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1996-1998 Civic HX With CVT Shudder, Judder, Surging, Shock, Noise, or Idle Fluctuation Repair Manual

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PROBABLE CAUSE The problem may have one or more of these causes: •TCM control unit programming is too sensitive. •The start clutch assembly is worn. •The start clutch control valve is contaminated. CORRECTIVE ACTION Replace the start clutch assembly, the start clutch control valve, and the TCM. PARTS INFORMATION Start Clutch Kit: P/N 06220-P2M-305, H/C 7073448 Honda ATF-Z1 (seven quarts required): P/N 08200-9001, H/C 6512628 REQUIRED SPECIAL TOOLS Start Clutch Remover: T/N 07TAE-P4VA120 Start Clutch Installer: T/N 07TAE-P4VA130 WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 219167 Flat Rate Time: 6.0 hours Failed Part: P/N 22020-P4V-325 H/C 5192349 Defect Code: 034 Contention Code: C99 Template ID: 02-003A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE NOTE: Make sure the work surface and the CVT are completely clean. Use lint-free towels, and use a dedicated, clean solvent tank for cleaning the CVT parts. If you do not keep everything very clean, the repair may not be successful. 1. Soak the new start clutch assembly in Honda ATF-Z1 for at least 30 minutes. 2. Remove the transmission from the vehicle. See page 14-304 of the 1996-00 Civic Service Manual. 3. Cover with clean shop towels all of the openings in the transmission and anything else that might get damaged by water and cleaning chemicals (axle openings, breather, and electrical connectors). Clean all the dirt and grease off of the transmission before you start disassembly

LEAKS FROM REAR HALFSHAFT AXLE SEAL REPAIR MANUAL

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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.

1996 – 2000 Civic 2-door Front Windows Bind or Have Come Out of the Run Channel Repair Manual

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REPAIR PROCEDURE 1. Remove the door panel. Refer to section 20 of the 1996-00 Civic Service Manual. 2. Remove the armrest bracket, then pull down the plastic cover to gain access to the window regulator. 3. Carefully move the glass until you can see the glass mounting bolts, then loosen them. Slide the guide rearward, remove the glass from the guide, and carefully pull the glass out through the window slot. 4. Check the year and VIN. If the vehicle is a 1996 or 1997 within the affected VIN range, replace the window regulator. Go to step 5. If the vehicle is not a 1996 or 1997 within the affected VIN range, go to step 8. 5. Remove the two roller guide bolts and the two rear regulator mounting bolts; then remove the front regulator mounting bolts. 6. Disconnect the power window motor connector, and detach the harness clip (if applicable); then lift and remove the regulator through the opening in the door. 7. Install the new regulator in the door, then loosely install the two rear mounting bolts and the two roller guide bolts. Do not tighten the two front mounting bolts yet. Go to step 9. 8. Loosen the window regulator’s two rear mounting bolts, two front mounting bolts, and two roller guide bolts

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

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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

2004 Ford Truck Ranger 2WD Transmission Position Switch/ Sensor Service and Repair MANUAL

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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.