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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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2004 Ford Truck Ranger 2WD Transmission Position Switch/ Sensor Service and Repair MANUAL

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

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Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the shift cable from the manual control lever. 3. Disconnect the digital transmission range (TR) sensor electrical connector. 4. Remove the manual control outer lever nut and manual control outer lever. 2004 Ford Truck Ranger 2WD V6-4.0L VIN E 5. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. 2004 Ford Truck Ranger 2WD V6-4.0L VIN E Copyright © 2007, ALLDATA 9.50 Page 3 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted correctly.

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ALL INFINITI BRAKE NOISE/ JUDDER/ PEDAL FEEL DIAGNOSIS AND REPAIR MANUAL

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Filed Under (Infiniti Manuals) by admin on 23-04-2012

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SERVICE PROCEDURE 1. Verify the condition by road testing the vehicle with the customer. 2. Determine the specific brake issue based on the description in the Service Information above. 3. Follow the appropriate repair procedure(s), listed on the following pages, for your specific issue BRAKE NOISE • Brakes can make a range of noises when applied or released. Some noises are normal and no repair action should be taken. • Use the following descriptions to identify the specific type of brake noise and the appropriate repair: Squeak noise when the brakes are cold: • Usually occurs during the first few stops in the morning. • This is a normal condition. No service action is necessary Squeak noise with the brakes at normal operating temperatures: • listed under Brake Service on page 5 of this bulletin and the appropriate Service Manual procedures. • Refer to technical bulletins specific to the model of vehicle regarding this issue. If there are no bulletins for the car you are working on, install OE type pads using the information Notes about brake pads and brake noise: Original Equipment (OE) brake pads are installed on all current Infiniti vehicles at the factory. The OE pads use a Non-asbesto • s Organic (NAO) compound. The NAO material provides state of the art resistance to squeal noise. • ervice parts and must be used if replacing brake pads under the terms of • ted under Brake Service on page 5 of this bulletin and the appropriate Service Manual Gro n s after coming to a stop: • It is a normal condition. No repair or service is necessary. Groan noise during stopping: • Usually caused by glazing of the rotor’s surface as a result of heavy or frequent braking. • Refer to technical bulletins specific to the model of vehicle regarding this issue. • Replace the brake pads, then resurface the rotors and finish them with sand paper. Refer to Brake Service on page 5 for additional detail. Single clunk noise from front suspension when applying the brakes: • The noise is a result of the brake pads shifting in the direction of rotor rotation when the brakes are applied. Can be duplicated by lightly touching the brake pedal. • • If the brake pedal is pushed hard, the noise is less likely to occur. Make sure the brake pads and pad hardware (shims, springs, clips, etc) are installed correctly. Refer to ASIST for vehicle specific brake service information. Refer to Brake Service on page 5 for additional detail. Mull e he engine is started: • st er models, the self check occurs the first aches 5 mph after the engine is started. ors or drums. • WARNING: Brake dust may be hazardous if inhaled. Refer to the Service Manual (ESM) for brake • n and lubrication of brake pads, CAUTION: Do not get grease on the brake pad friction surface. A • Brake Judder is caused by rotor thickness variation and/or rotor run out.

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Honda Navigation System Information and DVD Information and Inspection Manual

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

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REVISION SUMMARY •Under BACKGROUND, more sources for navigation service and user information are listed. •Under DVD LABEL COLOR IDENTIFICATION BY MODEL, the Latest DVD Version available is updated. •Under REPLACING THE NAVIGATION CONTROL UNIT AND TRANSFERRING THE NAVIGATION DVD, a step was added to Save Users Memory when replacing the navigation control unit. •Under ENTERING THE ANTI-THEFT CODE, the instructions about obtaining the serial number from a navigation unit without removing it were clarified. •Under NAVIGATION SYSTEM PLATFORMS, HFL was added to the list of Distinguishing Features . BACKGROUND Use this information to avoid possible customer dissatisfaction issues caused by incorrect or outdated DVD installation. For more information about the navigation system and its operation, refer to the following resources: •Service Manual – Printed or on ISIS •Quick Start Guide •Online University – Use the keyword NAVI . •Navigation System Manual – Besides the one that comes with the vehicle, the navigation system manual is also available online. Select SEARCH BY PUBLICATION , select Consumer Information , select your applicable vehicle, then select Navigation Manual from the list. •Service Bulletins – Use the keyword NAVI . •ETM (electrical troubleshooting manual) This bulletin provides the following navigation system DVD service information: •DVD label color identification by model •Earliest DVD version application for each model •How to identify navigation DVD versions •Checking a DVD for damage •Ordering a DVD •Navigation DVD stocking concerns •DVD handling and cleaning •Installing a navigation DVD •Precaution on customer “sneak previews” of a newer navigation DVD version •Answering customer questions about navigation coverage and POI (point of interest) •Pitfalls when interchanging navigation DVD/parts during diagnosis •Replacing the navigation control unit and transferring the navigation DVD •Entering the anti-theft code •Navigation system platforms VEHICLES AFFECTED • 2003-09 Accord • 2005-07 Accord Hybrid • 2006-09 Civic • 2006-09 Civic Hybrid • 2007-09 CR-V • 2009 Element • 2009 Fit • 2000-09 Odyssey • 2003-09 Pilot • 2006-09 Ridgeline WARRANTY CLAIM INFORMATION None. This service bulletin is for information only. Refer to the flat rate manual whenever servicing or repairing the navigation system

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Acura MDX Torque Converter Shudder or Vibration Between 35 and 40 MPH Repair Manual

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Filed Under (Acura Manuals) by admin on 24-11-2011

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1. To confirm the client’s complaint, test-drive the vehicle on a smooth road, preferably with a slight incline. Set the cruise control between 35 and 40 mph, and monitor the engine rpm using the vehicle’s tachometer, or use the HDS to take a snapshot of the engine rpm. 2. If the engine speed fluctuates several hundred rpm while maintaining a constant vehicle speed, disconnect the EGR valve and retest the vehicle. •If the fluctuation is gone, refer to the EGR troubleshooting in the service manual. •If the engine rpm still fluctuates, and the transmission does not have any other symptoms (shifting problems, slipping, transmission DTCs) go to step 3. 3. Drain the transmission fluid, then strain it through a paint strainer. •If you find little or no contamination in the strainer, the ATF is OK, even if it smells burnt, is discolored, and/or the magnetic drain plug has small chips, flakes, or metal fuzz on it. Go to REPAIR PROCEDURE A . •If you find large amounts of contamination (pieces of metal or friction material) in the strainer, go to REPAIR PROCEDURE B . REPAIR PROCEDURE A 1. Remove the torque converter: •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. Install the torque converter: •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. 3. 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 . 4. Do the idle learn procedure: •Make sure all electrical items (A/C, audio unit, defogger, lights, etc.) are 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. 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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HONDA Accord V6, Odyssey, Pilot Idle Vibration or Harsh Shifting Repair Manual

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Filed Under (Honda Manuals) by admin on 04-06-2012

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SYMPTOM There is a vibration at idle or harsh engagement when shifting the transmission between between Park, Drive, and Reverse. PROBABLE CAUSE The front hydraulic engine mount may have deteriorated and torn. PARTS INFORMATION Front Engine Mount Assembly: 1998-02 Accord V6 – P/N 50810-S87-A82, H/C 7981657 1999-04 Odyssey – P/N 50800-S0X-A04, H/C 7978927 2003-05 Pilot – P/N 50800-S3V-A82, H/C 7984560 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Failed Part: P/N 50810-S87-A81 H/C 5438593 Defect Code: 01102 Symptom Code: 04501 Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. DIAGNOSIS 1. Bring the engine up to operating temperature, and fully apply the parking brake. 2. Have an assistant view the top of the front engine mount while standing to the side of the vehicle. Shift the transmission to Drive. With your foot firmly on the brake pedal, quickly depress the accelerator pedal and release it. Your assistant should look for contact between the top of the engine mount and the bottom of the front engine mount bracket, and listen for noise from that area. REPAIR PROCEDURE 1. Drive the vehicle onto a lift, but do not raise it. 2. Odyssey – Remove the intake manifold cover and the front ignition coil cover: •See page 9-4 of the 1999-04 Odyssey Service Manual. •Online, enter keyword INTAKE , and select Intake Manifold Removal and Installation from the list. 3. Odyssey – Remove the radiator cover: •See page 10-16 of the 1999-04 Odyssey Service Manual. •Online, enter keyword RADIATOR , and select Radiator and Fan Replacement from the list

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2004-2007 Ford F-Super Duty SLIDING POWER WINDOW (BACK GLASS) SERVICE MANUAL

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

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FORD: 2004-2007 F-Super Duty ISSUE SERVICE PROCEDURE Some 2004-2007 F-Super Duty vehicles, equipped with a power sliding rear window (back glass), may 1. Prior to window removal, verify that center exhibit a stuck or binding concern. This condition glass is centered in the upper plastic channel may be due to the center glass not being positioned (Figure 1). If center glass is not inside upper correctly inside the upper or lower channel, the plastic channel, pull channel down and out of channel being warped, bent, or center glass upper aluminum channel and slide back in de-bonded. making sure the entire center glass is inside the plastic channel. ACTION Follow the Service Procedure steps to correct the condition. Figure 1 – Article 06-15-5 2. If Step 1 resolves the issue, return the vehicle 4. Refer to window removal procedure. (Refer to back to customer after verifying the window Workshop Manual (WSM), Section 501-11-24 functions properly. If it did not resolve the and 501-11-25.) issue, proceed to Step 3. 5. Remove cable clips from sheet metal. (Refer to 3. Open the rear window approximately half way. WSM, Section 501-11-28.) 6. Remove three (3) motor bracket attaching bolts. (Refer to WSM, Section 501-11-28. 7. Disconnect motor wiring harness from vehicle 9. Pull outer rubber seal from window frame body harness. (Refer to WSM, Section (Figure 2). 501-11-29.) 8. Remove window assembly from vehicle window opening. Figure 2 – Article 06-15-5 10. Locate two (2) screws in bottom of lower frame and remove them with a R1 square bit screw driver (Figure 3). Figure 3 – Article 06-15-5

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2004 Toyota Prius EV (Electric Vehicle) Button Installation Instructions

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Filed Under (Toyota Manuals) by admin on 31-03-2012

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Time and Difficulty: I found the install to be moderately difficult and pretty time-consuming (about 3 hours) ; others have found it simple and report they have done it in as little as 30 minutes. Your experience will depend on your familiarity with the tools and electronics. I, personally, found insertion of the connection pin into the HV ECU plug to be difficult and almost got the first pin irrevocably stuck in the slot. I spent quite a bit of time with that part alone. I also found threading the wire behind the dash to be fairly tricky. I think the average person, not encountering any problems, could do this job in about 1-1½ hours. Procedure in Brief: 1) Remove bottom cover of steering wheel 2) Locate and unplug flasher plug 3) Open plug and remove 1-3 unused connector pins 4) Reattach steering wheel cover 5) Dismantle part of dash (vents) and remove lower glove box 6) Locate HV ECU (gray plugs) and remove lower plug 7) Solder wire to connector pin and insert into ECU plug (#27) 8) Splice EV button ground wire into ECU plug ground wire (#1) 9) Plug ECU plug back into the ECU 10) Thread wire behind dash to opening near dimmer switch 11) Attach switch to cover and solder wires in place 12) Reassemble the dash 13) Test Procedure in Detail: *Review ALL steps before proceeding and be sure you understand all terms used and you’ve looked at all diagrams and pictures. 1) Remove the bottom cover of the steering wheel by releasing the steering wheel adjustment handle and unscrewing the silver screw in that recess. 2004_prius_evv2.doc Page 4 of 20 Last updated March 13th, 2004 Then, turn the steering wheel 90 degrees right and remove the black screw that becomes visible on the right side of the steering column. Then turn the wheel 180 degrees left (90 degrees from normal position) and remove the black screw on the left side of the steering column. Carefully pull down on the lower portion of the steering column cover until it releases. Mine was a bit stiff/stuck to the upper part and you may need to carefully use a butter knife or screwdriver to start prying them apart. 2004_prius_evv2.doc Page 5 of 20 Last updated March 13th, 2004 2) Locate and unplug the white flasher plug visible just on the left side of the bottom of the steering column. 3) 2 little clips keep a cover locked in place. Pull those apart and remove the cover. Inside you’ll see lines of silver connector pins–some with wires attached, some without. You should remove between 1 and 3 of those pins–2 is probably safe, 3 might be better, since if you plan to install an OEM button at some point, you’ll probably need more pins for that. (You need one pin for the procedure, but it’s handy to have a back-up.) To remove the pins, you can use your paper clip to start the process of sliding them out, and then they just pull right out. 2004_prius_evv2.doc Page 6 of 20 Last updated March 13th, 2004 Stick them to a piece of tape or put them somewhere secure so you can find them later. Snap the cover back into place, and plug the flasher plug back in. 4) Replace the steering wheel cover by reversing the process. Be sure everything’s aligned properly and that there are no gaps. 5) Now you’ll need to dismantle part of the dash to get access to the ECU and other areas. First, open the top and bottom glove box doors. Squeeze the inside sides of the lower glove box together to get the catches past the portion of the dash frame that keeps the door from falling all the way open. Then pull the entire door straight toward you – it will unclip from the hinges at the bottom of the glove box. 2004_prius_evv2.doc Page 7 of 20 Last updated March 13th, 2004 You may also need to unclip the little hydraulic piston that keeps the door from falling open too quickly. Next, grasp the bottom of the silver vent piece next to the glove box. Pull it toward you firmly. It should unclip at the bottom first. Then pull the whole unit straight out

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2003 Honda ODYSSEY Intake Manifold Removal and Installation Manual

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Filed Under (Honda Manuals) by admin on 27-06-2012

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Removal 1. Remove the intake manifold cover (A) and ignition coil cover(s) (B). 1999-2001 models: 2002-2004 models: 2. Remove the evaporative emission (EVAP) canister hose (A) (1999-2001 models) or vacuum hose (A) (2002-2004 models). 3. Remove the vacuum hose(s) (B) and breather pipe (C), then remove the intake air duct (D). 1999-2001 models: 2002-2004 models: 4. Remove the throttle cable (A) and cruise control cable (B) by loosening the locknuts (C), then slip the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one. 5. Remove the engine wire harness connectors and wire harness clamps from the intake manifold. *Intake air temperature (IAT) sensor connector *Idle air control (IAC) valve connector *Throttle position (TP) sensor connector *Manifold absolute pressure (MAP) sensor connector *Evaporative emission (EVAP) canister purge valve connector (2002-2004 models) 6. Remove the brake booster vacuum hose (A) and positive crankcase ventilation (PCV) hose (B). 7. Remove the vacuum hoses (C) (1999-2001 models). 1999-2001 models: 2002-2004 models: 8. Remove the breather hose (A) and water bypass hoses (B), then plug the water bypass hoses. 9. Remove the EVAP canister hose (C) (2002-2004 models). 1999-2001 models:

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2004 Chevrolet TrailBlazer Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 18-02-2012

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This bulletin is being revised to add model years and provide important repair information. Please discard Corporate Bulletin Number 04-08-49-015 (Section 08 — Body and Accessories). Condition Some customers may comment on a noise coming from the instrument panel cluster (IPC) while driving or on initial start-up. Instrument clusters may contain stepper motor gages that can make noise during the following conditions: Subject: Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Models: 2003-2005 Buick LeSabre 2003-2007 Buick Rendezvous 2004-2005 Buick Rainier 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Cavalier, Impala, Monte Carlo 2003-2006 Chevrolet Avalanche, Suburban, Tahoe, TrailBlazer EXT 2003-2007 Chevrolet Silverado Classic, TrailBlazer 2003-2007 Chevrolet Kodiak Models 2004-2006 Chevrolet SSR 2003-2006 GMC Envoy XL, Yukon, Yukon XL 2004-2005 GMC Envoy XUV 2004-2007 GMC Envoy 2003-2007 GMC Sierra Classic 2003-2004 Oldsmobile Bravada 2003-2005 Pontiac Aztek, Bonneville, Sunfire 2003-2005 HUMMER H2 Attention: Appropriate repair is based on vehicle build date. Use GMVIS to determine the vehicle build date. • Initial startup (gages zero/reset)

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