how to replace 2002 tundra rear axle seal

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1997 Jeep Grand Cherokee Laredo 7 1/8″, 7 1/3″, 7 9/16″, 7 4/5″, 8 1/4″, 8 1/2″ & 8 9/10″ Ring Gears Removal And Installation Manual

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Filed Under (Jeep Manuals) by admin on 04-07-2012

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Removal (Model 194, 8 1/4″ & 1998 Grand Cherokee 216 Axles) 1. Raise and support vehicle. Remove rear wheel(s). If equipped with drum brakes, remove brake drum. If equipped with disc brakes, remove brake caliper and rotor. On all models, clean axle housing cover. Loosen cover bolts, and drain oil. Remove cover. 2. Remove differential pinion-shaft lock bolt. Remove pinion shaft from differential. Push in axle. Remove “C” clip from axle at pinion gear. Remove axle from tube. Remove axle shaft seal and bearing from axle tube. Installation 1. Grease bearing, and install into axle tube. Ensure bearing part number is facing outwards. Apply wheel bearing grease to axle shaft seal. Install seal in axle tube. Install axle shaft. 2. Install axle “C” clip. Pull axle out to seat “C” clip. Install pinion shaft. Install lock bolt, and tighten to specification. Apply RTV to axle housing cover. Tighten cover bolts to specification. See TORQUE SPECIFICATIONS table. Fill with gear oil. Removal (Model 198, 1999 Grand Cherokee 216 & 226 Axles) 1. Raise and support vehicle. Remove rear wheel(s). Remove brake drum. Remove nuts securing axle retainer plate to axle tube, and discard. Using slide hammer and Adapter (6790), remove axle shaft from axle tube. 2. Using a 3/8″ drill bit, drill a shallow hole into bearing retaining ring on axle. DO NOT drill into axle. Using a cold chisel, cut bearing retaining ring across drilled hole, and remove from axle shaft. Using a press and Bearing Remover (1130), remove bearing from axle shaft. Remove seal and retainer plate from axle shaft. Installation 1. Ensure axle shaft retaining plate is flat and not warped. Install retaining plate on axle shaft. Apply wheel bearing grease to axle shaft seal. Install seal on axle shaft. Grease bearing, and install on axle shaft with outer surface groove facing seal. 2. Using press and Bearing Installer (7913), press bearing onto axle shaft. Press NEW bearing retainer ring onto axle shaft. Install axle shaft in axle tube. Tighten NEW axle retainer plate nuts to specification. See TORQUE SPECIFICATIONS table. PINION SEAL & YOKE Removal

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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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1991 Infiniti G20 AXLE SHAFTS – FRONT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Infiniti Manuals) by admin on 13-02-2012

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REMOVAL & INSTALLATION FWD AXLE SHAFT Removal (Axle Shaft) 1. Raise and support vehicle. Remove front wheel assembly. Remove wheel bearing lock nut. Remove brake caliper, and support aside. Remove brake rotor. 2. Disconnect tie rod end. Remove upper knuckle nut, and separate knuckle assembly from third link assembly. Push axle shaft through hub, and separate axle assembly from knuckle assembly. 3. Insert screwdriver blade between transaxle case and right axle inner CV joint. Pry out on joint until joint pops free. Use care not to damage axle boot or axle seal. 4. On M/T vehicles, remove left axle in same manner. On A/T vehicles, insert screwdriver through differential, and drive axle out of transaxle case using a hammer. See Fig. 2 . PROBLEM Possible Cause/Action GREASE LEAKING Ripped CV Boot Replace Boot CLICKING NOISE WHILE CORNERING Dry/Worn CV Joints Replace Outer CV Joints CLUNK ON ACCELERATION Dry/Worn CV Joints Replace Inner CV Joints Worn Transmission Gears/Bearings Inspect Transmission VIBRATION/SHUDDER ON ACCELERATION Dry/Worn CV Joints Replace CV Joints Alignment Out Check Alignment Incorrect Spring Height Check Spring Height SQUEALING OR HUMMING Dry/Worn CV Joints Lube/Replace CV Joints Faulty Wheel Bearing Replace Wheel Bearing NOTE: DO NOT allow brake caliper to hang from brake hose. CAUTION: Use care not to damage pinion mate shaft or side gear while driving out axle. 1991 Infiniti G20 AXLE SHAFTS – FRONT’ ’1991-92 DRIVE AXLES FWD Axle Shafts None Page 2
Fig. 2: Removing Left Drive Axle (A/T Vehicles) Courtesy of NISSAN MOTOR CO., U.S.A. Removal (Outer CV Joint) 1. Remove and discard boot bands. Slide boot off joint housing. Thread wheel bearing lock nut onto joint. Using a slide hammer and bearing puller, remove joint from axle shaft. See Fig. 3 . NOTE: Outer joint cannot be disassembled. Remove and inspect joint and replace if damaged or worn. 1991 Infiniti G20 AXLE SHAFTS – FRONT’ ’1991-92 DRIVE AXLES FWD Axle Shafts None Page 3 2. Remove circlip from end of axle, and remove boot. If boot is being reused, take care not to cut boot on axle splines during removal. Clean CV joint in suitable solvent. Inspect components, and replace joint if necessary.

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2000 Ford F-Super Duty 250-550/ Excursion/ F-53 Motorhome Chassis Workshop Manua

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Filed Under (Ford Manuals) by admin on 19-02-2011

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Removal 1. Set the parking brake. 2. Loosen the retaining bolts. 3. Raise the vehicle to the desired working height, keeping the axle parallel with the floor; for additional information, refer to Section 100-02 . 4. Release the parking brake. 5. Remove the wheel(s); for additional information, refer to Section 204-04 . 6. Remove the brake caliper and rotor on the single rear wheel axle; for additional information, refer to Section 206-04 . 7. Remove the retaining bolts and axle shaft. 9. d the hub nut if es apart during removal. no circumstances e operations. NOTE: The hub nut will ratchet during this operation. Remove the hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread). 10. Install the Step Plate. 11. Install the 2-Jaw Puller and loosen the rear hub to the point of removal. 12. hub bearing when b. Remove the rear hub assembly. 3. l a new hub seal ub assembly is removed. NOTE: The inner bearing is located behind the hub seal. Pack each bearing and replace the hub seals; for additional information, refer to Bearings, Cups and Seals in this section. 14. treme care not to scratch or gouge the seal or bearing surfaces. If after hub removal, the hub seal or seal inner sleeve remains on the spindle, remove it as shown using the Step Plate and the 2-Jaw Puller. 15. Inspect the seal surface and inner shoulder for scratches and damage. ? Remove all scratches, gouges or galling damage with #600 or finer crocus cloth. Installation 1. NOTE: Clean the spindle thoroughly after removing the rear hub. Coat the spindle with axle lubricant. 2. b bearings must be prelubed prior to installation. Fill the hub cavity with 29.6 ml (1 oz) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 3. treme care not to damage the hub g it to contact the spindle during installation. NOTE: Coat the spindle and hub seal inside diameter with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL- M2C192-A. NOTE: Installing the rear hub in this manner causes the outer bearing to act as a pilot making the installation easier. Push the rear hub and outer bearing onto the spindle as an assembly. ? Hold the outer bearing seated and use the bearing as a pilot

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1997-2005 Ford Expedition REAR AXLE NOISE REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 16-09-2011

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5L3Z-4209-F = (9.75-Inch Ring Gear/3.73 ratio) •205-506 – Seal Protectors (Rotunda Tool) (1997-2005 F-150, 1997-2005 •W710084-S439 – Wheel End Nuts Expedition/Navigator) •390266-S100 – Differential Slave Pin Bolt (9.75? axles) NOTE 9.75 REAR AXLE HOUSINGS WERE •387426-S100 – Differential Slave Pin Bolt (8.8? REDESIGNED IN MID-1999, INCREASING FRONT axles) PINION BEARING SIZE. REPLACING RING & •4B422 – Axle Circlips PINIONS IN AN OLD-STYLE AXLE ASSEMBLY •ZC-21 – Metal Surface Cleaner WILL REQUIRE INSTALLATION OF SPACER P/N •TA-29 – Ultra Silicone Sealant YL3Z-4662-CA. SPACER IS TO BE INSTALLED BETWEEN INNER PINION BEARING AND •TA-27 – Stud and Bearing Mount Retaining COLLAPSIBLE SPACER. Compound and Sealer •F3TZ-4121-AA – Fluid Tag (REQUIRED IF FLUID THE AXLE SERVICE KITS INCLUDE THE TYPE IS CHANGED FROM FEHP DURING FOLLOWING COMPONENTS: REPAIR) •4630 – Head Bearing WARRANTY STATUS: Eligible Under Provisions Of •4628 – Head Bearing Cup New Vehicle Limited •4676 – Pinion Seal Warranty Coverage •386989-S2 – Washer (Slinger) OPERATION DESCRIPTION TIME •4621 – Tail Bearing 052303A 1997-2002 Expedition, 4.7 Hrs. 1998-2002 Navigator, •4616 – Tail Bearing Cup 1997-2004 F-150 Heritage, •4222 – Differential Bearing Cups 2004-2005 F-150: Rear •4221 – Differential Bearings Axle Noise Repair •4209 – Gear Set (includes pinion shims, pinion (Includes Time For Road nut and crush spacer) Test To Verify Concern (Beam Axle)) (Do Not Use •4209 – Instruction Sheet With 4205A Or 4205A4) NOTE 052303A 2003-2005 Expedition: 5.8 Hrs. THE KIT DOES NOT INCLUDE THE FOLLOWING Rear Axle Noise Repair ITEMS. SOME OR ALL OF THESE ITEMS WILL (Includes Time For Road BE REQUIRED TO COMPLETE THE AXLE Test To Verify Concern (Irs SERVICE, DEPENDING ON AXLE Axle)) (Do Not Use With APPLICATION/STYLE. 4010D Or 4010D4) 052303A 2003-2005 5.9 Hrs. ORDER AS NEEDED:

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4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal)4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Transmission Repair

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Filed Under (More Manuals) by admin on 08-01-2012

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Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission – 4L60-E/4L65-E. Important: Subject: 4L60-E Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Models: 2004-2005 Buick Rainier 2003-2005 Chevrolet TrailBlazer Models 2003-2005 GMC Envoy Models 2003-2004 Oldsmobile Bravada 2005 Saab 9-7X with 4.2L In-Line 6 Cylinder Engine (VIN S — RPO LL8) • Visible rust on the transmission fluid level indicator. • Visible water in the oil pan. • A milky white substance inside the pan area. • Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. • Rust on internal transmission iron/steel components. • Remove the surge tank cap and examine the coolant for signs of contamination with transmission fluid (the coolant will have a milky, not clear appearance). • If the coolant has a normal, clear appearance, the radiator should not be replaced. • The cooler can also be tested by following the Coolant System Leak Test procedure (SI Document ID# 877442). Do NOT replace a radiator without verifying that the transmission oil cooler is leaking. If water or coolant is found in the transmission, the following components MUST be replaced. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Element Replacement (SI Document ID# 1364496). 2. Remove the transmission fluid level indicator from the filler tube. 3. Remove the filler tube nut (2) located on the right side of the engine. 4. Remove the filler tube from the vehicle. Tip It is necessary to remove the two A/C line (suction line / low side of muffler hose) retainers and reposition • Replace all of the rubber type seals. • Replace all of the composition-faced clutch plate assemblies including the band. • Replace all of the nylon parts (Thrust Washers). • Replace the torque converter. • Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. • Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30- 052C or newer – Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow .
the A/C line to allow proper clearance for installation of the new transmission fluid fill tube. 5. Remove the A/C line at the oil level indicator tube bracket nut. 6. Remove the A/C bracket bolt from the engine lift hook. 7. Reposition the A/C line upward. 8. Install the new transmission filler tube, P/N 15000220, into position but NOT into the transmission at this time. 9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID# 744862). 10. Remove the two bolts securing the transmission heat shield to the transmission. 11. Remove the transmission heat shield from the transmission. 12. Remove the old filler tube seal from the transmission case. 13. Install a new seal, P/N 1259475 into the transmission case. 14. Position the new transmission filler tube into the transmission seal. 15. Install the transmission heat shield to the transmission. 16. Install the two bolts securing the transmission heat shield to the transmission. Tighten Tighten the bolts to 17 N·m (13 lb ft). 17. Lower the vehicle. 18. Install the nut securing the filler tube to the stud. Tighten Tighten the nut to 10 N·m (89 lb in). 19. Reposition the A/C line into place. 20. Install the A/C line bracket to the oil level indicator tube stud and secure the bracket with the nut. 21. Install the A/C line bracket to the engine lift bracket and secure the A/C bracket with the bolt

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Troubleshooting and Resolving Water Leaks for FUNSPORT Sunroofs

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Filed Under (More Manuals) by admin on 13-03-2012

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1. Opening the sunroof, just after it rains. Standing water on the glass will usually result in water dripping into the cabin. This is not a sunroof fault. Prevention is the solution! Simply drive a short distance to allow any standing water to blow off the glass prior to opening the sunroof. 2. Only after a car wash. High pressure water sprayed directly at the seal will often deflect the seal enough to enter the cabin. This is not a sunroof fault. Prevention is the solution! Don’t spray high pressure water directly on the seal. 3. During a rainstorm, water is immediately visible dripping on the rubber seal under the glass. There may be a problem with glass to seal contact. Carefully examine the seal. If it is visibly damaged or worn, it may need replacement. If dirty, it needs cleaning. An adjustment may solve the problem. Always water test to verify (see sprinkle test procedure below). a. Often dirt or debris will prevent proper contact between the glass and seal. Clean both the glass and seal with plain water (a damp cloth), or if very dirty, a mild detergent solution. Repeat water test after cleaning. If water intrusion between glass and seal continues, adjust the glass hardware. b. Adjust the glass hardware to increase clamping pressure on the seal. See procedure below. Repeat water test after adjusting. If water intrusion between glass and seal continues, replace seal. 4. Water is visible dripping through the glass hardware: Water test to verify (soak and sprinkle). You may need to slightly shift the glass hardware or change the rubber gaskets under the rectangular mounting plates. 5. After a long soaking rain the headliner gets wet. This is likely the result of water coming under the main frame or under the seal. Only a soak test will prove this. a. Under the main frame: remove the screw cover strip or pull back the headliner (of wrapped) and examine the clamping screws. Water spots or rusty screws are an indication that water is coming under the main frame. Remove the clamp frame and water spots or rust will likely be visible on the inside of the roofskin. This can be the result of an over-cut hole, a sunroof not centered on the hole (left a gap) or inadequate sealant. Solution: Remove the sunroof and re-install with new sealant. If the hole was over-cut, a larger size may be required. b. Underneath the main seal: carefully examine and verify proper seal insertion around perimeter of sunroof frame. Bottom of seal should be adhered to main frame with butyl tape. Top outer lip should be mechanically inserted into groove in frame. You may be able to manipulate the seal slightly to correct the problem. Otherwise replace the seal. c. Frame joint: typically will see water spots or rust on hinge block and handle mounting screws, particularly on the right hand side. Remove the knock-in bead and examine the channel for water or water spots. Solution: pull back the main seal at the passenger side and apply a small amount of silicone sealant across the frame joint. Allow to dry before reinserting the main seal.

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2007 HONDA ODYSSEY SPLASH GUARDS INSTALLATION INSTRUCTIONS

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Filed Under (Honda Manuals) by admin on 14-10-2011

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INSTALLATION NOTE: •These instructions show the left splash guards being installed. The same procedure applies to installing the right splash guards. •Clean and wax the areas to be covered with a high-quality paste wax. Installing the Front Splash Guards 1. Turn the steering wheel all the way counter clockwise to provide access to the left front fenderwell. 2. Remove the two self-tapping screws from the left front inner fender. PARTS LIST Right front splash guard Left front splash guard Right rear splash guard Left rear splash guard 6 Self-tapping screws 2 Spring nuts 2 Square head grommets 3. Using a pushpin, make a small hole through the center of the upper clip. UPPER CLIP PUSHPIN SELF-TAPPING SCREW LEFT FRONT INNER FENDER SPLASH GUARDS P/N 08P00-SHJ-101 2 of 2 All 33039-33598 (0608) LEFT REAR SPLASH GUARD SELF-TAPPING SCREW LEFT REAR FENDERWALL SELF- TAPPING SCREW (reused) REAR BUMPER LEFT REAR SPLASH GUARD There must be no clearance. REAR BUMPER LEFT FRONT INNER FENDER LEFT FRONT SPLASH GUARD LEFT FRONT INNER FENDER SELF- TAPPING SCREW LEFT FRONT SPLASH GUARD CLIP CLIP SELF- TAPPING SCREW SELF-TAPPING SCREW (reused) LOWER HOLE 5. While holding the left splash guard against the fender, tighten the self-tapping screws in the order shown. 6. Turn the steering wheel all the way clock wise and repeat steps 2 through 4 to install the right front splash guard. Installing the Rear Splash Guard 7. Using a floor jack, lift up the left rear side of the vehicle according to the service manual. 8. Remove the self-tapping screw from the rear bumper. Using a pushpin, make a hole through the center of the recess. 9. Install one square head grommet into the hole in the left rear fenderwall. Slide one spring nut over the hole you made in step 8 in the rear bumper. 10. Position the left rear splash guard on the left rear fenderwall and rear bumper, and loosely install one self-tapping screw you removed, and the two self-tapping screws supplied with the kit. LEFT REAR FENDERWALL REAR BUMPER SELF-TAPPING SCREW (Reuse.) SQUARE HEAD GROMMET SPRING NUT RECESS PUSHPIN REAR BUMPER With RECESS SELF- TAPPING SCREW 4. Install the left front splash guard using the two self-tapping screws removed in step 2, and one self-tapping screw supplied with the kit. Do not tighten the self-tapping screws yet. 11. Hold the left rear splash guard against the fenderwall and check that there is no clearance between the splash guard and rear bumper. Tighten the three self-tapping screws in the sequence shown. 12. Repeat steps 7 thru 11 to install the right rear splash guard

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FORD F450/ 550 SUPER DUTY CHASSIS CABS OWNERS MANUAL

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Filed Under (Ford Manuals) by admin on 21-05-2012

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LATERAL CONTROL ROD AXLE BRACKET INSTALLATION 1. Remove and discard the OEM shock absorbers, but retain the mounting fasteners (bolts & nuts) for re-use. 2. Remove the top d-bushing mount bolts and disconnect the axle breather tube (See Figure 2- 1). 3. If the truck is equipped with an S110 4.25″ X 4.25″ square axle (most F450s and F550s), install both axle spacer tabs on the axle bracket using (4) 1/2 x 1 1/4 UNC FLANGE BOLTS and (4) UNC TOP LOCK FLANGE NUTS. (See Figure 2-2). 4. Loosely fasten the axle bracket to the axle as shown in Figure 2-3 using (2) M12 x 1.75 x 40 METRIC BOLTS and (2) 1/2″ WASHERS. 5. Reconnect the axle breather tube to the axle. LATERAL CONTROL ROD (LCR) FRAME BRACKET INSTALLATION 1. On the PASSENGER side, remove to two top rivets from the OE bumper bracket and ream the holes to 0.47″ (See Figure 3-1) 2. Install the frame bracket as shown in Figure 3-2 using (4) 7/16 UNC TOP LOCK FLANGE NUTS. FIG. 3-2 Frame bracket Remove these two rivets and ream to 0.47″ DRIVER SIDE DISASSEMBLY 1. With weight taken off the rear springs, as noted in pre-installation checklist, remove the rear leaf spring hanger. Removal of the rear overload spring bracket is optional See Figure 4-1. 2. Remove the front spring hanger bracket and the front overload spring bracket. (See Figure 4-2). 3. Remove existing U-bolts that attach the axle to the leaf spring and keep the OE U-bolt plate for later use. (See Figure 4-3) After this is done, the axle, spring, and hanger will be loose. Remove and discard the spring and hangers from the axle.DRIVER SIDE ASSEMBLY 1. Review Figure 5-1 & Figure 13-2 to acquaint yourself with the various parts of the UltraRide suspension. 2. Fasten the Front Hanger to the frame using (6) 9/16 x 1-1/2 UNF BOLTS, (6) 9/16 UNF NUTS, and (12) 9/16 FLAT WASHERS. Route the parking brake cables through the corresponding holes on the Front Hanger. 3. Assemble the Suspension Arm to the axle using (2) M20 X 2.50, 79 X 425 METRIC U- BOLTS, (4) M20X2.5 METRIC NUTS, and original OE top plate and axle bracket. Make sure the arm/axle locating pin is properly inserted into the mating hole on the axle pad and that the bottom side of the arm rests evenly on the axle pad. 4. Insert the Bolt Spacer Tube into the arm bushing and loosely fasten the arm to the front hanger using (1) 3/4 X 7 UNF BOLT, (1) 3/4 UNF NUT, (2) 3/4 WASHERS, and (2) plastic wear washers. 5. Loosely fasten the Lateral Control Rod Axle Bracket to the Arm using (2) 1/2 X 1-1/4 UNC FLANGE BOLTS (See Figure 5-2). 6. Bolt the Air Spring Bracket Assembly to the frame using (5) 1/2 X 1-1/4 UNC FLANGE BOLTS and (5) 1/2 UNC TOP LOCK FLANGE NUTS. One frame hole will need to be reamed to 0.53″ on each side. See Figure 5-2. 7. Bolt the Air Spring to the Suspension Arm using (1) 1/2 UNC JAM NUT. Make certain the air spring is not twisted or creased after tightening the nut.

1979-1985 Toyota Pick-Up 4WD Superlift 7″ Lift System for INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 24-03-2012

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INSTALLATION PROCEDURE 1) FRONT OF VEHICLE… â Put the transmission in neutral. Position a floor jack under the front axle and raise vehicle. Place jack stands under the frame rails a few inches behind the spring’s rear shackles. Ease the jack down until the frame is resting in the stands. Keep a slight load on the jack. Put the vehicle in gear or park, set emergency brake and chock rear wheels to prevent any possibility of movement. ââ Remove tires and shocks. Remove the engine belly-pan to gain access to the anti-sway bar. Remove and discard the anti-sway bar assembly. Our spring/shock rate and the bars design render it useless. Reinstall belly-pan. ââ Detach the flexible rubber brake hoses at the calipers only and pinch closed with vise-grips to prevent fluid loss. SEE SEPERATE INSTRUCTIONS. You will install the Superlift hoses later. â Remove the stock drag-link. SEE SEPERATE INSTRUCTIONS. You will install the Superlift link and steering arm later. FORM #7047 .01-080707 PRINTED IN U.S.A. PAGE 2 OF 5 â Remove the bolt attaching the trac-bar (or torque rod) to its bracket on the drivers side of the axle. Unbolt the driveshaft at the front axle and tie it up and out of the way. ââ Remove the spring U-bolts. Ease down the front axle by lowering the jack. The axle vent hose may need rerouting of replacing. Install the Polyurethane bushings into the spring eyes. Lubricate all bushing wear surfaces with light grease. ââ Install the Superlift springs so that the thick end of the degree shims, attached to the bottom of the spring, are pointing towards the front of the vehicle. NOTE: There is a driver (DR) and passenger (PA) side spring. Start, but do not tighten the spring hanger/shackle bolts. ââ Raise the axle up to the springs. Be sure the spring center bolt heads seat properly in the axle perch holes. Attach with the new furnished U-bolts and evenly torque to 131ft. lbs. â Install the superlift Trac-Bar Bracket. â Install the Superlift steering Arm and Adjustable Drag- Link. ââ Install the front Superlift Extended Length Brake Hoses. ââ Install shocks, tires and lower vehicle. ââ With the vehicle weight on the suspension, tighten the front and rear spring hanger bolts. Do not over tighten; tighten only until the bushing flanges compress slightly. 2) REAR OF VEHICLE… NOTE: Before starting, with the vehicle weight on the suspension, rotate the position of the brake proportioning rod where it goes into the proportioning valve; which is located on the passenger side frame rail. On most vehicles, the rod is pretty much horizontal at the attaching point. After the lift is installed, re-bend the rod to its stock position at the proportioning valve. ââ Place a floor jack under the rear axle and raise vehicle. Place jack stands under the frame rails, a few inches in front of the rear springs front hangers. Ease the jack down until the frame is resting on the stands. Keep a slight load on the jack. Chock the front wheels to prevent any possibility of movement. Remove tires, U-bolts and shocks. ââ Disconnect the emergency brake cables at the rear wheels. Lower the axle housing by easing down the jack. Do not overextend the brake and axle vent hoses; both may need rerouting or replacing. If a Superlift rear hose is to be installed detach the stock rubber hose at the axle housing only and pinch closed with vise-grips to prevent fluid loss. You will install the new hose after installing the other rear components

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