1989 dodge ram 150 electrical diagram

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1998 Ford F 150/250 Instrument Panel and Console REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 15-05-2012

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Instrument Panel Removal 1. If equipped with power seats, move the seat fully rearward. 2. Remove the passenger air bag. For additional information, refer to Section 501-20B . 3. Remove the driver air bag. For additional information, refer to Section 501-20B . 4. NOTE: On vehicles equipped with automatic transmissions, move the shift lever to the 1 position to ease removal. Carefully pry to release the (A) clips and remove the (B) steering column opening cover. 5. Position the electrical connector aside. * Release the push clip from the lower instrument panel steering column cover (044F08). 6. Pull to release the three (A) clips and remove the (B) fuse door. 7. Position the hood latch release handle aside. 1. Remove the screws. 2. Position the hood latch release handle aside. 8. Position the parking brake release handle aside. 1. Remove the screws. 2. Position the parking brake release handle aside. 9. If equipped, remove the instrument panel floor duct panel. * Remove the two push clips and release the expander clip. 10. Remove the lower instrument panel steering column cover (04459). 1. Remove the bolts. 2. Remove the lower instrument panel steering column cover. 11. Remove the LH and RH scuff plates. 12. Remove the LH and RH cowl side trim panels. 13. Disconnect the brake pedal position (BPP) switch electrical connector. 14. Remove the (A) radio ground and the (B) GEM/CTM ground bolts. 15. Disconnect the LH instrument panel main harness connectors. 16. Remove the bulkhead wiring harness electrical connectors from inside the engine compartment. 1. Loosen the bolts. 2. Disconnect the bulkhead electrical connectors. 17. Remove the bulkhead electrical connector from the dash panel. 1. Release the six locking tabs. 2. Remove the bulkhead connector from the dash panel. 18. Disconnect the air bag diagnostic monitor electrical connectors. 19. Disconnect the inertia fuel shutoff switch electrical connector. 20. Remove the RH ground bolts. 21. Disconnect the RH instrument panel main harness connectors. 22. Disconnect the electronic blend door actuator electrical connector. 23. Disconnect the climate control head vacuum harness connector. 24. Remove the instrument panel steering column opening cover reinforcement (04502). 1. Remove the nuts. 2. Remove the instrument panel steering column opening cover reinforcement. 25. Disconnect the air bag sliding contact electrical connectors and the anti-theft sensor electrical connector.

1998 Pontiac Grand Prix DTC P0753 1-2 Shift Solenoid Circuit Electrical Repair Manual

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Filed Under (Pontiac Manuals) by admin on 07-06-2012

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Test Description The numbers below refer to the step numbers on the diagnostic table. 6. This step isolates the fault between the engine harness and the transmission harness. 8. This step verifies that circuit 1222 is neither open nor shorted to power. 11. This step verifies that the 1-2 shift solenoid has neither shorted across its windings nor increased its resistance. DTC P0753 1-2 Shift Solenoid Circuit– Electrical Step Action Value(s) Yes No 1 Was the Powertrain On-Board Diagnostic (OBD) System Check performed? — Go to Step 2 Go to Powertrain On Board Diagnostic (OBD) System Check 2 1. Install the Scan Tool . 2. Turn the ignition switch to the RUN position. Important Before clearing the DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data. 3. Record the DTC Freeze Frame and Failure Records, then clear the DTC. — Go to Are DTCs P0758, P1860 or P0740 set? Step 3 Go to Step 6 3 1. Remove the TCC fuse. 2. Inspect the fuse for an open. Was a condition found and corrected? — Go to Step 4 Go to Step 5 4 Repair short to ground in engine harness circuit 1339 or transmission harness circuit 839. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 — 5 Repair the open in engine harness circuit 1339 or transmission harness circuit 839. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 — 6 1. Turn the ignition switch OFF. 2. Disconnect the Automatic Transmission 7-way connector. 3. Install the J 38835 Transmission Electrical Jumper on the engine harness connector. 4. Connect a test lamp from terminal E to terminal A of the jumper using a J 35616-A Connector Test Adapter Kit. Important Additional DTCs will set. 5. With the engine OFF, turn the ignition ON. Is the test lamp ON? — Go to Step 7 Go to Step 8 7 Inspect engine harness circuit 1222 for a short to ground. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 Go to Step 20 8 Using the scan tool command the 1-2 solenoid ON and OFF three times. Does the test lamp cycle ON and OFF as commanded? — Go to Step 11 Go to Step 9 9 Inspect engine harness circuit 1222 for an open. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 Go to Step 10 10 Inspect engine harness circuit 1222 for a short to power. Refer to General Electrical Diagnosis Procedures . Was a condition found and corrected? — Go to Step 21 Go to Step 19 11 1. Turn the ignition OFF. 2. Disconnect the J 38835 Transmission Electrical Jumper from the engine harness. 3. Connect the J 38835 Transmission Electrical Jumper to the Automatic Transmission 7-way connector. 4. Connect a J 39200 Digital Multimeter (DMM) from 19 ohms to 31 ohms terminal E to terminal A of the jumper. Is the measured resistance within the specified range? Go to Step 15 Go to Step 12 12 Is the resistance greater than the specified value? 31 ohms Go to Step 13 Go to Step 15 13 Inspect the transmission harness RED wire circuit 839 and the LT GRN wire circuit 1222 for an open. Refer to General Electrical Diagnosis Procedures . Was a condition found? — Go to Step 14 Go to Step 18 14 Replace the Automatic Transmission Wiring Harness. Refer to Solenoids and Wiring Harness Replacement . Is the replacement complete? — Go to Step 21 — 15 Connect the J 39200 Digital Multimeter from terminal A of the jumper to ground. Is the resistance less than the specified value? 100 ohms Go to Step 16 Go to Step 18 16 Inspect the transmission harness LT GRN wire circuit 1222 for a short to ground or short to power. Refer to General Electrical Diagnosis Procedures . Was a condition found? — Go to Step 17 Go to Step 18 17 Replace the Automatic Transmission Wiring Harness. Refer to Solenoids and Wiring Harness Replacement . Is the replacement complete? — Go to Step 21 — 18 Replace the 1-2 Shift Solenoid Valve Assembly. Refer to Solenoids and Wiring Harness Replacement . Is the replacement complete? — Go to Step 21 — 19 Inspect PCM connector C1 (Blue) for bent, damaged or backed out connector pins. Was a condition found and corrected? — Go to Step 21 Go to Step 20 20 Replace the PCM. Refer to PCM Replacement/Programming . Is the replacement complete? — Go to Step 21 — 21 In order to verify your repair, perform the following procedure: 1. Using the scan tool, clear DTCs. 2. Operate the vehicle under the following conditions: { The engine speed is more than 500 RPM. { The vehicle is not in fuel shut off. { System voltage is 10-16 volts. { Drive the vehicle through the 1-2 shift. { When the 1-2 SS Valve Assembly is commanded ON, the voltage decreases to zero. { When the 1-2 SS Valve Assembly is commanded OFF, the voltage increases to B+. { All conditions are met for 5 seconds.

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1989-1996 Dodge Dakota Trucks COIL Ignition Tests Manual

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Filed Under (Dodge Manuals) by admin on 18-06-2012

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Dakota Trucks 1989-1996 Ignition Tests COIL The ignition coil for the vehicles covered by this guide is in the following locations: • 1989-92 engines: mounted to the firewall • 1993-96 2.5L engines: mounted on the thermostat housing in front of the coolant temperature sensor • 1993-96 V6 and V8 LDC engines: mounted to a bracket bolted to the right engine cylinder head • 1993-96 5.9L HDC engines: mounted to a bracket bolted to the air injection pump (AIR pump) mounting bracket. Fig. 2: Ignition coil mounting-all 1989-92 models Fig. 3: Ignition coil wiring and mounting hardware-1993- 96 2.5L engine 1. Inspect the ignition coil for arcing while the engine is running. If the engine will not start, this can be performed while the engine is cranked by either an assistant or a remote starter. Look at the coil in dim or low light to aid visibility of any arcing. Fig. 4: Ignition coil mounting-1993-96 3.9L and 5.2L/5.9L LDC engines 2. Arcing at the tower will carbonize the wire boot, which, if it is connected to a new ignition coil, will cause the coil to fail. In such cases, clean all the carbonization away or replace the components as necessary. Fig. 5: Ignition coil mounting-1993-96 5.9L HDC engine 3. Using a coil tester or ohmmeter according to the manufacturer’s instructions, test the primary and secondary resistance. Replace any coil that does not meet the specifications indicated in the accompanying chart. 4. Inspect the secondary coil wire for any sign of damage. Replace if any damage is found. Carbon tracking on the old wire can cause arcing and the failure of a new ignition coil. REMOVAL & INSTALLATION 1989-92 Models See Figures 6 and 7 1. Disconnect the negative battery cable. 2. Disconnect the three wires from the coil. Mark them to identify for installation. Fig. 6: Remove the coil bracket bolt at the cowl Fig. 7: Unscrew the coil mounting hardware, then remove the coil from the vehicle 3. Unplug the condenser suppressor connector from the coil, if equipped. 4. Unbolt and remove the coil. To install: 5. Bolt down the coil with old bolts. 6. Connect wires to coil making sure that the proper wires are connected where they should be. 7. Connect the condenser suppressor, if equipped. 8. Connect the battery negative cable Removal and Installation V6 AND V8 ENGINES 1. Disconnect the negative battery cable. 2. Disconnect the primary wiring from the ignition coil. 3. Disconnect the secondary spark plug wire from the coil. 4. Remove the two bolts and withdraw the coil from its mounting bracket. To install:
5. Position the coil on its bracket and install the two bolts. Tighten them to 100 inch lbs. (11 Nm). If the bracket has been tapped for coil mounting bolts, these fasteners require less torque, so tighten them to 50 inch lbs. (5 Nm). 6. Connect all wiring to the ignition coil. TESTING See Figure 1 The only test you can perform without a DRBII scan tool, or equivalent, is a basic check of the sensor only.

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1999 Ford Windstar Instrument Panel and Console REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals, Uncategorized) by admin on 23-04-2012

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Instrument Panel Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Remove the steering wheel. Refer to Section 211-04 . 2. Remove the passenger side air bag module. Refer to Section 501-20B . 3. Disconnect the antenna in-line connector. 4. Remove the RH instrument panel reinforcement bolt. 5. Close the glove compartment. 6. Remove the utility compartment. 1. Remove the four two part pin type retainers. 2. Remove the utility compartment. * Disconnect the power point electrical connector. 7. If equipped, disconnect the compact disc changer electrical connector. 8. Release the compact disc changer electrical connector locator. 9. Remove the LH and RH scuff plates. 10. Remove the LH and RH A-pillar lower trim panels. 11. Position the LH and RH front door weatherstrip seals aside. 12. Remove the RH ground bolts. 13. If equipped, remove LH and RH instrument panel lower insulators. 14. Remove the instrument panel lower steering column opening cover. 1. Remove the screws. 2. Remove the instrument panel lower steering column opening cover. 15. Remove the instrument panel opening cover reinforcement. 1. Remove the bolts. 2. Remove the instrument panel opening cover reinforcement. 16. Disconnect the LH wiring harness electrical connectors. 17. Disconnect the electronic crash sensor (ECS) electrical connector. 1. Release the locking clip. 2. Disconnect the ECS electrical connector 18. Disconnect the automatic transmission shift cable. 1. Disconnect the cable from the steering column shift tube lever. 2. Disconnect the cable from the steering column bracket. 19. Separate the intermediate shaft from the steering column. 1. Remove the pinch bolt. 2. Separate the intermediate shaft from the steering column. 20. Disconnect the climate control harness electrical connector. 21. Disconnect the climate control vacuum harness connector. 22. Disconnect the fuse junction panel electrical connectors. 23. Remove the LH instrument panel reinforcement bol 4. Remove the four instrument panel center support bolts. 25. Remove the instrument panel defroster opening grille. * If equipped, disconnect the sunload sensor electrical connector. 26. Remove the cowl top bolts. 27. Remove the RH cowl side bolts. 28. Remove the LH cowl side bolts. 29. NOTE: Two technicians are required to carry out this step. Remove the instrument panel. Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: Two technicians are required to carry out this step

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2000 Ford Crown Victoria/ Grand Marquis Intake Manifold – Gasoline Engines Removal and Installation Manual

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Filed Under (Ford Manuals) by admin on 16-04-2012

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Intake Manifold—Gasoline Engines Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Drain the engine cooling system. For additional information, refer to Section 303-03 . 3. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 . 4. Disconnect the fuel line. For additional information, refer to Section 310-00A or Section 310-00B . 5. Remove the wiper arm and pivot shaft. For additional information, refer to Section 501-16 . 6. Remove the drive belt. For additional information, refer to Section 303-05 . 7. Raise the vehicle on a hoist. For additional information, refer to Section 100-02 . 8. Disconnect the electrical connector at the crankshaft position (CKP) sensor. * Disconnect the pin-type retainer from the A/C compressor bracket. 9. Disconnect the electrical connector from the A/C compressor. 10. Remove the oil bypass filter. 11. Disconnect the oil pressure sensor electrical connector and the power steering pressure (PSP) switch electrical connector. 12. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold 13. Lower the vehicle. 14. Disconnect the two differential pressure feedback EGR hoses. 15. Disconnect the RH heated oxygen sensor electrical connector. 16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils. 17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors. 18. Disconnect the accelerator cable and the speed control actuator cable. 19. Remove the cables from the EGR tube heat shield and position out of the way. 20. Remove the bolts and the EGR tube heat shield. 21. Disconnect the evaporative emissions (EVAP) return tube, the main chassis vacuum supply line, and the EGR valve vacuum supply. 22. Disconnect the positive crankcase ventilation (PCV) tube assembly at two locations and remove. 23. Disconnect the electrical connector from the EGR vacuum regulator solenoid. 24. Disconnect the vacuum line from the EVAP canister purge valve. 25. Disconnect the generator cable and electrical connector 26. Remove the bolts and the generator mounting bracket. 27. Remove the upper radiator hose. 28. Disconnect the electrical connector from the idle air control (IAC) valve and the throttle position (TP) sensor. 29. Disconnect the heater water hose. 30. Disconnect the EGR tube from the EGR valve. 31. NOTE: The LH heated oxygen sensor and the transmission electrical connectors are attached to the wiring bracket and must be separated from the bracket. Remove the wiring bracket. * Disconnect the wiring connectors. * Separate the transmission harness from the stud. * Remove the nut and the bolt and remove the bracket.

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1989 Honda Accord LXi FUSES AND CIRCUIT BREAKERS IDENTIFICATION / REPAIR MANUAL

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Filed Under (Honda Manuals) by admin on 19-05-2011

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1 – 15 Amp Charge Warning Light, Voltage Regulator, Cooling Fan Timer Control Unit, Fuel Cut-off Relay, Speed Sensor, PGM-FI Main Relay, Fuel Pump, Control Solenoid Valves, Emission Control Unit, Speed Sensor (Automatic Seat Belts, 1988-89) 1989 Honda Accord LXi FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1986-89 Honda 1989 Honda Accord LXi FUSES & CIRCUIT BREAKERS’ ‘Fuses & Circuit Breakers 1986-89 Honda None Sunday, August 10, 2008 12:33:23 AM Page 1 © 2005 Mitchell Repair Information Company, LLC. None Sunday, August 10, 2008 12:33:26 AM Page 1 © 2005 Mitchell Repair Information Company, LLC. ? 2 – 10 Amp Safety Indicator, Shift Lever Position Indicator, Clock & Gauges, Tachometer, Back-Up Lights, Turn Signal Relay & Lights, Integrated Control Unit, Warning Lights, Cruise Control Indicator, Light Dimming Circuit, Automatic Seat Belt Control Unit, Shift Lock Solenoid (1989) ? 3 – 20 Amp Wiper Motors, Washer Motors, Intermittent Wiper Relay, Sun Roof Relays, Power Window Relay ? 4 – 7.5 Amp Cruise Control Unit, Cruise Control Indicator Light ? 5 – 10 Amp Rear Window Defogger Relay, Rear Window Defogger Indicator Light, Heater Control Amplifier, Fan Motor, A/C Compressor Clutch & Relay, A/C Delay Unit, Heater Control Panel ? 6 – 10 Amp Right Headlight Low Beam ? 7 – 10 Amp Left Headlight Low Beam ? 8 – 15 Amp Left Headlight High Beam ? 9 – 15 Amp Right Headlight High Beam, High Beam Indicator Light ? 10 – 7.5 Amp Brake Warning Bulb Check Circuit, PGM-FI ECU, PGM-FI Main Relay, Emission Control Unit ? 11 – 15 Amp Headlight Retractor Control Unit (Up) ? 12 – 15 Amp Power Door Mirrors, EFE Heater Unit, Radiator Fan Relay, Cooling Fan Timer Unit ? 13 – 10 Amp Power Antenna Motor, Stereo Radio/Cassette Player, Power Amplifier (SEi Model) ? 14 – 15 Amp Vanity Mirror Light, License Plate Lights, Taillights, Rear Side Marker Lights, Dash Light Brightness Control Unit, Cigarette Lighter Illumination, Ashtray Light, Headlight Retractor Control Unit (Light-On), Dash & Switch Lights ? 15 – Blank

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2001 Dodge Durango BLOWER MOTOR RELAYS REPAIR MANUAL

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Filed Under (Dodge Manuals) by admin on 13-02-2012

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BLOWER MOTOR RESISTOR 1. Disconnect negative battery cable. Disconnect blower motor resistor harness connector. Using DVOM, check for continuity between all blower motor resistor terminals. If continuity exists between all terminals, go to next step. If continuity does not exist between all terminals, replace faulty blower motor resistor. 2. Check for open or short in circuits between blower motor resistor and heater control panel. Also check for open or short in wire between blower motor resistor and blower motor. BLOWER MOTOR SWITCH 2000 Dakota, 2000 Durango & 2000-01 Ram Pickup 1. Remove Power Distribution Center (PDC) cover. Using DVOM, check for battery voltage at PDC fuse No. 5 (40-amp) on Dakota and Durango; PDC fuse No. 12 (40-amp) on Ram Pickup. If battery voltage exists, go to next step. If battery voltage does not exist, check for open in Red wire between battery and underhood PDC. If Red wire is okay, replace underhood PDC. 2. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel cable, electrical and vacuum connectors as necessary. Using DVOM, check for continuity between heater control panel harness connector terminal No. 7 (Black wire on Dakota and Durango; Black/Orange on Ram Pickup) and ground. See Fig. 5 . If continuity exists, go to step 4 . 3. If continuity does not exist, repair open in Black wire or Black/Orange wire between heater control panel 2001 Dodge Durango 2000-01 HEATER SYSTEMS’ ‘RWD Trucks & Vans harness connector terminal No. 7 and ground connector located at lower right corner of instrument panel (Dakota and Durango) or behind center of instrument panel (Ram Pickup). 4. Place heater mode control knob to any position except OFF. Using DVOM, check for continuity between heater control panel terminal No. 7 and terminals No. 3, 4, 5 and 6 while rotating blower motor switch. See Fig. 5 . 5. If continuity does not exist at any terminal, replace faulty heater control panel. If continuity exists as specified, check for open in circuits between heater control panel and blower motor resistor. Also check for an open in circuit between heater control panel and blower motor. See WIRING DIAGRAMS . Fig. 5: Identifying Heater Control Panel Blower Switch Connector Terminals (2000 Dakota & Durango Are Shown; Ram Pickup Is Similar) Courtesy of CHRYSLER CORP. Ram Van/Wagon 1. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel harness connectors. Using DVOM, check for continuity between heater control panel C3 harness connector terminal “C” (Black wire) and ground. See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between heater control panel and ground connector located at lower right of steering column. 2. Place heater mode control selector to any position, except OFF. Using DVOM, check for continuity between appropriate terminals of heater control panel, for C3 connector terminals “B” (Violet wire) and “C” (Black wire). If continuity exists through heater control panel, go to next step. If continuity does not exist, replace faulty heater control panel assembly. 3. Using DVOM, check for continuity between heater control panel C3 connector terminal “B” (Violet wire) and C1 connector terminal “E” (Violet wire). See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Violet wire between heater control panel C3 and C1 connectors.

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Hemi Chrysler 300C, Dodge Magnum and Dodge Charger Installation instructions

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Filed Under (More Manuals) by admin on 06-12-2011

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Installation instructions: 1. Raise and support vehicle. 2. Lubricate factory rubber hangers with penetrating oil. 3. Remove fasteners attaching driver side tailpipe/resonator assembly to rear of center-mount factory muffler. Remove tailpipe/resonator from factory hangers and from vehicle. 4. Loosen stock clamps attaching stock exhaust to converter pipe outlets near front of vehicle. 5. Remove black factory stiffener cross-brace from bottom of vehicle. 6. With a helper, remove factory hanger rods from rubber hangers and remove remaining exhaust system from vehicle. 7. Place two supplied clamps over inlets of X-pipe and install assembly over outlets of factory converter pipes. The X- pipe should be installed to position the slotted-hole brackets towards the top of the pipes. Do not fully tighten clamps at this time. 8. Using two supplied clamps, install mufflers over outlets of X-pipe assembly. Do not fully tighten clamps at this time. 9. Using two supplied clamps, install left and right tailpipes to outlets of mufflers and insert hanger rods into factory rubber hangers. Do not fully tighten clamps at this time. 10. Install tips with clamps over outlets of tailpipes. 11. Reinstall factory body stiffener brace to bottom of vehicle. 12. Starting at front of vehicle, align system and tighten clamps. You may need to push system upwards while tightening clamps to be sure system adequately clears stiffener brace. 13. Align tips and tighten clamps .

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1999 Ford Crown Victoria/ Grand Marquis Instrument Panel and Console Removal/ Installation Manual

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Filed Under (Ford Manuals) by admin on 05-07-2012

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Instrument Panel Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Remove the driver side air bag module. For additional information, refer to Section 501-20B . 2. Remove the passenger side air bag module. For additional information, refer to Section 501-20B . 3. Close the glove compartment. 4. Position the speed control servo aside. 1. Disconnect the electrical connector. 2. Remove the nuts. 3. Position the speed control servo aside. 5. Disconnect the LH engine compartment in-line electrical connector. * Release the wiring harness locators. 6. Disconnect the brake fluid sensor electrical connector. 7. Disconnect the windshield wiper motor electrical connector. * Release the wiring harness locators. 8. Disconnect the LH engine compartment in-line electrical connectors. 9. Unseat the LH wiring harness grommet 10. Disconnect the blower motor electrical connector. 11. Disconnect the A/C pressure cut-off switch electrical connector. 12. Disconnect the RH engine compartment in-line wiring harness connectors. 13. Disconnect the vacuum line at the intake manifold. 14. Disconnect the electronic air temperature control (EATC) variable blower motor controller electrical connector. * Release the wiring harness locators. 15. Remove the RH front wheel and tire assembly. For additional information, refer to Section 204-04 . 16. Remove the upper front fender splash shield bolts. 17. Remove the lower front fender splash shield bolt and locator. 18. Position the front fender splash shield away from the dash panel. 19. Unlock the wiring harness guide. 20. Unseat the RH wiring harness grommet. 21. Install the RH front wheel and tire assembly. For additional information, refer to Section 204-04 . 22. Remove the RH instrument panel lower insulator. 1. Remove the pin-type retainers. 2. Release the locking tab. 3. Remove the instrument panel lower insulator. * Disconnect the courtesy lamp.

2004-2005 FORD F-150 FRONT BRAKE ROUGHNESS/ SHUDDER WHILE BRAKING REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 10-06-2012

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ISSUE b. If new level (47 fin) rotors are present, Some 2004/2005 F-150 vehicles built before perform one (1) of the following: 11/29/2004 may exhibit front brake roughness and or shudder while braking. (1) If rotors are within minimum thickness specifications, machine the rotors using ACTION the Rotunda on vehicle brake lathe and Service the rack and pinion, rotors, and caliper the Rotunda adapter kit 201-R0093. assemblies as needed, based on vehicle build date Refer to the Workshop Manual, Section and current part levels installed on the vehicle. 206-00 for the correct on-vehicle brake Refer to the following Service Procedure. lathe procedure. SERVICE PROCEDURE (2) If rotors are beyond machinable thickness, the front rotors must be 1. Vehicles built prior to 8/20/2003 require the replaced. replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop 3. Install new service fix calipers. Manual, Section 206-03 and 211-02. NOTE 2. Determine if the vehicle has the old or new REPLACE CALIPERS WITH NEW SERVICE FIX level rotors (Figure 1). CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. PART NUMBER PART NAME 6L3Z-2B120-A Caliper Asy (Right Side) 6L3Z-2B121-A Caliper Asy (Left Side) 5L3Z-1102-AB Rotor (4X2, 6 Lug) 5L3Z-1102-BA Rotor (4X2, 7 Lug) 5L3Z-1125-AA Rotor (4X4, 6 Lug) 5L3Z-1125-BA Rotor (4X4, 7 Lug) 6L3Z-3504-AA Steering Gear (Super Cab/Crew 4X2) 6L3Z-3504-BA Steering Gear (Super Cab/Crew 4X4) Figure 1 – Article 05-21-19 6L3Z-3504-CA Steering Gear (Regular Cab 4X2) 6L3Z-3504-DA Steering Gear (Regular Cab 4X4) a. If old level rotors, replace the front rotors 6L3Z-3C294-AA Retainer Spindle Nut and front caliper assemblies. Refer to Workshop Manual, Section 206-00 for front rotor and caliper replacement.

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