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2004 Chrysler Pacifica DISC BRAKE SHOES Removal And Installation Manual

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

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DISC BRAKE SHOES Removal (Front) 1. Remove master cylinder fluid reservoir cap. 2. Raise and support vehicle. 3. Remove tire and wheel assembly. 4. Place appropriately sized C-clamp over brake caliper, placing screw-drive head against outboard shoe and hook against rear of caliper. Slowly tighten screw-drive retracting caliper pistons into bores and brake outboard brake shoe free from caliper fingers. See Fig. 22 . Remove C-clamp. 5. Once outboard shoe is free from caliper fingers, slide caliper inboard on guides providing clearance between the rotor and inboard brake shoe. 6. Slide an appropriate prying tool through center opening in top of caliper behind brake shoe between 2 caliper pistons. Use care not to come in contact with pistons or dust boots potentially damaging them. Pry against rear of inboard brake shoe braking it free from caliper pistons. 7. Remove the 2 brake caliper guide pin bolts. See Fig. 23 . 8. Remove disc brake caliper from brake adapter and hang out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this. 9. Remove brake shoes from disc brake caliper adapter. See Fig. 27 . 10. Install master cylinder fluid reservoir cap. 2. Install disc brake caliper over brake shoes on brake caliper adapter. See CALIPER . 3. Align guide pin bolt holes with guide pins and install caliper guide pin bolts. See TORQUE SPECIFICATIONS . 4. Install tire and wheel assembly. See TORQUE SPECIFICATIONS . 5. Lower vehicle. 6. Pump brake pedal several times to seat shoes to caliper and brake rotor. 7. Check and fill brake fluid level as necessary. See CHECKING & FILLING under BRAKE FLUID in SERVICE. 8. Road test vehicle making several stops to wear off any foreign material on brakes and to seat brake shoes. Removal (Rear) 1. Raise and support vehicle. 2. Remove both rear tire assemblies from vehicle. 3. Remove 2 caliper guide pin bolts. 4. Remove the 2 caliper guide pin bolts. See Fig. 24 . 5. Remove caliper from caliper adapter. See CALIPER . 6. Remove outboard brake shoe by pushing shoe away from caliper fingers, dislocating locating pins built into shoe backing plate from holes in caliper fingers, then sliding brake shoe down and off of brake caliper. See Fig. 28 . 7. Pull inboard brake shoe away from caliper piston, dislocating retaining clip from cavity in piston. Remove inboard shoe. NOTE: In some cases, it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle. This can usually be accomplished before guide pin bolts are removed, but grasping rear of caliper and pulling outward working with guide pins, thus retracting piston. DO NOT push on piston directly as it may get damaged.

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2008 Ford Taurus AWD V6-3.5L – Rear Brake Pads Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 25-06-2012

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Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer’s specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake fluid to come in contact with the adhesive backing on the brake pads. If brake fluid is spilled onto the brake pads, new pads must be installed. CAUTION: Use only specified brake parts cleaner. Use of other cleaners may leave a residue on the brake caliper preventing the brake pads adhesive surface from bonding with the brake caliper. 1. Remove the wheel and tire. 2. Check the brake fluid level in the brake fluid reservoir. * If required, remove fluid until the brake master cylinder reservoir is half full. 3. Remove the brake caliper bolts. 4. CAUTION: Do not use the brake caliper sight hole to retract the pistons as this may damage the pistons and boots. CAUTION: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. CAUTION: Care must be taken when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fittings may occur. Using hand force and a rocking motion, separate the brake caliper from the anchor plate. Position the brake caliper aside. * Support the caliper with mechanic’s wire. 5. CAUTION: When the brake pads are separated from the brake caliper , new brake pads must be installed to prevent brake noise. The brake pads are one-time use only. Remove and discard the brake pads and spring clips from the brake caliper anchor plate. 6. NOTE: Do not remove the anchor plate guide pins. The guide pins are press fit to the brake caliper anchor plate. If the guide pins are damaged a new anchor plate must be installed. Inspect the brake caliper anchor plate assembly. * Check the guide pins and boots for binding or damage. * Install a new brake caliper anchor plate if it is worn or damaged. Installation 1. NOTE: To move the piston back into the caliper, the LH piston is turned clockwise and the RH piston is turned counterclockwise. NOTE: A moderate to heavy force toward the caliper piston must be applied. If sufficient force is not applied, the internal park brake mechanism clutch cone will not engage and the piston will not compress. Using the special tool (or equivalent such as OTC tool 7317A), compress the brake caliper piston into its cylinder. 2. Clean the residual adhesive from the brake caliper fingers and pistons using the specified brake parts cleaner. 3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pad or caliper mating surface or damage to components may occur. Do not install contaminated pads. NOTE: Install all the new hardware supplied with brake pad kit. Install the new spring clips and brake pads. 4. Position the brake caliper and install the 2 bolts. * Tighten to 29 Nm (21 lb-ft). 5. If necessary, fill the brake fluid reservoir with clean, specified brake fluid. 6. With the vehicle engine running, apply 89-133 N (20-30 lb) of pressure on the brakes for approximately one minute, to make sure the brake pads adhere to the caliper before any contamination can be introduced. 7. Test the brakes for normal operation.

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1999-2006 TOYOTA TUNDRA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the passenger sides of the vehicle. Next remove the wheels from both sides. 2. Using a 17mm socket, remove the lower sway bar link bolt from both sides. HINT: If the stud turns together with the nut use a hex wrench or vice grips to hold the stud . 4. Next remove the strut’s lower mounting bolt with a 19 mm socket and wrench. NOTE: Once the nut is removed, it may be necessary to use a punch and hammer to free the bolt. 5. Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 6. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the steel strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 7. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the steel spacer the strut will be rotated 180° when reinstalled. 8. Place strut back into upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 9. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. 10. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 11. Repeat Steps 3 through 10 on the opposite side of the vehicle. 12. Reattach the sway bar link assembly on both sides of the vehicle. Torque to OEM specs. For 2wd trucks skip Step 13. 13. For 4×4 models only it is necessary to lower the differential using the provided spacers and bolts. Install the spacers following the instructions provided with the spacers. 14. Reattach the wheels. Torque to OEM specs. 15. Lower vehicle to the ground and torque strut mounts to OEM specs. 16. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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2004-2008 FORD F150 FRONT LEVELING SYSTEM INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 19-12-2011

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Front End Installation: 1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the p sides of the vehicle. Next remove the wheel from both sides. assenger s 2. Remove the upper strut mounts with a 15-mm wrench or . m socket. Using a ball cket. Use an socket. You will need a socket to remove the far strut mount 3. Remove the sway bar lower link pin bolt from the bottom of the control arm with an 18 mm socket. 4. Disconnect the tie rod end with a 21 m peen hammer or impact tool, hit the steering knuckle (not the tie rod) until the tie rod pops out. If you use a tie rod pickle fork, be careful not to cut the tie rod boot. A severed tie rod boot will allow dirt and moisture to damage the tie rod end. 5. Remove the upper ball joint nut with a 21 mm so impact tool or ball peen hammer and hit the steering knuckle until the upper control arm pops out.
6. Support the knuckle with a bungee cord or safety wire so not to overextend the CV axel or stretch the brake hydraulic hose. 7. Next remove the struts lower bolt. Using a 27 mm wrench, hold the nut and remove the bolt with a 30 mm socket. 8. Remove the strut assembly. 9. Place the strut extension on the top of the strut, hold the part up to start the nuts onto the factory studs. ** Caution: Use the factory nuts with the factory studs** 10. Run down nuts snug with end wrench. Torque to OEM specs. 11. Place strut back into upper strut mount. Tighten provided nuts snug with wrench or ratchet (after install, you will torque to OEM specs). 12. Use a pry bar to position the lower control arm and the strut mount to reinstall the mounting bolt. Torque to OEM specs. 13. Place a jack under the lower control arm. Raise the lower control arm to reattach the ball joint. A pry bar may be used to hold the upper control arm into position. Torque the ball joint nut to OEM specs. 14. Reattach the tie rod end. Torque to OEM specs. 15. Reattach the sway bar. Torque to OEM specs. 16. Reattach the wheel. Torque to OEM specs. 17. Repeat on opposite side. 18. Lower vehicle to ground and torque strut mounts to OEM specs. 19. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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2004 Ford Expedition/ Navigator Brake Pads REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 19-06-2012

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Removal 5. NOTE: Verify if the anchor housing spring has 1. CAUTION: Install a new lining if worn 1 end with 2 tabs. If yes, the LH side anchor to or past the specified thickness above the housing spring must be installed with the metal backing plate or rivets. Install new 2-tabbed end in the upper brake caliper cavity. pads in complete axle sets. For the LH brake caliper, release the lower If necessary, using a suitable suction device, portion of the anchor housing spring. remove the brake fluid in the master cylinder •Apply force at the center of the anchor reservoir until it is half filled. housing spring and pull outward at the bottom of the anchor housing spring to 2. Remove the wheel and tire assembly. For remove it from the lower brake caliper additional information, refer to Section 204-04. cavity. 3. Inspect the brake pads for wear or contamination. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper. Do not install a damaged anchor housing spring. Remove the anchor housing spring. REMOVAL AND INSTALLATION (Continued) 6. Rotate the spring upward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose. Remove the brake caliper. 7. NOTE: On the RH side, the anchor housing 1 Remove the zero-drag spring. spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The 2 Remove and discard the brake illustration below shows the anchor housing caliper-to-anchor plate bolts, guide pins and spring end with 2 tabs. boots. For RH brake caliper, release the upper portion of the anchor housing spring. •Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 10. Remove the brake pads from the brake caliper. 11. NOTE: Use a wood block or used brake pad to protect the brake caliper piston boots. Compress the brake caliper pistons. 8. Rotate the spring downward then remove it from the brake caliper.

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2004 Ford Expedition/ Navigator Brake Pads REMOVAL AND INSTALLATION

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Filed Under (Ford Manuals) by admin on 26-01-2011

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1. CAUTION: Install a new lining if worn 1 end with 2 tabs. If yes, the LH side anchor to or past the specified thickness above the housing spring must be installed with the metal backing plate or rivets. Install new 2-tabbed end in the upper brake caliper cavity. pads in complete axle sets. For the LH brake caliper, release the lower If necessary, using a suitable suction device, portion of the anchor housing spring. remove the brake fluid in the master cylinder •Apply force at the center of the anchor reservoir until it is half filled. housing spring and pull outward at the bottom of the anchor housing spring to 2. Remove the wheel and tire assembly. For remove it from the lower brake caliper additional information, refer to Section 204-04. cavity. 3. Inspect the brake pads for wear or contamination. 4. CAUTION: If the anchor housing spring is to be reused, do not force the anchor housing spring off the brake caliper. Do not install a damaged anchor housing spring. Remove the anchor housing spring. REMOVAL AND INSTALLATION (Continued) 6. Rotate the spring upward then remove it from the brake caliper. 9. NOTE: Do not allow the brake caliper to hang from the brake hose. Remove the brake caliper. 7. NOTE: On the RH side, the anchor housing 1 Remove the zero-drag spring. spring must be installed with the 2-tabbed end in the lower brake caliper cavity. The 2 Remove and discard the brake illustration below shows the anchor housing caliper-to-anchor plate bolts, guide pins and spring end with 2 tabs. boots. For RH brake caliper, release the upper portion of the anchor housing spring. •Apply force at the center of the anchor housing spring and pull outward at the top of the anchor housing spring to remove it from the upper brake caliper cavity. 10. Remove the brake pads from the brake caliper. 11. NOTE: Use a wood block or used brake pad to protect the brake caliper piston boots. Compress the brake caliper pistons. 8. Rotate the spring downward then remove it from the brake caliper.

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2007 Volkswagen Rabbit BRAKES Brake System removing and installing

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Filed Under (Volkswagen Manuals) by admin on 18-01-2012

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Fig. 49: Torque Wrench V.A.G 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. * Torque wrench V.A.G 1331 Fig. 50: Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC. * Piston resetting tool T 10145 Brake pads, removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! * Remove wheels. Fig. 51: Locating Brake Wear Pad Indicator Connector Courtesy of VOLKSWAGEN UNITED STATES, INC. * Disconnect connector – 1 – for brake pad wear indicator. Fig. 52: Protective Caps Courtesy of VOLKSWAGEN UNITED STATES, INC. * Remove caps – arrows -. Fig. 53: Removing/Installing Brake Caliper Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC. * Loosen both guide pins – arrows – and remove from brake caliper. * Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose. * Remove brake pads from brake caliper. Cleaning: * Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion. * Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Brake pads, installing Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Fig. 55: Identifying Brake Pad Retaining Springs Courtesy of VOLKSWAGEN UNITED STATES, INC. * Insert inner brake pad (piston side) – 1 – and outer brake pad – 2 – with retaining springs into brake caliper. * Inner brake pad (piston side) with large three-finger clip – 1 -. * Outer brake pad with small three-finger clip – 2 – (colored black). Fig. 56: Identifying Lower Part Of Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. * Place brake caliper with brake pads on brake carrier first at bottom – arrow

1996-2004 TOYOTA TACOMA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 96-04 Tacoma 11/07 5. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the provided strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 6. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the provided spacer the strut will be rotated 180° when reinstalled. 7. Place strut back into the upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 8. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. HINT: It may be helpful to use a pry bar to press down on the steering knuckle for reinstalling the mounting bolt. 9. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 10. Repeat Steps 2 through 9 on the opposite side of the vehicle. 11. Reattach the wheels. Torque to OEM specs. 12. Lower vehicle to the ground and torque strut mounts to OEM specs. 13. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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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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FRONT WHEEL SPEED SENSOR CORROSION REPAIR MANUAL

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

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1999-2002 CHEVROLET SILVERADO 2000-2002 CHEVROLET TAHOE, SUBURBAN 2002 CHEVROLET AVALANCHE 1999-2002 GMC SIERRA 2000-2002 GMC YUKON, YUKON XL LOCATED IN THE SEVERE CORROSION AREAS LISTED BELOW Service Procedure The following procedure provides instructions for repairing a corrosion condition where the front wheel speed sensor mounts on the front wheel bearing assembly. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tires and wheels. 3. Compress the front brake caliper pistons. 3.1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. 3.2. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. 3.3. Remove the C-clamp from the caliper. Important: It is not necessary to remove the front brake caliper from the bracket when removing the bracket in the next step. 4. Remove the two bolts that attach the front brake caliper mounting brackets to the knuckle. Notice: Support the brake caliper with heavy mechanic’s wire, or equivalent, whenever it is separated from its mount, and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 5. Remove the brake caliper and bracket as an assembly and support it with heavy mechanic’s wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Mark the relationship of the rotor to the bearing hub. 7. If equipped, remove the rotor retaining push nuts from the wheel studs

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