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2006 Ford Pickup F350 Super Duty Intake Manifold Component Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 13-05-2011

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Removal All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose. Fig. 23: Locating Upper Radiator Hose Courtesy of FORD MOTOR CO. Fig. 24: Locating Turbocharger-To-CAC Duct Courtesy of FORD MOTOR CO. 5. Remove the turbocharger-to-CAC duct Vehicles with dual generators 6. Remove the accessory drive belt. Fig. 25: Rotating Drive Belt Tensioner Clockwise Courtesy of FORD MOTOR CO. 7. Remove the bolt and the accessory drive belt tensioner. Fig. 26: Locating Accessory Drive Belt Tensioner Bolt Courtesy of FORD MOTOR CO. 8. Remove the accessory drive belt. Fig. 27: Rotating Accessory Drive Belt Tensioner Courtesy of FORD MOTOR CO. 9. Remove the bolts, bracket and accessory drive belt idler pulley. Fig. 28: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts Courtesy of FORD MOTOR CO. 10. Remove the bolts and the accessory drive belt tensioner. Fig. 29: Locating Accessory Drive Belt Tensioner Bolts Courtesy of FORD MOTOR CO. 11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire. Fig. 30: Locating Wire Retainer And Generator Electrical Connectors Courtesy of FORD MOTOR CO. 12. Remove the bolts and the generator with mounting bracket.

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2006 Ford F-SUPER DUTY Class A Motorhome Chassis INCOMPLETE VEHICLE MANUAL

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Filed Under (Ford Manuals) by admin on 26-05-2012

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Certain exhaust system components, including exhaust heat shielding systems, have been installed on some vehicles in our assembly plants in an effort to provide protection against engine compartment and exhaust system temperatures. Subsequent aftermarket installers/manufacturers are responsible for providing thermal protection (e.g. underbody heat shields) for any structure and/or equipment added to the vehicle and should not remove any components or exhaust heat shielding installed on the vehicle by Ford Motor Company. All exposed interior sheet metal of closed structures (e.g. fl oor pan of cab and/or secondary structure, tool boxes, etc.) should be covered with an insulating material capable of protecting vehicle occupants and contents from temperatures potentially up to 700°F. OZONE DEPLETING SUBSTANCE (ODS) OZONE DEPLETING SUBSTANCE (ODS) The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identifi ed with a “clearly and conspicuously attached label.” Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 2006 Ford Truck incomplete vehicles will not have Class I ODS content. Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product warning label. (See EPA regulation on wording, placement, size, and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Important Vehicle Information (tune-up and fuel tank capacity) labels must be affi xed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be affi xed to any equipment that is easily detached from the vehicle. When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affi xed or to be affi xed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii). CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fi ll pipe. Fuel fi ller pipes installed per the Figure B on page 15 will comply with the “Specifi cations For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z” and extends outward from the Ford Motor Company supplied fuel pipe housing component. The fuel pipe housing component is shown on the referenced fi gures and is attached to the aftermarket body via 4.76 mm [.188 in.] diameter rivets. Fuel fi ller pipes installed using the alternative bracket shown in Figure B, will comply with the above California vapor recovery regulations provided the aftermarket body does not interfere with the access zone as defi ned by the California Air Resources Board, and the areas adjacent to this opening cannot foreseeably damage the nozzle bellows or face plate of nozzles during insertion, latching, disposing or removal

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2005 Ford F-Super Duty 250-550 Auxiliary Brake System/ Trailer Brake Control (TBC) Module Repair Manual

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Filed Under (Ford Manuals) by admin on 14-06-2012

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connected to the vehicle, the TBC module will enter a “sleep mode” but still continue to send a PWM voltage signal to the trailer tow connector every 4 seconds to detect when a trailer is connected. When the ignition key is in the RUN position and the module is in sleep mode, pressing a gain button or sliding the manual switch will cause the module to “wake up”. If a trailer is not connected to the vehicle, the display should prove out for 3 seconds, then the trailer icon should illuminate red and the IC message center should display TRAILER DISCONNECTED or CHECK TRAILER. If a trailer is connected to the vehicle, the display should prove out for 3 seconds and then the trailer icon should illuminate green. Inspection and Verification NOTE: A trailer brake emulator tool is available to verify that the TBC module and vehicle wiring are functioning correctly. 1. Verify the TBC system is correctly installed by checking that the vehicle is equipped with a brake pressure transducer on the master cylinder. If the brake pressure transducer is not present, then the TBC system has been erroneously installed. 2. Verify the customer concern. 3. NOTE: The TBC does not function with electric-over-hydraulic or surge trailer brake types. Verify that the trailer brakes are electric-actuated drum type brakes. 4. Verify the stoplamps operate correctly by applying and releasing the brake pedal with the ignition switch in the OFF position and the trailer disconnected. If the stoplamps do not operate correctly, refer to Section 417-01 . If the stoplamps operate correctly, proceed to the next step. 5. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 6. If the cause is not visually evident, connect the scan tool to the data link connector (DLC) and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: * check that the program card is correctly installed. * check the connections to the vehicle. * check the ignition switch position. 7. If the scan tool still does not communicate with the vehicle, refer to the scan tool operating manual. 8. Carry out the scan tool data link test. If the scan tool responds with: * CAN, ISO, or UBP circuit fault; all electronic control units no response/not equipped, refer to Section 418-00 . * No response/not equipped for the TBC, GO to Pinpoint Test A . * System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the TBC and the antilock brake system (ABS) module. 9. If the DTCs retrieved are related to the concern, go to the Trailer Brake Control (TBC) module Diagnostic Trouble Code (DTC) Chart or Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Chart to continue diagnosis. 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnosis. NOTE: Always retrieve the continuous DTCs after running the self-test.

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2001 – 2006 TOYOTA Sequoia BACK DOOR POWER WINDOW INOPERATIVE

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Filed Under (Toyota Manuals) by admin on 11-01-2012

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BACK DOOR POWER WINDOW INOPERATIVE – EL007-06 June 14, 2006 Page 2 of 6 ITEM NO. SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QTYDRW** 1 Plastic Pry Tool Set* NOTE: All components from this kit/set are required 00002-06000-01 1 21 *Essential SSTs. **Refers to drawer number in SST Storage System. NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. 1. Disconnect the negative (-) terminal of the vehicle battery. NOTE: Any time the negative (-) battery terminal has been disconnected, systems requiring initialization will need to be re-initialized after the negative (-) battery terminal has been reconnected. 2. Open the back door and leave open. 3. Using the plastic pry tool, remove the back door garnish center. 4. Using the plastic pry tool, remove the left and right back door side garnish panels. Required SSTs Repair Procedure : 5 Clips : 3 Clips BACK DOOR POWER WINDOW INOPERATIVE – EL007-06 June 14, 2006 Page 3 of 6 5. Remove the strap cover, bolt, and pull strap. NOTE: To remove the strap cover, push it toward the back door window as shown in the illustration. 6. Remove the back door trim board. A. Insert the plastic pry tool between the back door trim board to release the clips retaining the back door trim. NOTE: Be careful NOT to damage the back door and back door trim board. B. Release each clip as shown in the illustration. 7. Disconnect both connectors to the back door ECU and both clips holding the wire harness to the large service cover. 8. Remove both of the back door service hole covers. For 2001 – 2004 model year Sequoia vehicles, go to step 11. For 2005 – 2006 model year Sequoia vehicles, continue to step 9. 9. For 2005 – 2006 model year Sequoia vehicles ONLY: Remove the multiplex network door ECU. Using a drill of less than 3.2 mm (0.126 in.), drill out the two (2) rivet heads. HINT: Gently and vertically put the drill to the rivets and cut the rivet flanges. CAUTION: Take care as the cut rivets may be HOT. 10. For 2005 – 2006 model year Sequoia vehicles ONLY: Install the replacement multiplex network door ECU and rivets

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2006 Ford Explorer Scheduled Maintenance Guide

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Filed Under (Ford Manuals) by admin on 12-02-2012

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Scheduled Maintenance: 2006 Ford Explorer Driving Condition: Normal Condition Engine Displacement Transmission Fuel Cylinders Drivetrain 4.0 L Automatic Flexible 6 RWD ded Maintenance Mileage: Every 5,000 15 30 45 60 75 90 100 105 120 135 150 Value Package Price: See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer Change engine oil and replace oil filter (Up to 5 quarts of oil. Perform at specified mileage interval or every 6 months, whichever occurs first) – See dealer Perform multi-point inspection – See dealer Rotate and inspect tires; check wheel end play and turning noise – See dealer Inspect automatic transmission fluid level (if equipped with underhood dipstick) – See dealer Inspect brake pads/shoes/rotors/drums, brake lines and hoses, and parking brake system – See dealer Inspect engine cooling system and hoses – See dealer Inspect and lubricate all non-sealed steering linkage,ball joints,suspension joints,half and drive-shafts and u-joints – See dealer Inspect complete exhaust system and heat shields – See dealer Replace engine air filter – See dealer Replace fuel filter – See dealer Inspect 4×2 front wheel bearings; replace grease and grease seals, and adjust bearings – See dealer Change Premium Gold engine coolant – See dealer Inspect accessory drive belt(s) – See dealer Replace PCV valve – See dealer Replace spark plugs – See dealer Replace accessory drive belts (if not replaced within last 100,000 miles) – See dealer Replace rear axle lubricant – See dealer Change automatic transmission/transaxle fluid and filter – See dealer Notes: Prices are shown for illustrative purposes only and may vary based on required fluid quantities and other conditions. Information in this document is current as of January 07, 2010 and could change in the future.

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2004 – 2006 Toyota Sienna Vehicles Equipped w/ Power Back Door (Power Rear Liftgate) Repair Manual

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

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Certain 2004 – 2006 Model Year Sienna vehicles equipped w/Power Back Door (Rear Liftgate) Q1: What is the condition? A1: Toyota has determined that the gas struts used to help lift and support the Power Rear Liftgate in certain 2004 through 2006 model year Sienna vehicles could be wearing out sooner than expected. As the gas struts deteriorate, the performance of the Power Rear Liftgate will begin to degrade, and the Power Rear Liftgate will operate more slowly than when the gas struts were new. Only Sienna vehicles equipped with the Power Rear Liftgate are involved. Q2: Are there any warnings that this condition exists? A2: Owners may notice that the Power Rear Liftgate will not remain in the open position. If not repaired, the gas struts may not be able to support the weight of the liftgate when it is open, and eventually, the gas struts could deteriorate to the point that the liftgate will fall about ten inches after it reaches the fully open position, at which point the power motor will engage and power the liftgate to the fully closed position. This condition may cause injury to a person who is struck by the liftgate when it falls or when it is closing. Q3: When were these vehicles produced, and how many vehicles are involved? A3: Only certain 2004 through 2006 model year Sienna vehicles equipped with the Power Rear Liftgate, produced between January 2003 and December, 2006 are involved. Approximately 196,000 vehicles are involved nationwide.

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LEAKS FROM REAR HALFSHAFT AXLE SEAL REPAIR MANUAL

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Filed Under (More Manuals) by admin on 15-06-2012

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FORD: LINCOLN: 2002-2006 Explorer 2003-2005 Aviator 2003-2006 Expedition 2003-2006 Navigator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 05-15-5 to update the 3. Do not use a damaged seal installation tool vehicle model years, Parts, and Service Procedure. exhibiting nicks, burrs, or sharp edges. NOTE ISSUE THE USE OF SEAL PROTECTOR 1L2W-4N206-AA Some 2003-2006 Expedition/Navigator, 2002-2006 IS NO LONGER REQUIRED. Explorer 4dr/Mountaineer, and 2003-2005 Aviator vehicles equipped with the 8.8? or 9.75? ring gear 4. Do not tap directly on the back of the seal and independent rear suspension (IRS), may exhibit installation tool, always tap on the handle, per leaks at the rear halfshaft axle seals. A new Instruction Sheet. Seal should be driven evenly unitized seal is now available for service. The new into housing bore with only enough force to seal design eliminates the need to use seal seat in the bore. protectors during installation. Removal of the excluder seal (1L2W-1N013-BA) if present is 5. Before installing the halfshaft, verify that the required. inboard excluder seal (1L2W-1N013-BA) is not present on the halfshaft. If the excluder seal is ACTION present, follow the kit Instruction Sheet and Order and install the new seal kit to correct the leak remove the excluder seal. condition. Review the updated instruction sheet NOTE included in the kit and obtain the required tools before beginning repair. OVERFILLING THE AXLE CAN INCREASE POTENTIAL FOR LEAKS. INSTALLATION SERVICE TIPS PART NUMBER PART NAME Refer to the appropriate Workshop Manual, Section 7L1Z-4A109-B Axle Shaft Seal Kit (9.75 Axle) 205-02 for half shaft removal and installation. 7L1Z-4A109-C Axle Shaft Seal Kit (8.8 Axle) NOTE IN THE WORKSHOP MANUAL UNDER THE HALF WARRANTY STATUS: Eligible Under Provisions Of SHAFT REMOVAL/INSTALLATION SECTION New Vehicle Limited THERE ARE ADDITIONAL PARTS CALLED OUT Warranty Coverage THAT ARE REQUIRED TO BE REPLACED. OPERATION DESCRIPTION TIME THESE PARTS ARE NOT INCLUDED IN THE 062205A 2003-2006 0.8 Hr. AXLE SHAFT SEAL KIT LISTED. Expedition/Navigator: Replace Rear Axle (Stub) 1. Use only the proper seal installation tool, Lisle Shaft Seal Includes Time Special Seal Installer (LIS 17850) available To Remove And Install through the Rotunda Technician Tool Program. Halfshaft One Side (Do Not Use With 4139A, 2. Ensure the seal installation tool is clean and 4139A2) free of debris prior to inserting into new seal.

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2004 Ford Explorer/Mountaineer Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index Repair Manual

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Filed Under (Ford Manuals) by admin on 20-05-2011

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C1963 Stability Control Inhibit Warning ABS Module This DTC is for information only. CLEAR the DTC. REPEAT the self-test. C1991 Module Calibration Failure ABS Module Follow the diagnostic tool directions for the calibration procedure. C1996 Active Yaw Control Disabled ABS Module This DTC will be set if the stability assist system is activated for 15 seconds of continuous operation. CHECK for any major chassis modifications, gross suspension misalignment, or other items that can alter the vehicle tracking dynamics. CLEAR the DTC. REPEAT the self-test. C1998 Module Calibration Not Complete ABS Module Go To Pinpoint Test Q . C2769 (ABS only) Longitudinal Acceleration Sensor Circuit Failure ABS Module CLEAR the DTC. REPEAT the self-test. If DTC C2769 is present, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. C2769 (ABS with stability assist) Longitudinal Acceleration Sensor Circuit Failure ABS Module Go To Pinpoint Test H . C2770 (ABS with Stability Assist) Longitudinal Acceleration Sensor Signal Fault ABS Module Go To Pinpoint Test H . C2770 (ABS only) Longitudinal Acceleration Sensor Signal Fault ABS Module CLEAR the DTC. REPEAT the self-test. If DTC C2770 is present, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. C2777 Sensor Cluster Bus Failure ABS Module Go To Pinpoint Test H . C2778 Sensor Cluster Power Supply Failure ABS Module Go To Pinpoint Test H . U1900 CAN Communication Bus Fault-Receive Error Network Fault Section 418-00 . U1901 CAN Network #2 Communication Bus Fault- Receive Error Network Fault Go To Pinpoint Test H . U2023 Fault received from external node Network Fault Section 418-00

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VP44 Fuel Pump Can Not Reach Commanded Timing

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Filed Under (More Manuals) by admin on 23-01-2011

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check to see if the fault code is active at engine start-up. Conditions Turn keyswitch ON. Action Check to see if the fault code is active at engine start-up. Use INSITE™ electronic service tool to read active fault codes. Note: If Fault Code 368 is inactive, but other fault codes are active, troubleshoot the active fault codes. OK NOT OK Fault Code 368 inactive Fault Code 368 active and no other active fault codes present Applicable fault code(s) Go to 2A Guided Step 2 – Perform low pressure system checks. Guided Step 2A – Record findings for inlet restriction. Conditions Turn keyswitch OFF. Action Install a restriction gauge at the lift pump inlet. Install a pressure gauge at the fuel filter inlet. Refer to Procedure 005-045 (Fuel Lift Pump) in Section 5 in the Troubleshooting and Repair Manual, ISB and QSB5.9 Engines, Bulletin 3666193. Install a clear line at the fuel filter outlet and run the line into a bucket. With gauges and the clear line in place, bump the starter and leave the keyswitch ON. The lift pump will run for 25 to 30 seconds. While the
lift pump is running, record the inlet restriction. Note: Steps 2A through 2D can be observed and recorded with a single bump of the starter. OK NOT OK Restriction less than 152 mm Hg [6 in Hg] Inlet restriction greater than 152 mm Hg [6 in Hg] Find source of excessive restriction between the lift pump inlet and fuel tank. Fix the source of excessive restriction

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2000 – 2006 TOYOTA TUNDRA SPORT DUTY UNDERCARRIAGE MOUNTING INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 18-03-2012

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2000 – 2006 TOYOTA TUNDRA SPORT DUTY UNDERCARRIAGE MOUNTING INSTRUCTIONS The mounting procedure outlined below covers the 2000 – 2006 Toyota Tundra trucks. You will need to refer to the illustrations and familiarize yourself with each of the undercarriage components and their relative position to each other. Then proceed as follows: 1. Begin by removing the bolts holding the skid plate to the bottom of the bumper and the rear cross member. Remove the skid plate. Some vehicles are equipped with an additional skid plate that wraps up in front of the bumper. This skid plate must be removed also. 2. Remove the bolts connecting the tow hook, tie down brackets, and skid plate brackets (Refer to Figure 1) to the bottom of the frame. The bolts and tow hook will be used in the undercarriage installation. 3. Assemble Driver Side Push Beam Support Plate (62B) to the bottom of the driver side frame rail. Begin by installing the bolts removed in Step 2 into the two holes in the bottom of Diver Side Push Beam Support Plate (62B) . Tighten these two bolts. Next, drill the inside and outside frame wall for the upper hole in Driver Side Push Beam Support Plate (62B). Install one ½”-13 X 4-1/2″ Hex Head Bolt (D) and one ½”-13 Lock Nut (B) in the drilled hole. Tighten this bolt. 4. Repeat Step 3 on the passenger side frame rail. Include the tow hook over Passenger Side Push Beam Support Plate (62A). The skid plates, tie down brackets, and skid plate brackets (See Figure 1) will no longer be used but should be retained in case the undercarriage is ever removed. 5. Install Push Beam Assembly (62) between Push Beam Support Plates (62A & 62B) using eight ½”-13 X 1-1/2″ Hex Head Bolts (A) and eight ½”-13 Lock Nuts (B). For Light Duty Plow applications, the center of the receiver hole in Push Beam Assembly (62) should be 14-1/2″ from the ground. Leave hardware finger tight. 6. Assemble Angle Bracket (75) to the back of Push Beam Assembly (62) using four ½”-13 X1- 1/2″ Hex Head Bolts (A) and four ½”-13 Lock Nuts (B). Leave hardware finger tight. 3 7. Assemble the rear portion of Angle Bracket (75) to the truck’s cross member using two Nut Plates (101), two ½” Split Lock Washers (C) and two ½”-13 X 1-1/2″ Hex Head Bolts (A) . Nut Plates (101) must be inserted into the cross member through the large hole in the rear of the cross member. 8. Tighten all hardware beginning at the rear of Angle Bracket (75) and working forward. 9. With all undercarriage parts in place, securely fasten all mounting hardware. It is important that all fasteners be properly torqued (see Fig. 3) to assure a safe operating plow. Re-tighten all fasteners after 2 hours of plowing.

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