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Ball Joint Spacers for IFS Suspension

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1) Block rear wheels, place front end of truck on jack stands supported on the frame and remove the front wheels. 2) Remove the original upper ball joint hardware. 3) Knock the studs out of the ball joint with a small hammer. This is done most easily if the joint is pressed against the arm supported with a floor jack. 4) Remove the factory shock. 5) Trim the lip. An angle grinder with a cut-off wheel or a small reciprocating saw works well. Trim enough to allow installation of the spacer. 6) Put the spacer in place, NOTCH FACING DOWNWARD and, using a floor jack to control arm height, align the ball joint and install the hardware. The notch acts as a weep hole to let any water that gets in from above drain out to prevent the ball joint from rusting out. 7) Tighten ball joint hardware using the provided nylon lock nuts. 8) Install new extended length shock. 9) Repeat for other side. 10) Re-install the wheels. 11) If the end of the upper control arm is too close to the tire at this point, there are a few options: • You can replace your wheels with a higher off-set. • You can add a 1/4″ wheel spacer to move the wheel/tire away from the suspension. 12) Put the vehicle back on the ground. 13) For low profile bump stops only: • Shim them approx. 1/2″ with some washers or use stock bump stops. • Failure to do so could result in damage to CV joints, shocks, or other components 14) Even with stock bump stops, you may experience some CV axle binding. • To check, let the suspension hang’ at full droop. • Rotate each CV axle shaft by hand and check for any binding at the CV joints. • If felt, several options to fix it are available: o Add some shims for the low profile bump stops. o Or install a front differential drop kit to lower the differential and thus lessen the CV joint angles.

Toyota IFS Ball Joint Spacer Installation

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Ball Joint Spacer Installation Put the spacer in place, NOTCH FACING DOWNWARD and, using a floor jack to control arm height, align the ball joint and install the hardware. The notch acts as a weep hole to let any water that gets in from above drain out to prevent the ball joint from rusting out. Tighten ball joint hardware to 25 ft.lb. or 35 N.m. Note: Apply this torque to the allen head bolt and the Grade 10.9 nut only, then install the 2nd nylon lock nut and tighten it down snugly in order to lock the first nut in place. No need to toque the nylon lock nut to 25 ft.lb. value, it may strip. If you wish, you can spray the exposed head and threads of the bolts with some paint, as the black oxide coated hardware may tend to rust over time. Extend the shock to see if it needs shimming. (it likely will) Place the appropriate number of washers to ensure the shock does not limit down travel. Tighten shock hardware. Repeat for other side. Re-install the wheels. If the end of the upper control arm is too close to the tire at this point, there are several options: You can try and grind off part of the outer lip of the control arm (area at the left edge of the red circle in the photo above) You can add a 1/4″ wheel spacer to move the wheel/tire away from the suspension. You can swap to a narrower tire, for example changing from a 33×12.50 to a 33×10.50 tire will move the inner edge of the tire away from the control arm since it’ll have less sidewall bulge on the same wheel. You can swap to a wheel with less back side spacing, for example going from a 4.75″ to a 4.5″ backspaced wheel will move the inner edge of the wheel and tire 1/4″ away from the control arm (stock wheels are ~4.75″ backspacing). Put the vehicle back on the ground. For low profile bump stops only: Shim them approx. 1/2″ with some washers or use stock bump stops. Failure to do so could result in damage to CV joints, shocks, or other components

1996-2000 Honda Civic Door Panel REMOVAL And INSTALLATION Manual

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Honda Door Panel 96-00 Civic REMOVAL & INSTALLATION Remove the screw from behind the interior door handle Slide out the door handle trim as shown Removing the door panel from the passenger side door View of the inside of the door, panel removed 1. Remove the screw from the door handle trim. 2. Slide the handle assembly forward and out to access the lock rod clip. 3. Release the clip 4. Disconnect the door lock switch 5. Remove the door opener handle assembly. 6. Carefully pry at the small opening on the bottom of the speaker grill. 7. Remove the speaker grille. 8. Remove the speaker mounting screws. 9. Detach the electrical connector and remove the speaker. 10. Remove the screws in the armrest. 11. Remove the center from the trim clip at the upper front of the door panel and remove the clip. 12. Using a suitable trim panel removal tool, unsnap the door panel from the door frame. 13. Carefully lift the door panel up and away from the door frame. To install: 14. Installation is the reverse of the removal procedure. Honda Civic/Del Sol 1996-2000 Electric Window Motor REMOVAL & INSTALLATION 1. Remove the regulator from the door assembly. 2. Except for the rear doors, drill a hole through the regulator sector gear and backplate. Install the bolt and nut to lock the sector gear in position. Be careful not to drill a hole closer than 7/ 16 in. (11mm) from the edge of the sector. Also, do not drill through the lift arm attaching portion of the sector gear, or the joint integrity will be jeopardized. 3. Drill out the ends of the motor attaching rivets using a 1/ 4 in. (6mm) bit. 4. Remove the motor and the remaining portions of the rivets from the regulator. Except for the rear doors, one rivet will not be accessible until assembly. Regulator and motor assembly—except rear doors Secure the rivets by collapsing the rivet ends using a ball peen hammer To install: 5. Position the new motor to the regulator. With the aid of an assistant, install new rivets by collapsing or crushing the rivet ends using a ball peen hammer. 6. Except for the rear doors, once two of the three rivets have been installed, remove the bolt securing the sector gear to the backplate, then use an appropriate electrical source (such as the vehicle’s window motor harness) to rotate the regulator, providing access to the remaining rivet. 7. Except for the rear doors, use a flat nosed rotary file to grind off one sector gear tooth from the side which does not contact the driven gear. This is necessary to reach the remaining rivet. Remove the old rivet, then install the remaining new rivet. 8. Install the regulator to the door assembly.

1989 Toyota 4Runner STEERING COLUMN REMOVAL AND INSTALLATION INSTRUCTIONS

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REMOVAL & INSTALLATION STEERING COLUMN Removal 1) Disconnect battery ground cable. Remove steering wheel. On Cressida, Corolla, MR2 and Tercel models, remove fuse box cover, lower instrument trim panel and air duct from under steering column. 2) On all models, remove upper and lower steering column covers. Remove combination switch. Mark position of “U” joints and shaft for reassembly. 3) On models with “U” joints, remove “U” joint retaining bolt. On models with flexible joint, remove flexible joint retaining bolt. NOTE: On 2WD Pickup models, remove steering column with intermediate shaft attached. 4) On all models, mark position of joint and pinion shaft for reassembly. Remove intermediate steering shaft. 5) Remove floor pan cover bolts. Remove tilt bracket-to- dashboard mounting bolts. Remove steering column toward inside of vehicle. Fig. 1: Exploded View of Camry, Corolla, MR2 & Tercel Steering Column Assembly Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 2: Exploded View of Celica, Cressida & Supra Steering Column Assembly Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 3: Exploded View of Land Cruiser, Pickup, Van & 4Runner Steering Column Assembly Courtesy of Toyota Motor Sales, U.S.A., Inc. Installation 1) To install steering columns, reverse disassembly procedure. Grease main steering shaft and all bearings. 2) Ensure marks made to flexible couplings and to “U” joints are aligned. Ensure steering column and shafts do not bind after installation. STEERING COLUMN OVERHAUL NOTE: Camry, Corolla, MR2 and Tercel steering columns are similar. Some of the following procedures will not pertain to all models. Disassembly (Camry, Corolla, MR2 & Tercel) 1) Remove tension springs, grommets and screws from tilt bracket. Remove tilt lever left-hand set bolt. Remove column upper support lock bolt. 2) Remove tilt steering support bolts and pawl set bolts. Place bushings and “O” rings aside and keep them clean. Remove ignition lock cylinder. 3) Using a screwdriver, push 2 thrust stoppers into bearing retainers. Pull out shaft from column. Remove the No. 1 column ring, bearing retainer, thrust stoppers and No. 2 column ring from shaft. 4) Remove snap ring and lower bearing from shaft. Remove bearing inner snap ring. Remove upper bracket retaining bolts and ground strap. Separate upper bracket from column. Inspection 1) Check that steering lock mechanism operates properly. Check upper bearing for smooth rotation or excessive noise. Replace upper bearing (if necessary). 2) Using Drift (09631-00020) and Adapter (09627-30010), drive bearing from upper bracket. Pack new bearing with grease. Using the same drift and adapter used in removal, drive new bearing into upper bracket. 3) Inspect lower bearing for smooth rotation or excessive noise. If lower bearing shows signs of wear or damage, replace with a new one. Reassembly 1) Install upper bracket onto column. Install ground strap. Tighten retaining bolts to 14 ft. lbs. (19 N.m). Install inner snap ring on shaft groove nearest to center of shaft. 2) Install lower bearing and lower bearing snap ring. Place No. 2 column ring into position next to bearing on side nearest center of shaft. See Fig. 4.

1989 Toyota 4Runner ENGINE PERFORMANCE Removal Overhaul And Installation

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CARBURETOR (COROLLA) REMOVAL 1) Drain cooling system. Disconnect air intake hose. Disconnect emission control hoses from air cleaner. Remove air cleaner mounting bolt and wing nut. Remove air cleaner. 2) Disconnect accelerator cable. Disconnect throttle cable (A/T). Disconnect carburetor wiring connector. Disconnect emission control hoses and tag for installation. Disconnect fuel inlet hose. Remove 4 carburetor mounting nuts and No. 1 vacuum pipe. Remove carburetor. DISASSEMBLY Air Horn 1) Remove air cleaner setting bolt. Remove fuel pipe clamp, union, fuel pipe and gaskets. Remove vacuum hoses. Remove pump and pivot screw and pump arm with connecting link. Disconnect choke link and choke opener link. 2 Remove 8 air horn screws and number plate, fuel pipe support and wire clamps. Remove air horn from carburetor body. Disconnect wiring from solenoid valves. 3) Remove float pivot pin, float and needle valve assembly. Remove air horn gasket, needle valve seat and gasket, power piston retainer, power piston and spring. Remove pump plunger and boot. See Fig. 2.
Fig. 1: Exploded View of Aisan Carburetor Main Body (Corolla) Courtesy of Toyota Motor Sales, U.S.A., Inc. Fig. 2: Exploded View of Air Horn Assembly (Corolla) Courtesy of Toyota Motor Sales, U.S.A., Inc. Main Body 1) Remove solenoid valves from carburetor body. Remove stopper gasket. Disconnect throttle positioner links and remove bracket attaching bolts. Remove accelerator pump retainer gasket and remove pump discharge weight, long spring and discharge large ball. See Fig. 1. 2) Remove pump dampening spring. Using tweezers, remove plunger retainer and check ball. Disconnect throttle positioner link and throttle position levers, washer and spring. Remove primary and secondary main passage plugs and gaskets. Remove primary and secondary main jets and gaskets. 3) Remove auxiliary acceleration pump (AAP) housing, spring and diaphragm. Remove AAP inlet plug and check ball. Remove outlet plug, short spring and small ball. Remove primary and secondary small venturies. 4) Remove sight glass retainer, sight glass and “O” ring. Remove throttle lever return spring and back spring. Remove throttle lever and fast idle cam. 5) Disconnect link and remove secondary throttle valve diaphragm assembly and gasket. Remove throttle position switch and bracket. Remove 3 body-to-flange screws and vacuum passage screw. Separate body from flange. See Fig. 3. Remove washer from throttle valve shaft. Remove idle mixture adjusting screw and idle speed adjusting screw.