97 thunderbird ford headlight installation manual

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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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1994-2003 Ford F-Series Power Stroke 7.3L Edge Evolution Programmer Installation Manual

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Filed Under (Ford Manuals) by admin on 25-05-2012

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Connecting the Evolution 1. Turn the ignition switch to the OFF position. Locate the diagnostic connector under the dash near the steering column or under the glove compartment and connect the Evolution cable to this connector. After making the connection, the screen will first display the Edge Products logo and then the main startup displays: The numbers in the upper left portion of the screen represent the version number of the Evolution programmer. The character in the upper right portion of the screen represents the current programmed state of your vehicle. The following letters may appear: I – Programming was interrupted. (See Programming Interrupted section for more information) 1 – Vehicle has been programmed to L1 – TOW. 2 – Vehicle has been programmed to L2 – RACE. 3 – Vehicle has been programmed to L3 – EXTREME. Evolution FORD Power Stroke 7.3 Liter 11 2. Select your desired option by pressing the up or down keys on the left side of the programmer and press . Continue to the next section. Evolution FORD Power Stroke 7.3 Liter 12 Power Programming “Caution: Vehicle manufacturers do not recommend vehicle programming in extreme temperature. Please see the service manual of your vehicle to ensure that programming is being done in accordance to the original equipment manufacturers specifications.” If you selected Diagnostics from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Performance from the Main Menu, go to that section in this instruction manual and follow the steps. If you selected Power Programming, the screen displays the following message: 1. After turning the key ON (do not start the engine) and pressing , the screen displays the following message: Evolution FORD Power Stroke 7.3 Liter 13 Evolution FORD Power Stroke 7.3 Liter 14 2. The Evolution will check the PCM and determine if it is in the Master Calibration list. If the calibration is available, you will see the following message: Otherwise you will see the following message (See Update Required for more information): 3. You will then be instructed to turn the key OFF, Press and turn the key back to ON (do not start) to begin saving STOCK: Evolution FORD Power Stroke 7.3 Liter 15 During the storing process, you will see the following display:
Evolution FORD Power Stroke 7.3 Liter 16 4. If this is the first time the unit is used on a particular vehicle, the Evolution will build and verify the modified calibrations (Skip to step 5 for subsequent programming operations). During this process, you will see the following displays

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Ford SVT Contour/ Mercury 2.5L V-6 Cougar (5 Speed Manual Transmission Only) Supercharger System Installation Manual

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Filed Under (Ford Manuals) by admin on 24-05-2012

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1998-2000 FORD SVT CONTOUR/ MERCURY 2.5L V-6 COUGAR Installation Instructions For best performance and continued durability, please take note of the following key points: 1. Use only premium grade fuel 92 octane or higher (R+M/2). 2. The engine must have stock compression ratio. 3. If the engine has been modified in any way, check with Vortech prior to using this product. 4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until problem is resolved. 5. Perform an oil and filter change upon completion of this installation and prior to test driving your vehicle. Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter every 3,000 miles or less. Never attempt to extend the oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential damage to the supercharger may result. 6. Before beginning installation, replace all spark plugs that are older than 1 year or 10,000 miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or as indicated on the factory underhood emissions tag). Do not use platinum spark plugs unless they are original equipment. Change spark plugs at least every 20,000 miles and spark plug wires at least every 50,000 miles. TOOL & SUPPLY REQUIREMENTS: •Factory Repair Manual •3/8″ Socket and Drive Set: SAE & Metric •1/2″ Socket and Drive Set: SAE & Metric •3/8″ NPT Tap and Handle •Adjustable Wrench •Open End Wrenches: 3/8″, 7/16″, 1/2″, 9/16″ •Center Punch •Ford Springlock 3/8″ Fuel Fitting Disconnect Tool •5 Quarts SH/CF Rated Quality Engine Oil •Oil Filter and Wrench •Flat #2 Screwdriver •Phillips #2 Screwdriver •Heavy Grease •Silicone Sealer •Drill Motor •1/8″, 3/16″, 27/64″ Drill Bits •9/16″ Rota Broach Tool (also available from Vortech) •Molylube •Wire Strippers and Crimpers •Utility Knife If your vehicle has in excess of 10,000 miles since its last spark plug change, then you will also need: •Spark Plug Socket •NEW Spark Plugs

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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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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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Toyota Landcruiser 70 Series SIBS Installation And Servicing Manual

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Filed Under (Toyota Manuals) by admin on 14-11-2011

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Remove the parts from their packaging and carefully check that the kit contains all the parts listed on the delivery document. Familiarize yourself with each part and learn where it goes. Keep the parts clean at all times. WARNING: A SIBS unit must not be contaminated with any external material/substance – this may adversely affect its operation and reliability. 3.1. Suggestions: 3.1.1. Inspect each brake and supplied items against the packing list included in the shipment. 3.1.2. Ensure all items are included as described. 3.1.3. Ensure all components remain in their original packaging until required for assembly. 3.1.4. Ensure vehicle stub shafts are clean, free from rust, dirt, corrosion or any foreign material. 3.1.5. Thoroughly read the Service Manual. Familiarize yourself with the tools required and prepare them for use; familiarise yourself with the parts of the brake and the process required for fitting each brake and control system. 3.1.6. Ensure complete cleanliness of all brake components and the working environment around the vehicle. 3.1.7. Ensure no contamination of the brake assemblies occurs during installation. 3.1.8. Follow the points in the manual as described; if you are not sure – check the Manual. 3.1.9. Place each brake close to the vehicle adjacent to the axle where the brake is to be fitted, ensuring that they cannot by contaminated by any foreign material.
S4 6 Manual for Toyota Land Cruiser 70 Series (Post March 2007 models) MAN-003 REV07 (June 2009) Section 4: Pre-Installation Check 4. Pre-Installation Check 4.1. Preparation Ensure all the tools, equipment and brake components are readily available. Before starting the installation, check as required according to the system you are fitting: 4.1.1. The battery is disconnected. 4.1.2. The vehicle is standing safely on a hoist. 4.1.3. The original TOYOTA brake and hub assemblies have been removed as required for Rear only or Full vehicle ABT installation. For full installation remove front brake hoses also. 4.1.4. The handbrake cable and lever have been removed. 4.1.5. The required amount of SIBS® fluid is available. 4.1.6. An empty drain pan is available. 4.2. Fitting Sequence 4.2.1. Rear inner housing (left and right) 4.2.2. Rear outer housing (left and right) 4.2.3. Rear Expansion Chambers 4.2.4. EMMA™ Engine Bay Pump Assembly (under the bonnet) 4.2.5. EMMA™ PECB and Cabin Harness (inside Cabin) 4.2.6. Bleeding of the EMMA™ system 4.2.7. Front inner housing (left and right) 4.2.8. Front outer housing (left and right) 4.2.9. Front Expansion Chambers 4.2.10. Brake master cylinder & vacuum booster 4.2.11. Bleeding the service brake system Drawings 24-0110 (Brake Assy Front) and 24-0110 (Brake Assy Rear) show how the parts are assembled. Table 1 and Table 2 enlist individual parts in their respective assemblies. NOTE: Refer to Appendix for complete SIBS Product and Spare Parts List

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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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2006 TOYOTA RAV4 TOWING HITCH INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 17-03-2012

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TOYOTA RAV4 2006 TOWING HITCH Section II Installation Procedure Page 2 of 7 pages Issue: A 10/11/05 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 Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Prepare for Installation. (a) Verify kit contents (b) Wear Safety Glasses. (c) Raise Vehicle . (d) Caution Muffler might be hot 2. Remove Rear Bumper Fascia (a) Remove (2) Phillips head screws (A) from both sides of the rear fascia (Fig. 2-1). (b) Remove (7) push pins (A) on edges of fascia (Fig. 2-2) (c) Remove (2) Phillips head screws (B) from bottom of fascia (Fig. 2-2). (d) See Fig. 2-3 for removal of fastener (C). Fig. 2-1 Rear Tire A A (Drivers Side) – Phillips screwdriver A A A A A C A A B B – Phillips screwdriver – Straight shank screwdriver Fig. 2-2 TOYOTA RAV4 2006 TOWING HITCH Section II Installation Procedure Page 3 of 7 pages Issue: A 10/11/05 (e) Remove (1) 10 mm hex head bolt (C) from right hand (RH) side of fascia. (Fig. 2-3) (f) With one person on each end, remove fascia from vehicle. Store in a safe place to avoid damage during installation. 3. Remove Vehicle Tie Down (a) Remove (2) M12 Bolts and vehicle tie down (A) from the left hand (Drivers Side) rear of vehicle (Fig. 3-1). (b) Dispose of bracket and (2) bolts. 4. Detach Muffler (a) Protect exhaust tip with a rag or protective tape during installation of hitch (Fig. 5). (b) Detach muffler from exhaust hangar (Fig. 5) 5. Install Bumper Brackets (a) Remove M8 bolts from the vehicle bumper beam, and install (RH) and (LH) bumper brackets with (3) OE supplied M8 bolts, each with a lock washer and a flat washer (Fig. 5-1). Do not tighten at this time. 6. Install Hitch (a) Lift hitch into place (requires 2 people) and install the (3) M12 x 35 bolts into the (3) weld nuts in the bottom of the frame rails (Fig. 6-1). (b) Loosely secure the middle bolts first, then the (2) forward and aft bolts on each side. (c) Do not tighten bolts at this time. 7. Install Drivers Side Brackets (a) Install LH Frame Bracket (A) to the side of the frame rail using (2) of the M12 x 35 bolts (Fig. 7-1). NOTE: Excess body sealant may require removal of sealant before continuing installation Protect any bare areas with 3MTM Autobody sealant. (b) Install LH Support Bracket (B) to Driver’s Side of Hitch (C), and to bottom of LH Frame Bracket using (4) M12 x 35 bolts. Do not tighten (Fig. 7-1). (c) Fasten LH Support Bracket (B) to LH Bumper Bracket (D) using (4) M12 x 35 bolts. Do not tighten (Fig. 7-1)

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1995 Mazda MX-6 FRONT DISC BRAKE PADS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mazda Manuals) by admin on 16-02-2012

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REMOVAL & INSTALLATION FRONT DISC BRAKE PADS Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . Pivot caliper upward and support using rope. 2. Remove pads, shims, guide plates or pad guides and “V” springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Fig. 2: Exploded View Of Front Brake Disc Assembly Courtesy of MAZDA MOTORS CORP. MINIMUM PAD LINING SPECIFICATIONS (FRONT) Application Thickness In. (mm) MX-6, 626 FRONT DISC BRAKE CALIPER Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system. FRONT BRAKE ROTOR Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). Remove rotor. 2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table. To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation 1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See Fig. 3 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston. 2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove “M” springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04″ (1.0 mm). 3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

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2008 Ford F-250/350/450 6.4L Powerstroke diesel aft-filter system Installation Manual

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Filed Under (Ford Manuals) by admin on 08-12-2011

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Installation instructions: 1.) Raise and support vehicle. 2.) Lubricate all factory rubber hangers and pipe slip-connectors with penetrating oil. 3.) Loosen clamp, attaching inlet of stock muffler to inlet pipe. 4.) Remove muffler/tailpipe assembly from inlet pipe and rubber hangers; remove from vehicle. Removal of muffler/tailpipe can be made easier by first cutting the tailpipe from the muffler with a reciprocating saw. 5.) Remove hanger rod on inlet pipe from rubber frame hanger. 6.) Loosen clamp attaching inlet pipe to outlet of converter and remove pipe from vehicle. 7.) Place supplied 3.5? clamp with hole over small end of supplied adapter and install onto outlet of converter. Engage slot in adapter with index bump on converter outlet and place hole in clamp over bump. Tighten clamp fully. 8.) Place one supplied 4? clamp over inlet pipe slip-connector and install pipe onto adapter. Insert hanger rod on pipe into corresponding rubber hanger on frame. 9.) Rotate inlet pipe as needed to orient end of hanger rod, which is inserted into rubber hanger, in a horizontal position and tighten clamp at slip-connector fully 10.) Place one supplied 4? clamp over muffler inlet and install muffler onto inlet pipe. 11.) Place one supplied 4? clamp over inlet of tailpipe section “A” and install pipe onto muffler and into corresponding factory rubber hangers just above muffler. 12.) Place one supplied 4? clamp over inlet of tailpipe section “B” and install pipe into rear-most rubber frame hanger and onto outlet of tailpipe section “A”. 13.) Place remaining 4? clamp over tip inlet and install tip onto outlet of tailpipe section “B”. 14.) Align all components for desired fit and tighten all clamps fully

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