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2005 Ford F-150 Drive Pinion Flange and Drive Pinion Seal Repair Manual

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Filed Under (Ford Manuals) by admin on 21-04-2012

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the brake disc. For additional information, refer to Section 206-04 . 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ? Using mechanic’s wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.2005 F-150 Workshop Manual 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. 6. l a new pinion nut with the same iginal if not replacing the collapsible spacer. If a installed, install the nut in the kit, as indicated in the chart below, or damage to the component may occur. Position the new pinion nut. Pinion Nut 7. no circumstances ut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ? Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ? Install a Nm (lb-in) torque wrench on the pinion nut. ? Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ? If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. For additional information, refer to the Specification portion of this section. 8. Position the driveshaft and align the index mark on the pinion flange.

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1994 Ford Explorer FRONT WHEEL BEARINGS MANUAL

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Filed Under (Ford Manuals) by admin on 08-07-2012

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FRONT WHEEL BEARINGS Dana 35-IFS & Automatic Locking Hubs 1. Raise and support vehicle. Remove front wheel assemblies. Remove retaining washers from wheel lug nut studs. See Fig. 1 . 2. Remove automatic locking hub assemblies. Remove snap ring and axle shaft spacer. Carefully pull plastic cam assembly from bearing adjusting nut. Remove 2 plastic thrust washers from adjusting nut. 3. Using magnet, remove locking key from spindle keyway. It may be necessary to rotate adjusting nut slightly to relieve pressure for locking key removal. Loosen adjusting nut with 2 3/8″ Hex Socket (T70T- 4252-B). 4. Tighten adjusting nut to 35 ft. lbs. (47 N.m) while turning hub back and forth to seat bearings. Spin hub and back off adjusting nut 90 degrees. Retighten adjusting nut to 16 INCH lbs. (1.8 N.m). 5. Align nearest hole in adjusting nut with center of spindle keyway slot. If necessary, advance nut to next lug. Install locking key in spindle keyway under adjusting nut. Install 2 thrust washers. Press plastic cam assembly onto adjusting nut while lining up key in fixed cam with spindle keyway. 6. Install axle shaft spacer. Clip snap ring onto end of spindle. Install automatic locking hub assembly with 3 legs of hub assembly inserted into 3 pockets of cam assembly. Install retaining washers and wheel assembly. Check hub and rotor assembly end play. End play should be 0-.003″ (0-.08 mm)

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2009 HONDA CIVIC 4-DOOR CARGO NET INSTALLATION INSTRUCTIONS

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Filed Under (Honda Manuals) by admin on 10-10-2011

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INSTALLATION Customer Information: The information in this installation instruction is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely add equipment to your vehicle. These procedures should not be attempted by “do-it-yourselfers.” 1. Temporarily install two bolts into each anchor “A” and four self-tapping screws into each anchor “B”. 2 Anchors “A” 2 Bolts 4 Self-tapping screws 2 BOLTS 2 ANCHORS “A” 4 SELF-TAPPING SCREWS 4 ANCHORS “B” Template “L” 08L96-SNA-1000-91 4 Anchors “B” Template “R” 2 Rivet nuts All 40266 Put this information in the glove box with the vehicle’s owner’s manual 2 of 5 All 40266 (0809) Open the trunk, and remove the two clips from the trunk side lining. 3. While wearing eye protection, drill the two clip holes in the right and left trunk side panels to 9 mm. Remove any burrs, and apply touch-up paint to each hole. TRUNK SIDE LINING TRUNK SIDE PANEL CLIPS (Discard.) TRUNK SIDE LINING DRILL DRILL BIT (9 mm) DRILL BIT Installing the Rivet nuts 4. Thread the rivet nut onto the mandrel of the rivet nut tool as shown. 5. Insert the rivet nut into the 9 mm hole in the vehicle panel. 6. While holding the rivet nut tool with the hex wrench, rotate the 19 mm wrench clockwise and install the rivet nut on the vehicle panel. RIVET NUT TOOL MANDREL RIVET NUT RIVET NUT VEHICLE PANEL Hold. HOLE DRILL BIT (9 mm) HOLE RIVET NUT TOOL RIVET NUT HEX WRENCH 27 mm WRENCH VEHICLE PANEL RIVET NUT RIVET NUT TOOL HEX WRENCH Fold the rear seat-back forward by pulling the levers under the rear parcel shelf. Remove the trunk floor mat (two clips). 5224093S 9. Install the two bolt/anchor “A” assemblies into the rivet nuts. ANCHOR “A” TRUNK SIDE LINING TRUNK SIDE PANEL RIVET NUT BOLTS BOLT/ANCHOR “A” ASSEMBLY 7. Remove the rivet nut tool from the rivet nut by turning the hex wrench counterclockwise. RIVET NUT TRUNK FLOOR MAT 2 CLIPS LEVERS REAR SEATBACK 8. Install a rivet nut into the other 9 mm hole using the above procedures. 11. Position template “R” on the right trunk side floor by aligning the clip with the hole and the edge parallel with the trunk side lining. Mark the floor using a felt-tip pen. Remove the template.

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1994 Ford Explorer SPINDLE AND SHAFT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 01-02-2012

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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).

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1997 Ford F-250/ 350/ Super Duty Steering Knuckle REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 13-06-2012

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Steering Knuckle Removal 1. Remove the front wheel spindle (3105) and the right and left shaft and joint assembly. Refer to Spindle, RH and LH Shaft and Joint Assembly in the Removal and Installation portion of this section. 2. Disconnect the steering linkage, if necessary, from the knuckle. Refer to Section 11-03 in the Body, Chassis Manual. Steering Knuckle Installation 3. Remove the cotter pin from the stud of the front suspension upper ball joint (3049). Loosen the nut on the top stud and the bottom nut inside the steering knuckle. Remove the top nut. 4. Sharply hit the top stud with a plastic or rawhide hammer to free the knuckle from the axle arm. Remove and discard bottom nut. 5. NOTE: Note the orientation of the camber adjuster to make sure of the same camber setting. Remove camber adjuster by hand or, if difficulty is encountered, use Pitman Arm Puller T64P-3590-F. 6. Place steering knuckle in vise and remove snap ring from bottom ball joint socket if so equipped. 7. Remove plug from U-Joint Tool T74P-4635-C and replace with Plug T80T-3010-A4 (part of 4WD Ball Joint Tool Set T80T-3010-A). 8. Assemble U-Joint Tool T74P-4635-C and Receiving Cup T80T-3010-A2 (part of 4WD Ball Joint Tool Set T80T-3010-A). 9. NOTE: Always remove front suspension lower ball joint first. Turn forcing screw clockwise until front suspension lower ball joint is removed from steering knuckle. 10. Repeat procedure and remove front suspension upper ball joint. Installation 1. Clean steering knuckle bore and insert front suspension lower ball joint as straight as possible. 2. NOTE: If ball joint cannot be installed to the proper depth, realign Receiving Cup T80T-3010-A3. To replace the front suspension lower ball joint, assemble U-Joint Tool, Receiving Cup T80T-3010-A3 (part of 4WD Ball Joint Tool Set T80T-3010-A) and Installing Cup from Ball Joint Adapter Set D81T-3010-A or equivalent. 3. Turn forcing screw clockwise until front suspension lower ball joint is firmly seated. 4. Install the snap ring on the front suspension lower ball joint. 5. To install front suspension upper ball joint, assemble the C-Frame, Receiving Cup T80T-3010-A3 and Replacer T80T-3010-A1 (both part of 4WD Ball Joint Tool Set T80T-3010-A). 6. Turn forcing screw clockwise until front suspension upper ball joint is firmly seated. 7. Assemble knuckle to axle arm assembly. Install camber adjuster on the stud of the front suspension upper ball joint with the arrow pointing outboard for positive camber, pointed inboard for negative camber. 8. Install new nut on bottom socket finger-tight. Install and tighten nut on top socket finger-tight. Tighten bottom nut to 47 Nm (35 lb-ft). 9. CAUTION: If the tightening sequence is not followed in this step and Step 10, ball joint life will be reduced. NOTE: Do not loosen top nut to install cotter pin. Tighten top nut to 136 Nm (100 lb-ft), then advance nut until castellation aligns with cotter pin hole. Install cotter pin. 10. Retighten bottom nut to 123-149 Nm (91-110 lb-ft). 11. Install the front wheel spindle and the right and left shaft and joint assembly as described in this section. 12. Connect steering linkage, if necessary, to the knuckle. Refer to Section 11-03 in the Body, Chassis Manual.

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1997-2005 Ford Expedition REAR AXLE NOISE REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 16-09-2011

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5L3Z-4209-F = (9.75-Inch Ring Gear/3.73 ratio) •205-506 – Seal Protectors (Rotunda Tool) (1997-2005 F-150, 1997-2005 •W710084-S439 – Wheel End Nuts Expedition/Navigator) •390266-S100 – Differential Slave Pin Bolt (9.75? axles) NOTE 9.75 REAR AXLE HOUSINGS WERE •387426-S100 – Differential Slave Pin Bolt (8.8? REDESIGNED IN MID-1999, INCREASING FRONT axles) PINION BEARING SIZE. REPLACING RING & •4B422 – Axle Circlips PINIONS IN AN OLD-STYLE AXLE ASSEMBLY •ZC-21 – Metal Surface Cleaner WILL REQUIRE INSTALLATION OF SPACER P/N •TA-29 – Ultra Silicone Sealant YL3Z-4662-CA. SPACER IS TO BE INSTALLED BETWEEN INNER PINION BEARING AND •TA-27 – Stud and Bearing Mount Retaining COLLAPSIBLE SPACER. Compound and Sealer •F3TZ-4121-AA – Fluid Tag (REQUIRED IF FLUID THE AXLE SERVICE KITS INCLUDE THE TYPE IS CHANGED FROM FEHP DURING FOLLOWING COMPONENTS: REPAIR) •4630 – Head Bearing WARRANTY STATUS: Eligible Under Provisions Of •4628 – Head Bearing Cup New Vehicle Limited •4676 – Pinion Seal Warranty Coverage •386989-S2 – Washer (Slinger) OPERATION DESCRIPTION TIME •4621 – Tail Bearing 052303A 1997-2002 Expedition, 4.7 Hrs. 1998-2002 Navigator, •4616 – Tail Bearing Cup 1997-2004 F-150 Heritage, •4222 – Differential Bearing Cups 2004-2005 F-150: Rear •4221 – Differential Bearings Axle Noise Repair •4209 – Gear Set (includes pinion shims, pinion (Includes Time For Road nut and crush spacer) Test To Verify Concern (Beam Axle)) (Do Not Use •4209 – Instruction Sheet With 4205A Or 4205A4) NOTE 052303A 2003-2005 Expedition: 5.8 Hrs. THE KIT DOES NOT INCLUDE THE FOLLOWING Rear Axle Noise Repair ITEMS. SOME OR ALL OF THESE ITEMS WILL (Includes Time For Road BE REQUIRED TO COMPLETE THE AXLE Test To Verify Concern (Irs SERVICE, DEPENDING ON AXLE Axle)) (Do Not Use With APPLICATION/STYLE. 4010D Or 4010D4) 052303A 2003-2005 5.9 Hrs. ORDER AS NEEDED:

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2005 TOYOTA AVALON TVIP V4 (REMOTE ENGINE STARTER) INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 26-03-2012

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TOYOTA AVALON 2005 – TVIP V4 (REMOTE ENGINE STARTER) Procedure Page 2 of 33 pages Issue: C 02/02/05 Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document. This document covers such items as:- • Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). • Safety (eye protection, rechecking torque procedure, etc.). • Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). • Electrical Component Visassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Vehicle Disassembly. (a) Remove the negative battery cable. (Fig. 1-1) (1) Protect the fender before starting. (2) Do not touch the positive terminal with any tool removing the cable. (b) Remove the glove box under-dash cover. (Fig. 1-2) (c) Remove the passenger’s step cover. (Fig. 1-3) Fig. 1-1 10mm Wrench Negative Battery Cable Battery Step Cover Fig. 1-3 Nylon Panel Removal Tool Fig. 1-2 Under-Dash Cover Nylon Panel Removal Tool TOYOTA AVALON 2005 – TVIP V4 (REMOTE ENGINE STARTER) Procedure Page 3 of 33 pages Issue: C 02/02/05 (d) Remove the passenger’s cowl cover. (Fig. 1-4) (1) Remove one nut securing the cowl cover. (e) Remove one screw and one bolt from the glove box assembly. (Fig. 1-5) (f) Remove the glove box assembly. (Fig. 1-6) (1) Open the glove box door and remove three screws securing the glove box assembly. (2) Disconnect the trunk opener cancel switch from the glove box assembly if equipped. For vehicles with Smart Entry, the disassembly process ends on Step f. Go to Section 5. For vehicles without Smart Entry, continue the disassembly process. FOR VEHICLES WITHOUT SMART ENTRY SYSTEM ONLY. (Step g) NOTE: Do not perform this step if the vehicle has Smart Entry. (g) Remove the driver’s step cover. (Fig. 1-7) Screw Fig. 1-5 10mm Wrench, Phillips Screwdriver Bolt Glove Box Assembly Cowl Cover Fig. 1-4 Nut Fig. 1-6 Nylon Panel Removal Tool, Phillips Screwdriver Screws (x3) Glove Box Assembly Trunk Opener Cancel Switch Connector Fig. 1-7 Step Cover Nylon Panel Removal Tool
TOYOTA AVALON 2005 – TVIP V4 (REMOTE ENGINE STARTER) Procedure Page 4 of 33 pages Issue: C 02/02/05 FOR VEHICLES WITHOUT SMART ENTRY SYSTEM ONLY. (Steps h-l) NOTE: Do not perform this step if the vehicle has Smart Entry. (h) Remove the driver’s cowl cover. (Fig. 1-8) (1) Remove the one nut securing the cowl cover. (i) Remove the hood release cable. (Fig. 1-9) (1) Do not bend the hood release cable. (j) Open the screw cover on the lower dash cover. Insert the tip of a Nylon Panel Removal Tool in the upper slot to loosen it. (Fig. 1-9) (1) Remove one screw and one bolt securing the lower dash cover. (k) Remove the lower dash cover. (Fig. 1-10) (1) Disconnect the temperature sensor (connector and aspirator hose) from the lower dash cover if equipped. (l) Carefully remove the driver side airbag assembly. (Fig. 1-11) (1) Remove four bolts securing the driver side airbag assembly. (2) Be careful not to get cut by the sharp metal edges. (3) Do not disconnect the airbag assembly. (4) Use the empty V4 kit box to support the airbag assembly on the floor

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2000-2006 TOYOTA TUNDRA 2WD AND 4WD 6″ SUSPENSION SYSTEMS INSTALLATION MANUAL

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

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FRONT INSTALLATION INSTRUCTIONS 1. On 4WD models only, remove grease cap, cotter pin and locking cap. (Illustration 1) While applying the brakes, loosen both Driver side and Passenger front axle nuts but do not remove. 2. Raise the vehicle. If working without a shop hoist, support vehicle with suitable safety jack stands. Put vehicle in gear, set emergency brake and block rear wheels, both in front and behind tires. Loosen front wheel lug nuts. Place floor jack under the lower control arm’s front crossmember and raise vehicle. Place safety jack stands under frame rails, behind front wheel wells, and lower the frame onto the stands. Once securely on jack stands remove floor jack. Remove front wheels. Illustration 1 7 RCD Suspension 619-588-4723 3. Place a jack under front lower a-arm. Remove lower nut from front shock mount. Next, locate the three nuts at the top of the front shock. (Illustration 2) Remove these nuts, lower the a-arm and remove front shock. Repeat on opposite side of vehicle. 4. Locate and remove the nut, retainer collar and cushion that attaches the Sway Bar end to the lower a-arms. (Illustration 3) Remove the two brackets that attach the Sway Bar to the frame. (Illustration 4) Stock Sway Bar can be discarded but make sure to keep original mounting brackets. 5. Detach bolt and brake line hose clamp from the front spindle. (Illustration 5) Next, remove the two bolts that attach the brake caliper to the front spindle. Remove the brake caliper and tie it up with safety wire. DO NOT LET IT HANG BY THE BRAKE LINE. Illustration 2 Illustration 3 Illustration 4 Illustration 5 8 RCD Suspension 619-588-4723 6. Remove rotor using snap ring pliers to remove inner snap ring. (Illustration 6) (Some models may not have snap ring and rotor can just be removed at this point) 7. Remove Cotter pin and loosen nut located on upper front ball joint. (Illustration 7) (on 4WD models use a strap to support the Front Drive Axle and keep it from resting at full bind) Using Ball joint puller, remove upper control arm from spindle. 8. Next, remove the cotter pin and nut located at the Tie Rod End on the Spindle. Using the Tie Rod Puller, disconnect the Tie Rod from the Spindle. (Illustration 8) 9. On 4WD models remove the axle nut. On ABS equipped vehicles, detach the ABS speed sensor from stock spindles. 10. Locate the four bolts attaching the Lower Ball Joint on the a-arm to the front spindle. (Illustration 9) Remove the bolts and take spindle off of vehicle. 11. Repeat steps 5 through 10 on opposite side of vehicle

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4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal)4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Transmission Repair

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Filed Under (More Manuals) by admin on 08-01-2012

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Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission – 4L60-E/4L65-E. Important: Subject: 4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer Models 2003-2005 GMC Envoy Models 2003-2004 Oldsmobile Bravada 2005 Saab 9-7X with 4.2L In-Line 6 Cylinder Engine (VIN S — RPO LL8) • Visible rust on the transmission fluid level indicator. • Visible water in the oil pan. • A milky white substance inside the pan area. • Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. • Rust on internal transmission iron/steel components. • Remove the surge tank cap and examine the coolant for signs of contamination with transmission fluid (the coolant will have a milky, not clear appearance). • If the coolant has a normal, clear appearance, the radiator should not be replaced. • The cooler can also be tested by following the Coolant System Leak Test procedure (SI Document ID# 877442). Do NOT replace a radiator without verifying that the transmission oil cooler is leaking. If water or coolant is found in the transmission, the following components MUST be replaced. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Element Replacement (SI Document ID# 1364496). 2. Remove the transmission fluid level indicator from the filler tube. 3. Remove the filler tube nut (2) located on the right side of the engine. 4. Remove the filler tube from the vehicle. Tip It is necessary to remove the two A/C line (suction line / low side of muffler hose) retainers and reposition • Replace all of the rubber type seals. • Replace all of the composition-faced clutch plate assemblies including the band. • Replace all of the nylon parts (Thrust Washers). • Replace the torque converter. • Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. • Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30- 052C or newer – Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow .
the A/C line to allow proper clearance for installation of the new transmission fluid fill tube. 5. Remove the A/C line at the oil level indicator tube bracket nut. 6. Remove the A/C bracket bolt from the engine lift hook. 7. Reposition the A/C line upward. 8. Install the new transmission filler tube, P/N 15000220, into position but NOT into the transmission at this time. 9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID# 744862). 10. Remove the two bolts securing the transmission heat shield to the transmission. 11. Remove the transmission heat shield from the transmission. 12. Remove the old filler tube seal from the transmission case. 13. Install a new seal, P/N 1259475 into the transmission case. 14. Position the new transmission filler tube into the transmission seal. 15. Install the transmission heat shield to the transmission. 16. Install the two bolts securing the transmission heat shield to the transmission. Tighten Tighten the bolts to 17 N·m (13 lb ft). 17. Lower the vehicle. 18. Install the nut securing the filler tube to the stud. Tighten Tighten the nut to 10 N·m (89 lb in). 19. Reposition the A/C line into place. 20. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. 21. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt

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Peugeot 306 Timing belt replacement Removal And Installation Manual

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Filed Under (Peugeot Manuals) by admin on 23-02-2011

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Removal Removal Raise and support front of vehicle. 1. Remove: RH front wheel. Engine undershield (if fitted). Lower inner wing panel. Auxiliary drive belt(s). 307: Engine tie-bars. Crankshaft pulley [1] . Timing belt upper cover [2] . Timing belt centre cover [3] . Timing belt lower cover [4] . 2. Turn crankshaft to setting position. Insert timing pins in camshaft sprocket and flywheel [5] & [6] . 3. Slacken tensioner nut to release tension on belt [7] . Lightly tighten nut. 4. Remove timing belt. 5. Installation – -1997 Installation – -1997 Ensure timing pins located correctly [5] & [6] . 1. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. 2. Manufacturer: Peugeot Model: 306 (93-97) 1,4 Engine code: TU3M/Z (KDZ) Output: 55 (75) 5800 Tuned for: R-Cat Year: 1993-97 – Tensioner pulley. NOTE: Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner nut [7] . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. 3. Remove timing pins [5] & [6] . 4. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 5. Slacken tensioner nut [7] . 6. Tension belt as follows: 7. Turn tensioner anti-clockwise until tension gauge indicates 45 SEEM units. 8. Tighten tensioner nut to 20 Nm [7] . 9. Remove tension gauge. 10. Turn crankshaft four turns clockwise to setting position. 11. Ensure timing pins can be inserted [5] & [6] . 12. Wait 1 minute to allow belt to settle. 13. Apply firm thumb pressure to belt at . 14. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 15. Slacken tensioner nut [7] . 16. Turn tensioner anti-clockwise to tension belt. New belt: 40 SEEM units. Used belt: 36 SEEM units. 17. Tighten tensioner nut to 20 Nm [7] . 18. Remove tension gauge [8] . 19. Turn crankshaft two turns clockwise. 20. Ensure flywheel timing pin can be inserted [6] . NOTE: DO NOT allow crankshaft to turn anti-clockwise. 21. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 22. Check tension gauge reading. New belt: 51±3 SEEM units. Used belt: 45±3 SEEM units. 23. Install components in reverse order of removal. 24. Tighten crankshaft pulley bolts to 8 Nm [9] . 25. Installation – 1997- Installation – 1997- Ensure timing pins located correctly [5] & [6] . 1. Fit timing belt in following order: Crankshaft sprocket. Camshaft sprocket. Water pump sprocket. Tensioner pulley. NOTE: Ensure belt is taut between sprockets on non-tensioned side. 2. Slacken tensioner nut [7] . Turn tensioner anti-clockwise to tension belt. Temporarily tighten nut. 3. Remove timing pins [5] & [6] . 4. Attach tension gauge to belt at [8] . Tool No.(-).0192/SEEM C.Tronic 105.5. 5. Slacken tensioner nut [7] . 6. Tension belt as follows: 7. Remove cylinder head cover. 8. Install valve spring compressor. Tool No.0132AE [10] . 9. Turn tensioner anti-clockwise until tension gauge indicates the following: Except 307: 31 SEEM units. 307: 44 SEEM units.

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