9 . Remove spindle, spindle seat (if equipped) and splash shield. 3. On right side applications, remove and discard keystone clamp from shaft assembly and stub shaft. Slide rubber boot onto stub shaft. Remove shaft assembly from right axle. See Fig. 9 . 4. Remove left shaft assembly (if required). On all applications, wrap spindle in protective cloth and place second step of spindle in soft-jawed vise. 5. On Explorer and Ranger, remove oil seal using slide hammer and Seal Remover (TOOL-1175-AC). Remove needle bearing from spindle. Press seal from shaft assembly. See Fig. 9 . 6. On Bronco and F150, remove needle bearing and oil seal using slide hammer and Cup Puller (T77F- 1102-A). Press seal from shaft assembly. Installation 1. Clean all dirt and grease from spindle bearing bore. Ensure bearing bore is free of nicks and burrs. On Explorer and Ranger, install seal on shaft assembly using press and Seal Installer (T83T-3132-A). 2. On Bronco and F150, install seal on shaft assembly, with seal lip toward spindle. On right side applications, install rubber boot and NEW keystone clamps on stub shaft. Install right shaft assembly into stub shaft, with stub shaft missing spline aligned with shaft assembly. 3. Ensure splines are fully engaged. Install rubber boot over assembly and tighten keystone clamps. On left axle applications, install shaft assembly through steering knuckle, and engage in splines. 4. Install needle bearing in spindle, with manufacturer identification mark facing away from spindle bore. For bearing installation, use Handle (T80T-4000-W), and Bearing/Seal Installer (T83T-3123-A for Explorer and Ranger; T80T-4000-S for Bronco and F150). CAUTION: Install spindle needle bearing with manufacturer’s identification mark away from spindle bore.