2000 montero sport transfer case diagram

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2000 Chevy Truck S10/T10 Blazer Transfer Case Removal And Installation Manual

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Filed Under (Chevy Manuals) by admin on 18-05-2011

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Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front propeller shaft. Refer to Propeller Shaft Replacement- Front. 3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement-Rear. 4. Remove the vent hose from the transfer case. 5. Disconnect the vehicle speed sensor electrical connectors. 6. Remove the electrical connectors from the transfer case motor/encoder. 9. If equipped with a manual transmission, remove the bolt securing the left side support brace to the transmission. 10. If equipped with a manual transmission, remove the bolt and stud securing the left side support brace to the transfer case 11. If equipped with a manual transmission, remove the two bolts securing the right side support brace to the transmission and transfer case. 12. For vehicles equipped with a manual transmission, remove the six nuts securing the transfer case and bracket to the transmission 13. Remove the transfer case. * Start by pulling the transfer case straight back from the transmission. * After the transfer case is pulled out from the transmission turn and lower the transfer case. 14. For vehicles equipped with a automatic transmission, remove the six nuts securing the transfer case and bracket to the transmission adapter. 15. Remove the transfer case. * Start by pulling the transfer case straight back from the transmission. * After the transfer case is pulled out from the transmission turn and lower the transfer case. 16. Remove and discard the gasket. Installation Procedure 1. Install a new gasket to the transmission. Use sealer GM P/N 12346004 in order to hold the gasket in place. 2. Raise and position the transfer case to the vehicle Notice: Refer to Fastener Notice in Service Precautions. 3. For vehicles equipped with a automatic transmission, install the six nuts securing the transfer case and bracket to the transmission adapter. * Tighten the nuts to 47 Nm (35 lb ft) . 4. For vehicles equipped with a manual transmission, install the six nuts securing the transfer case and bracket to the transmission. * Tighten the nuts to 47 Nm (35 lb ft)

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Toyota V6 Adapter Plate Installation Manual

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Filed Under (Toyota Manuals) by admin on 30-03-2012

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Apply silicone to face of single or dual transfer case assembly. Install adapter plate on face of transfer case, using 4 M10-1.25×35 bolts (provided). We recommend applying blue LocTite® to threads before installation. Torque four plate bolts to 30 ft. lbs. Step 2 Install M-10-1.25×30 allen head bolt using blue Loc- Tite® torque to 30 ft. lbs. Step 3 Remove rear transmission seal using a seal remover or claw hammer. Step 4 Step 5 Install M-10-1.25x 35 bolt using blue LocTite® torque to 30 ft. lbs. Using degreaser, clean the rear transmission seal sur- face. Step 6
Ensure two dowels are in place in the transmission. If dowels are in the transfer case move them to the trans- mission. Step 8 Step 11: Apply silicone to rear face of transmission Slide coupler into place on the back of the transmis- sion. Step 7 Step 9 Step 10 Apply silicon to smaller end of seal adapter Install Seal Adapter into rear of transmission. Gently seat seal adapter into place using rubber mallet Step 11 After Assembling Adapter Plate & T/Case(s): Install replacement v6 dual transfer case crossmember Reconnect 4 wheel drive indicator (This may require cutting and splicing connector from original case) 1988-1991 Application, reconnect speedometer cable (Use speedometer extension cable for dual case applications) 1992-1995 Application will need a replacement VSS for the transfer case Reattach front and rear drive shafts (drive shaft lengths may need to be changed) Fill transfer case with 90W GL5 gear oil, check gear oil level in transmission Reinstall transfer case shifter and boot Drain and replace transfer case oil after first 1,000 miles and every 30,000 thereafter Full synthetic gear oil may be used. Step 12 Using 6 of the 9 stock bolts, 1 allen head bolt and 2 M10-1.25×35 bolts, attach transfer case to transmission. Use blue LocTite® on all bolts. Tighten bolts to 30 ft. lbs. The second allen head bolt should be installed in position shown on the upper right (passenger) side. Step 13 These instructions are designed as a general installation guide. Installation of many Trail-Gear Products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 559-252-4950 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Trail-Gear Inc are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use.

Vehicles Equipped with a Webasto Sunroof System

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Filed Under (More Manuals) by admin on 13-02-2011

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Models: 1997-2000 Buick Century 1988-1991 Buick Reatta 1988-1999 Buick Riviera 1989-2000 Buick Park Avenue 1998-2000 Buick Regal 1988-1997 Cadillac Seville 1988-1996 Cadillac Fleetwood 1988-2000 Cadillac Eldorado 1989-2000 Cadillac DeVille 1995-2000 Chevrolet Cavalier 1998-2000 Chevrolet Malibu 2000 Chevrolet Impala, Monte Carlo 1988-1995 Oldsmobile Ciera 1989-1996 Oldsmobile Ninety Eight 1994-1998 Oldsmobile Achieva 1995-1999 Oldsmobile Aurora 1997 Oldsmobile Silhouette 1998-1999 Oldsmobile Cutlass 1998-2000 Oldsmobile Intrigue 1999-2000 Oldsmobile Alero 1987 Pontiac 6000 1989-1998 Pontiac Bonneville 1994-2000 Pontiac Grand Am 1995-2000 Pontiac Sunfire 1997-1998 Pontiac Trans Sport 1997-2000 Pontiac Grand Prix 1997-2000 Chevrolet & GMC S/T Models (Blazer, Jimmy) 1997-2000 Oldsmobile Bravada #99-08-67-003: Info – Vehicles Equipped with a Webasto Sunroof System – (Jul 23, 1999) This bulletin is being revised to update the model information. Please discard Corporate Bulletin Number 43-10-18A (Body Section)

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2000 Dodge Dakota & Durango Power Windows ADJUSTMENTS

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

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ADJUSTMENTS WINDOWS Remove door trim panel. See DOOR TRIM PANEL under REMOVAL & INSTALLATION. Loosen bolts holding window to regulator. Raise window fully, seating window in frame. Tighten bolts. Install door trim panel. TROUBLE SHOOTING POWER WINDOWS On Dakota, inspect circuit breaker No. 20 (20-amp) in junction block. On Durango inspect circuit breaker No. 21 (25-amp) in junction block. On all models, junction block is located on left end of instrument panel. Inspect fuse No. 9 (40-amp on Dakota, 50-amp on Durango) in Power Distribution Center (PDC). PDC is located in left front corner of engine compartment. Inspect power window system ground circuit. See WIRING DIAGRAMS . SYSTEM TESTS ALL WINDOWS INOPERATIVE Dakota 1. Check circuit breaker for power window system. See TROUBLE SHOOTING . Replace circuit breaker as necessary. If circuit breaker is okay, go to next step. 2. Disconnect negative battery cable. Remove driver’s front power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. Check for continuity between ground and terminal No. 3 (Black wire) at driver power window switch wiring harness connector. If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between driver power window 2000 Dodge Durango 2000 ACCESSORIES & EQUIPMENT’ ‘Power Windows – Dakota & Durango 2000 Dodge Durango 2000 ACCESSORIES & EQUIPMENT’ ‘Power Windows – Dakota & Durango switch connector and ground. See WIRING DIAGRAMS . 3. Connect negative battery cable. Turn ignition on. Measure voltage between ground and terminal No. 5 (Tan wire) at driver’s power window switch wiring harness connector. If battery voltage is present, check driver power window switch. See POWER WINDOW SWITCH under COMPONENT TESTS. If battery voltage is not present, repair open Tan wire between driver power window switch connector and ignition switch. See WIRING DIAGRAMS . See POWER DISTRIBUTION article in WIRING DIAGRAMS. Durango 1. Check circuit breaker for power window system. See TROUBLE SHOOTING . Replace circuit breaker as necessary. If circuit breaker is okay, go to next step. 2. Disconnect negative battery cable. Remove driver’s front power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. 3. Check for continuity between ground and terminal No. 5 (Black wire) at driver’s power window switch wiring harness connector. If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between driver’s power window switch connector and ground. See WIRING DIAGRAMS . 4. Reconnect negative battery cable. Turn ignition on. Measure voltage between ground and terminal No. 4 (Tan wire) at driver’s power window switch wiring harness connector. If battery voltage is present, check driver’s power window switch. See POWER WINDOW SWITCH under COMPONENT TESTS. If battery voltage is not present, repair open Tan wire between driver power window switch connector and ignition switch. See WIRING DIAGRAMS . See POWER DISTRIBUTION article in WIRING DIAGRAMS. ONE WINDOW INOPERATIVE

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1995-1997 FORD EXPLORER TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP

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Filed Under (Ford Manuals) by admin on 20-01-2012

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TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP ISSUE to the Data Link Connector (DLC) underneath The diagnostic procedure for binding or shudder the steering wheel. Monitor for any Diagnostic from transfer case in slow, tight turns while in 4 Trouble Codes (DTCs) set by the transfer case Auto mode may be inaccurate for some vehicles. that could indicate incorrect speed sensor function. Codes could include, but are not ACTION limited to: Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure. •P1836 – Front propshaft sensor circuit failure •P1837 – Rear propshaft sensor circuit failure DIAGNOSTIC PROCEDURE •P1874 – Hall effect sensor power short circuit to battery 1997 EXPLORER •P1875 – Hall effect sensor power circuit 1. Test drive the vehicle in 4 Auto, 4 High and 4 failure Low. Evaluate the vehicle in each of these NOTE modes. The vehicle should bind in turns in both ADDITIONAL CODES COULD BE SET AS WELL. 4 High and 4 Low, but not in 4 Auto. The 4 PLEASE REFER TO THE APPROPRIATE YEAR High mode is intended for severe winter EXPLORER SERVICE MANUAL FOR COMPLETE weather or off-road driving only. It is not LISTING AND EXPLANATION. intended for use on dry or merely wet pavement. 3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and 2. Verify the instrument panel has the proper 4X4 replace accordingly. Drive the vehicle to verify if selection label (Figure 1). Proceed to 1995-97 the shudder/binding has been eliminated. Send Explorer heading, Step 1. replaced speed sensor to the Ford Warranty 1995-97 EXPLORER Parts Return Center, Canton, MI. NOTE 4. Using NGS Tester, monitor the Parameter 4 AUTO IS THE FAR LEFT SWITCH POSITION Identification Display (PID) on the transfer case ON 1997 MODELS AND IS THE MIDDLE clutch duty cycle. If the 4 Auto mode reads POSITION ON 1996 MODELS. something higher than one (1), verify speed sensors have not set any Generic Electronic 1. If during test driving, the vehicle shudders or Module (GEM) DTCs and follow the speed binds in 4 Auto during slow forward or reverse sensor diagnostic procedure in the above Step parking lot maneuvers, proceed to Step 2. 2. Verify the following while checking PID: Mode Duty Cycle Indicator 4 Auto 0 or 1 4 High 13 4 Low 38 at 5 MPH 5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil

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4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0500, P0836, P1875 Set (Replace Encoder Motor Sensor, Reprogram TCCM, Inspect Front Drive Axle Engagement Sleeve for Damage/Repair if Necessary)

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Filed Under (More Manuals) by admin on 22-06-2012

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Correction Important: For ease of reassembly, shift the transfer case assembly to 2HI for the NV263 (NP1), or Neutral for the NV246 (NP8) prior to removing any components. For information on placing the NV246 (NP8) transfer case in NEUTRAL, see the procedure at the end of this bulletin. 1. Remove the transfer case and front axle/engine skid plates (if equipped). 2. Disconnect and position the front propeller shaft aside. 3. Disconnect the transfer case encoder motor wiring harness. 4. Remove the three (3) bolts that retain the encoder motor to the transfer case. 5. Separate the encoder motor assembly from the transfer case and place it on a work bench. Important: DO NOT REMOVE THE SCREWS INDICATED WITH THE (1) IN THE ABOVE ILLUSTRATION. 6. Remove the four screws on the outer perimeter of the encoder motor housing. Important: For proper timing and ease of reassembly, hold the gear in place as your remove the cover from the encoder motor assembly with your thumb or finger. 7. Carefully remove the cover from the encoder motor assembly. The cover has a seal on the bottom side. Place the cover in a position to protect this seal from damage and/or contamination. Important: Observe the location of the punch mark on the large gear in relation to the timing mark on the housing if the transfer case was placed in the 2HI for the NV263 (NP1), or Neutral for the NV246 (NP8). The timing marks should be within one tooth of proper alignment. If not, you must note the timing mark positions for reassembly. 8. Locate the two shims; one on the small gear and another on the larger gear. Set them aside on a clean surface for reuse. Important: After removing the large gear from the housing, a dark gray phenolic spacer should remain in the casting where the bottom of the large gear resides. Locate this spacer and save for reuse. 9. Carefully lift the large gear from the housing. The sensor and wiring harness will come with the gear. 10. Disconnect the wiring from the sensor. 11. Separate the sensor from the large gear.

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TOYOTA LC70 HYDRAPNEU LTPTO INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 01-12-2011

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INSTALLATION INSTRUCTIONS ` Raise the vehicle on a hoist to a workable height. Remove the front drive shaft (C) at the transfer case flange (D). In order to easily install the LTPTO, the cross member (E) must be lowered from the main chassis (F) by approximately 30mm. Using a 14mm socket loosen the eight bolts (g) supporting the cross member (E) . Use the appropriate safety equipment to support the cross member and prevent it from falling. Remove the rear backing plate (I) from the transfer case (t/case) (H) with a 14mm socket. Use a container to collect any oil that may leak from the t/case after the rear backing plate is removed. Remove all old gasket glue from around the mounting face (M) of the t/case (H) ensuring not to damage the mounting face. Then replace the rear backing plate (I) to prevent possible contamination during future steps. Parts of the t/case (H) must be modified in order to allow the units engagement cable to be mounted correctly. As illustrated in the picture, (looking from front of vehicle), remove the small amount of the material on the rib and lip as shown. The amount can be checked by loosely mounting the LTPTO unit and checking that the cable sheath does not foul on the case. While the rear backing plate is installed use a die grinder to complete this task, remove the backing plate to test the unit. A second rib may have to be modified, in order to determine this; loosely mount the LT PTO unit (1) and check to see if the rib (J) shown will prevent the unit from seating correctly with the transfer case. Then, if required, die grind a small amount of material from the rib (J) to ensure the correct mating of the two faces. A gap of at least 3mm between t/case (H) and LTPTO (I) should be sufficient to ensure a correct seal is created between the two faces. If the backing plate (18) on the LTPTO is installed at this stage remove it by undoing the nine x M5 Socket Head Cap (3) Screws (SHCS) – with a 4mm Allen key.

2007 Chevrolet Impala V6-3.9L – A/T 4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration

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Filed Under (Chevrolet Manuals) by admin on 16-06-2011

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This service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover ( Channel Plate ) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, other gaskets not included in this service kit will also be needed to complete the repair – a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering gasket kit 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to-Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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Filed Under (More Manuals) by admin on 07-07-2012

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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Filed Under (More Manuals) by admin on 19-05-2012

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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