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Installation of the Smitty 5-speed Toyota Kit

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Filed Under (Toyota Manuals) by admin on 25-10-2011

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Toyota pilot bearing: Toyota uses a ball pilot bearing which is a very accurate fit on the end of the pilot shaft. I had to sand my pilot shaft down slightly with wet/dry paper to get the bearing to be other than a force fit. You need a sliding fit for installation of the trans in the car. Pilot Tool adjustment: I believe it is necessary, or desirable at least, to tighten up the accuracy of the supplied plastic pilot tool to make sure the nose of the first-motion shaft will slide into the Toyota pilot bearing during installation of the trans. I wrapped the pilot tool with enough electrical tape so it was a perfect fit on both the pilot bearing and the clutch disc splines. 1 layer of tape around the contour of the splines did the trick. Smitty supplies an aluminum ring which holds the Toyota pilot bearing into the Healey flywheel. I used a vise to press the bearing into the ring, and a large 1-5/16 socket as a tool to hammer this into the recess in the flywheel. This was easy if you’re careful. Your lead hammer makes a dandy driver for this. Toyota Trans install: The shop manuals warn against tilting the engine into the radiator. Mine has the 6- bladed fan about 1/2″ back from the radiator and during this process it never came close to the radiator. If you have the block between the valve cover and the firewall, minor or no jacking of the engine should be necessary in order to get the Toyota trans in place. Position your trans jack or floor jack in the middle of the hole and place the Toyota trans on top of it. Lower enough to get the bell housing through the opening, then raise it back up to where the bolt holes align. Observe parallelism between the bell housing and engine flange. I believe the limiting factor here is the alignment of the Toyota pilot shaft with the pilot bearing–I believe this is at least as accurate as anything to do with the dowel bolts.

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2002 Toyota Truck 4 Runner Engine, Cooling and Exhaust Cooling System Radiator Removal and Installation Manual

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Filed Under (Toyota Manuals) by admin on 21-03-2012

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REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE Remove the 7 clips and radiator grille. 3. DISCONNECT UPPER RADIATOR HOSE 4. DISCONNECT RADIATOR RESERVOIR HOSE 5. DISCONNECT LOWER RADIATOR HOSE 6. REMOVE RADIATOR NO.2 FAN SHROUD 7. A/T: DISCONNECT OIL COOLER HOSES 8. REMOVE RADIATOR Remove the 4 bolts and the radiator. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No. 1 fan shroud. 2. REMOVE RADIATOR SUPPORTS 3. REMOVE DRAIN PLUG 4. ASSEMBLE SST SST 09230-01010 a. Install the claw to the overhaul handle, inserting it in the hole in part “A” as shown in the diagram. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram is 0.2 – 0.3 mm (0.008 – 0.012 inch). NOTICE: If this adjustment is not done, the claw may be damaged. 5. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 6. REMOVE TANKS AND O-RINGS a. Lightly tap the radiator port (inlet or outlet) with a soft faced hammer, and remove the tank. b. Remove the O-ring. REASSEMBLY 1. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 2. INSTALL NEW O-RINGS AND TANKS a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. b. Install the tank without damaging the O-ring. c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. 3. ASSEMBLE SST 09230-01010 a. Install the punch assembly to the overhaul handle, inserting it in the hole in part “A” as shown in the illustration. b. While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram. Dimension “B”: 8.4 mm (0.34 inch) 4. CAULK LOCK PLATE

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2008-2010 FORD F-Super Duty DIESEL ENGINES REPEAT RADIATOR LEAK BUILT ON OR BEFORE SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 17-01-2012

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DIESEL ENGINES REPEAT RADIATOR LEAK BUILT ON OR BEFORE ISSUE ECT temp. Some 2008-2010 F-Super Duty vehicles built on or b. Test results/next steps: before 9/14/2009 and equipped with a 6.4L diesel engine may exhibit repeat radiator leaks due to (1) If EOT is less than 8 °F (4.4 °C) malfunctioning (hyper-extended) high temperature higher than ECT, and the coolant temp thermostats. fluctuates roughly 5 °F (2.7 °C) – the thermostats are okay and do not need ACTION to be replaced. Replace just the Follow the Service Procedure steps to correct the radiator. Refer to WSM, Section 303-03 condition. (Engine Cooling). SERVICE PROCEDURE (2) If EOT exceeds ECT by greater than 8 °F (4.4 °C) or if the ECT readings 1. Verify the coolant leak is from the radiator, refer fluctuate 10 to 12 °F (5.55-6.66 °C) to pinpoint test (PPT) A found in the Workshop roughly every 30 seconds – replace Manual (WSM), Section 303-03. both thermostats and radiator. Refer to 2. Verify the venturi tee is installed. WSM, Section 303-03 (Engine Cooling). a. If installed, confirm it is installed correctly (note – orientation direction on part). 5. If vehicle is not drivable and the coolant leak is found to be from the radiator, remove and b. If not installed, install Venturi Tee Kit on replace both thermostats and radiator. Refer to vehicles built on or before 5/15/2008. WSM, Section 303-03 for both radiator and thermostat removal procedure and approved 3. Prepare the vehicle for a test drive. cooling system draining, filling and bleeding a. If the coolant leak at the radiator is large procedures. enough to cause an unsafe test drive or potential for engine/vehicle damage, proceed PART NUMBER PART NAME to Step 5. 8C3Z-8575-D Thermostat Assembly 8C3Z-8009-B Radiator Assembly b. Before driving the vehicle confirm the 8C3Z-8B379-B Venturi Tee coolant level is at minimum level or above in the degas bottle. If required, add 50/50 WARRANTY STATUS: Eligible Under Provisions Of mix to coolant bottle. New Vehicle Limited Warranty Coverage 4. Test Drive – use an Integrated Diagnostic IMPORTANT: Warranty System (IDS) or equivalent and monitor engine coverage limits/policies are oil temperature (EOT) and engine coolant not altered by a TSB. temperature (ECT) parameter identifiers (PIDS). Warranty coverage limits are determined by the identified causal par

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2007 TOYOTA TUNDRA SUPERCHARGER FIT KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 20-03-2012

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1. Installation Review and Vehicle Preparation. (a) Review the entire instruction instructions provided before beginning the installation (b) Review the parts list/kit contents to ensure that all parts are present before beginning the installation. If any items are missing contact Technical Support at (800) 688-5912 before proceeding. (c) Remove any low-octane fuel from the vehicle. Ensure that ONLY 91 octane or higher unleaded gasoline is used. (d) Place the vehicle onto vehicle hoist. (e) Protect the vehicle with protection blankets over the fenders and front of the vehicle. (f) Disconnect and remove the battery. (g) When draining the cooling system into a clean container in Step 3, save this coolant as it will be reused. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause the hot engine coolant and steam to blow out from the radiator. (h) All parts that are removed and not reused should be saved for the customer, i.e., “discard” means to save for the customer 2. Cover Removal. (a) Remove the engine V-bank cover by Lifting the front of the cover and pulling away from the firewall (Fig 2-1). Discard these parts. (b) If installed, remove the No. 1 engine under cover (Fig 2-2) by removing the 3 screws and 5 bolts. Save these parts for reuse. 3. Drain Engine Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Loosen the radiator drain cock plug (Fig. 3-1). (b) Remove the radiator cap. Then drain the coolant from the radiator into a clean container so it can be reused (Fig. 3-1). (c) Loosen the 2 cylinder block drain cock plugs (Fig.3-1). Then drain the coolant from the engine and save for reuse. (d) Tighten the 2 cylinder block drain cock plugs. Torque: 13 Nm (10 ft lbf) 4. Fan and Shroud Removal. (a) Remove the upper radiator hose. Mark the radiator end of this hose with a marker or tape. This hose will be re-installed inverted and the mark will help identify the ends. (b) Loosen the 4 nuts holding the fluid coupling fan (Figs. 4-1). (c) Remove the fan/generator V-rib belt. Discard this belt as it will be replaced by a new belt. (d) Disconnect the reservoir hose from the upper radiator tank. (e) For vehicles with Trailer Towing System: Detach the claw to open the No. 1 hose clamp on the side of the fan shroud (Fig 4-2). (f) Remove the 2 bolts holding the fan shroud (Figs 4-3). Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan. Retain these parts for reuse. Temporarily re-install the 4 nuts to keep the pulley in place (reference Fig 4-1). Do not tighten. CAUTION: Be careful not to damage the radiator core. It is helpful to protect the radiator core with a piece of cardboard to prevent damage during subsequent steps. 5. Air Cleaner Lower Box Replacement. (a) Remove the air cleaner hose by disconnecting the vacuum and ventilation hoses and loosening the 2 clamps. (Fig 5-1). Discard this hose and clamps

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HONDA Front Seat Belt Replacement Warranty Policy

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Filed Under (Honda Manuals) by admin on 24-11-2011

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CUSTOMER INFORMATION : The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment, and training to correctly and safely maintain your car. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your car, or that your car has the condition described. To determine whether this information applies, contact an authorized Honda automobile dealer. ? 1996 American Honda Motor Co., Inc. – All Rights Reserved . ATB 14788-17665 (9601) 1 of 2 JAN 22, 1996 92-012 BODY ALL 1986 and later Applicable To Model File U nder Issu e D ate Bulletin N o. Service Bulletin Front Seat Belt Replacement Warranty Policy (Supersedes 92-012, dated March 13, 1992) Warranty policy for front seat belt replacement is to replace either the belt/retractor mechanism or the buckle when either does not work properly. Warranty covers the replacement of the failed half of a belt, not the entire assembly (see PARTS INFORMATION ). NOTE: For 1970 through 1985 models, seat belts are replaced as a complete assembly under a separate warranty policy. COMPONENT REPLACEMENT Front seat belts are made by several suppliers, and some are sold as individual components (two separate halves); they are not stocked as a complete set. Therefore, whenever you replace a belt, make sure the new belt half is the same type and from the same manufacturer as the original – otherwise, the belt may not buckle properly. To determine the manufacturer and type (or “model”) of the belt, look for the white tag on the original belt in the car. The tag is on the retractor side of the belt (visible at the lower attachment point), or on the belt if you pull the belt all the way out. From the tag, mark down the manufacturer’s name (either Nippon Seiko K.K. or Takata), the belt “model” number and the date of manufacture. If the tag is missing or illegible, look on the buckle component for the name Nippon Seiko K.K. or the stylized “T” mark () for Takata. NOTE: Some belts may have NSK Warner K.K. as the manufacturer’s name. Use Nippon Seiko K.K. belts as the replacement. Take the information to your Parts Department to order the proper replacement belt. NOTE: For more information on seat belts and seat belt related items read: -Twisted Seat Belt (ServiceNews, July ’85) -Seat Belt Testing and Repair (Service Bulletin 86-014, August ’86) -Automatic Seat Belt Troubleshooting (ServiceNews, May ’89) -Lap Belt Retracts Slowly (Service Bulletins 90-003, January ’90 and 90-012, April ’90) -Torn Seal on Seat Belt Track (Service Bulletin 91-004, March ’91) -Slow to Retract Seat Belt, Cleaning the Guide Ring (ServiceNews, April ’91) -Accord Shoulder Belt System Wire Colors (ServiceNews, May ’91) -Seat Belt Slow to Retract (Service Bulletin 91-030, December ’91) Refer to your Service Bulletin Index and the ServiceNews Index for model specific information. Most repairs do not require seat belt component replacement. PARTS INFORMATION For front seat belt replacement ordering information and availability, contact your parts center.

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2003-2005 Toyota Corolla HEATER PERFORMANCE IMPROVEMENT Repair Manual

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Filed Under (Toyota Manuals) by admin on 23-01-2012

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HEATER PERFORMANCE IMPROVEMENT – AC002-05 February 14, 2005 Page 3 of 15 Install Air Conditioner Unit Assembly. Air Conditioner Unit Assembly 1. Evacuate Refrigerant HFC-134a (R-134a). Equipment: Robinair R-134a Refrigerant Recovery/Recycling Machine (Robinair P/N: 342000) 2. Disconnect Negative Terminal of Battery. 3. Drain Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot, as coolant and steam can be blown out under pressure. A. Remove the radiator cap. B. Loosen the radiator and engine drain plugs and drain the coolant. C. Close the drain plugs. Engine Drain Torque: 13 Nm (130 kgfcm, 9 ftlbf) HEATER PERFORMANCE IMPROVEMENT – AC002-05 February 14, 2005 Page 4 of 15 4. Disconnect Cooler Refrigerant Suction Hose No. 1. A. Install the SST to the piping clamp. SST: 09870-00015 HINT: Confirm the direction of the piping clamp claw and the SST using the illustration shown on the caution label. B. Push down the SST and release the clamp lock. NOTE: Be careful not to deform the tube when pushing the SST. C. Pull the SST slightly and push the release lever. Then remove the piping clamp with the SST. D. Remove the piping clamp from the SST. E. Disconnect the cooler refrigerant suction hose No. 1. NOTE: Disconnect the tube by hand only. Do not pry the tube apart. Cap the open fittings immediately to keep moisture or dirt out of the system. Disconnect the same way as cooler refrigerant suction hose No. 1. 6. Disconnect Heater Inlet Water Hose. Using pliers, grip the claws of the clip and slide the clip and disconnect the heater inlet water hose. 7. Disconnect Heater Outlet Water Hose. Using pliers, grip the claws of the clip and slide the clip and disconnect the heater outlet water hose. 8. Place Front Wheels Facing Straight Ahead. 9. Remove Horn Button Assembly. NOTE: If the airbag connector is disconnected with the ignition switch ON, DTCs will be recorded. Before working on SRS, please refer to the Technical Information System (TIS), 2005 model year Corolla Repair Manual: Supplemental Restraint System: Supplemental Restraint System: Precaution. A. Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.

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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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1998 Dodge Truck Caravan Replace Radiator Fan Relay

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Filed Under (Dodge Manuals) by admin on 16-06-2011

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1. With the ignition key in the OFF position, disconnect the battery. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable.

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Various Concerns With Shifter and/or Ignition Key (Replace Shifter Assembly/Shifter Components or Ignition Lock Cylinder )

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Filed Under (More Manuals) by admin on 05-05-2012

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2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) The illustration above shows the switch in a correct position. Cause 3 Metal flashing left in the cylinder may cause a high effort to rotate the key. Cause 4 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction 1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Correction 2 Important: A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Correction 3 Important: Refer to instruction sheet that is supplied with the lock cylinder kit. BO 47869 is an essential staking tool and must be used for the repair. Replace the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement in SI. Correction 4 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important: Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI

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2004 Chevrolet TrailBlazer Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 18-02-2012

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This bulletin is being revised to add model years and provide important repair information. Please discard Corporate Bulletin Number 04-08-49-015 (Section 08 — Body and Accessories). Condition Some customers may comment on a noise coming from the instrument panel cluster (IPC) while driving or on initial start-up. Instrument clusters may contain stepper motor gages that can make noise during the following conditions: Subject: Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Models: 2003-2005 Buick LeSabre 2003-2007 Buick Rendezvous 2004-2005 Buick Rainier 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Cavalier, Impala, Monte Carlo 2003-2006 Chevrolet Avalanche, Suburban, Tahoe, TrailBlazer EXT 2003-2007 Chevrolet Silverado Classic, TrailBlazer 2003-2007 Chevrolet Kodiak Models 2004-2006 Chevrolet SSR 2003-2006 GMC Envoy XL, Yukon, Yukon XL 2004-2005 GMC Envoy XUV 2004-2007 GMC Envoy 2003-2007 GMC Sierra Classic 2003-2004 Oldsmobile Bravada 2003-2005 Pontiac Aztek, Bonneville, Sunfire 2003-2005 HUMMER H2 Attention: Appropriate repair is based on vehicle build date. Use GMVIS to determine the vehicle build date. • Initial startup (gages zero/reset)

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