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Toyota T50 5 Speed Transmission Electronic Speedo Drive Installation Manual

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Filed Under (Toyota Manuals) by admin on 19-04-2012

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I have intentionally left the photos large, to try to clarify any detail I did not explain in the text. This modification DOES require the use of a lathe, I have tried to write it so as to allow you to go to your local machine shop, brother in law, mate or anyone with a lathe…and it will be done correctly Much thanks to John O’Rielly (PLAGER 7) in Brisbane for passing on the information and problems he had with this modification. Fig.1Standard Drive Assemblies T50 left and AE101 right T50 Speedo Drive Adaption Rev 1 Feb 2003 2 Step One:- Dissassembly T50 Drive:- Disassembly is simple, remove the “C” clip from the drive housing , just above the drive gear. This will allow the shaft/gear assembly to be withdrawn from the housing. Remove the “O” ring from the housing. Wash all parts internally and externally to remove oil, grease and road grime. Fig.2 T50 Drive Disassembled T50 Speedo Drive Adaption Rev 1 Feb 2003 3 AE101 Drive:- Disassembly is similar to T50, remove the “C” clip from the drive housing , just above the drive gear. This will allow the shaft/gear assembly to be withdrawn from the housing. Remove the “O” rings from the housing. Remove the three (3) philips head screws from the cover on the top of the drive housing. Carefully remove cover, be aware that the small parts in side may be stuck to the cover. Remove all internal parts, record order of assembly. Wash housing and shaft to remove oil, grease and road grime. Fig.3 AE101 Drive Disassembled T50 Speedo Drive Adaption Rev 1 Feb 2003 4 Step Two:- Shortening the Drive Shaft Drive Shaft:- The T50 drive shaft needs to be shortened to a similar length to the AE101. I reassembled the AE101 shaft and housing, and then measured from the top face of the AE101 housing down to the top of the AE101 drive shaft. ( Fig.4) Record this reference depth, (I got 17mm) . Fig.4 Drive Shaft Depth Std AE101 Shaft & Housing The T50 drive shaft will need to be shortened to give the same depth as measured in Fig.4. When I did mine, (and a few others), I found I needed the T50 shaft to be 68.0mm long. Fig.5 Fig.6 The drive shaft is hardened, so I used a belt linisher to shorten the shaft, it could as easily be done on a fine grinding wheel. Remember slowly does it, regular checks of depth in housing and do not let the shaft get too hot during grinding/linishing, this will affect the heat treatment and consequently affect the strength of the drive dogs on the shaft end. Carefully deburr and chamfer, end detail should be similar to original AE101

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2005 Ford F-150 Drive Pinion Flange and Drive Pinion Seal Repair Manual

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Filed Under (Ford Manuals) by admin on 21-04-2012

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the brake disc. For additional information, refer to Section 206-04 . 3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 4. Remove the 4 driveshaft flange bolts. 5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange. ? Using mechanic’s wire, position the driveshaft aside. 6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions. 7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.2005 F-150 Workshop Manual 8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed. Installation 1. Lubricate the new drive pinion seal with grease. 2. Using the special tool, install a new drive pinion seal. 3. Lubricate the pinion flange splines with axle lubricant. 4. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 5. Using the special tool, install the pinion flange. 6. l a new pinion nut with the same iginal if not replacing the collapsible spacer. If a installed, install the nut in the kit, as indicated in the chart below, or damage to the component may occur. Position the new pinion nut. Pinion Nut 7. no circumstances ut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur. NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench. Using the special tool to hold the pinion flange, tighten the pinion nut. ? Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly. ? Install a Nm (lb-in) torque wrench on the pinion nut. ? Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained. ? If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. For additional information, refer to the Specification portion of this section. 8. Position the driveshaft and align the index mark on the pinion flange.

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2000 Ford Crown Victoria/ Grand Marquis Intake Manifold – Gasoline Engines Removal and Installation Manual

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Filed Under (Ford Manuals) by admin on 16-04-2012

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Intake Manifold—Gasoline Engines Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Drain the engine cooling system. For additional information, refer to Section 303-03 . 3. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 . 4. Disconnect the fuel line. For additional information, refer to Section 310-00A or Section 310-00B . 5. Remove the wiper arm and pivot shaft. For additional information, refer to Section 501-16 . 6. Remove the drive belt. For additional information, refer to Section 303-05 . 7. Raise the vehicle on a hoist. For additional information, refer to Section 100-02 . 8. Disconnect the electrical connector at the crankshaft position (CKP) sensor. * Disconnect the pin-type retainer from the A/C compressor bracket. 9. Disconnect the electrical connector from the A/C compressor. 10. Remove the oil bypass filter. 11. Disconnect the oil pressure sensor electrical connector and the power steering pressure (PSP) switch electrical connector. 12. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold 13. Lower the vehicle. 14. Disconnect the two differential pressure feedback EGR hoses. 15. Disconnect the RH heated oxygen sensor electrical connector. 16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils. 17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors. 18. Disconnect the accelerator cable and the speed control actuator cable. 19. Remove the cables from the EGR tube heat shield and position out of the way. 20. Remove the bolts and the EGR tube heat shield. 21. Disconnect the evaporative emissions (EVAP) return tube, the main chassis vacuum supply line, and the EGR valve vacuum supply. 22. Disconnect the positive crankcase ventilation (PCV) tube assembly at two locations and remove. 23. Disconnect the electrical connector from the EGR vacuum regulator solenoid. 24. Disconnect the vacuum line from the EVAP canister purge valve. 25. Disconnect the generator cable and electrical connector 26. Remove the bolts and the generator mounting bracket. 27. Remove the upper radiator hose. 28. Disconnect the electrical connector from the idle air control (IAC) valve and the throttle position (TP) sensor. 29. Disconnect the heater water hose. 30. Disconnect the EGR tube from the EGR valve. 31. NOTE: The LH heated oxygen sensor and the transmission electrical connectors are attached to the wiring bracket and must be separated from the bracket. Remove the wiring bracket. * Disconnect the wiring connectors. * Separate the transmission harness from the stud. * Remove the nut and the bolt and remove the bracket.

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1998 Ford Ranger Heavy Duty Floor Crane Workshop Manual

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Filed Under (Ford Manuals) by admin on 02-02-2012

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1. Relieve the fuel pressure. For additional information, refer to Section 310-00 . 2. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 . 3. Drain the engine cooling system. For additional information, refer to Section 303-03 . 4. Remove the hood (16612). 5. Remove the air cleaner outlet tube (9B659). For additional information, refer to Section 303-12 . 6. Remove the accelerator control splash shield (9E766). 7. Remove the upper radiator hose (8260). 8. Remove the lower radiator hose (8286). 9. Remove the two bolts and position the fan shroud (8146) on the fan blade (8600). 10. Remove the water pump pulley, fan and shroud; refer to Section 303-03 . 11. Disconnect the radiator overflow tube. 2. On vehicles equipped with automatic transmissions, disconnect the transmission cooler lines. 13. Disconnect the mass air flow sensor. 14. Disconnect the heater water hoses (18472) at the inlet and outlet; refer to Section 303-03 . 15. Disconnect the power connection from the generator (10346). 16. Disconnect the vacuum connection to the vacuum reservoir. 17. Disconnect the throttle body heater hose. 18. Disconnect the A/C cycling switch. 19. Disconnect the connector from the powertrain control module (PCM) (12A650). 20. Remove the nut. 21. Remove the ground wire stud from the powertrain control module. 22. Recover the A/C system; refer to Section 412-00 . 23. Disconnect the power steering cut-out switch. 24. Disconnect the peanut fitting from the A/C condenser core (19712). 25. Disconnect the A/C high pressure cut-out switch. 26. Disconnect the A/C manifold hose. 27. Remove the nut. 28. Disconnect the accelerator cable (9A758) and the speed control cable. 29. Disconnect the brake booster vacuum hose and vacuum tube at the upper intake manifold assembly. 30. Disconnect the EVR vacuum supply hose and the vacuum reservoir vacuum line. 31. Disconnect the wiring connector. 32. Disconnect the fuel line; refer to Section 310-01 . 33. Remove the A/C compressor; refer to Section 412-03 . 34. Disconnect the power steering pressure and return hoses. 35. Remove the nut retaining the wiring harness. 36. Disconnect the block heater if equipped. 37. Raise the vehicle on a hoist; refer to Section 100-02 . 38. Disconnect the engine ground cable

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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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2009 Cadillac CTS AWD Front Wheel Drive Shaft Replacement – Left Side

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Filed Under (Cadillac Manuals) by admin on 16-05-2011

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Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle ( See: MaintenanceVehicle LiftingService and Repair ). 2. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation ( See: MaintenanceWheels and TiresService and Repair ). 3. Remove the left outer tie rod from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (All Wheel Drive) ( See: Steering and SuspensionSteeringTie RodService and RepairSteering Linkage Outer Tie Rod Replacement )Steering Linkage Outer Tie Rod Replacement (Rear Wheel Drive) ( See: Steering and SuspensionSteeringTie RodService and RepairSteering Linkage Outer Tie Rod Replacement ). 1. Install the new O-ring (2) on the intermediate shaft. 2. Install the new retaining ring (1) on the intermediate shaft. 3. Apply a small amount of grease GM P/N 01051344 (Canadian P/N 993037) or equivalent to the intermediate wheel drive shaft splines. 4. Install the left front wheel drive shaft in the intermediate shaft. 5. To ensure that the wheel drive shaft is installed properly, grasp the inner tripod housing and pulling it outward. DO NOT pull on the axle shaft . 6. Install the wheel drive shaft in the front knuckle. 7. Install the left upper control arm on the knuckle. Refer to Upper Control Arm Replacement ( See: Steering and SuspensionSuspensionControl ArmService and RepairRear SuspensionUpper Control Arm Replacement

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TOYOTA RAV4 STEERING INTERMEDIATE SHAFT NOISE SERVICE MANUAL

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Filed Under (Toyota Manuals) by admin on 25-01-2012

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Repair Procedure 1. Install a steering wheel holder. NOTE: Ensure the wheels are straight and the steering wheel is centered before removing the steering intermediate shaft by installing a steering wheel holder. 2. Remove the column hole cover silencer sheet. Turn back the floor carpet, remove the 2 clips, and remove the column hole cover silencer sheet. Production Change Information Parts Information Repair Procedure STEERING INTERMEDIATE SHAFT NOISE – ST001-08 February 8, 2008 Page 3 of 4 3. Remove the No. 2 steering intermediate shaft assembly. A. Place matchmarks (“a”) on the No. 2 steering intermediate shaft and steering column. B. Remove bolt A and detach the No. 2 steering assembly from the steering gear. C. Remove bolt B and detach the No. 2 steering intermediate shaft from the steering column. 4. Remove the No. 1 steering column hole cover sub-assembly by removing the clamp and disconnecting the column hole cover from the steering gear. 5. Remove the intermediate shaft. Remove the bolt and disconnect the steering intermediate shaft from the steering gear. 6. Install the NEW intermediate shaft onto the steering gear. Torque: 35 Nm (360 kgfcm, 26 ftlbf) 7. Install the No. 1 steering column hole cover sub-assembly onto the steering gear with a NEW clamp. Repair Procedure (Continued) B A a No. 2 Steering Intermediate Shaft Intermediate Shaft STEERING INTERMEDIATE SHAFT NOISE – ST001-08 February 8, 2008 Page 4 of 4 8. Install the No. 1 steering column hole cover sub-assembly by attaching clip B onto the body and installing the No. 1 hole cover onto the body with clip A. NOTE: Make sure that the lip of the No. 1 hole cover is NOT damaged. 9. Install the No. 2 steering intermediate shaft assembly. A. Align the matchmarks (“a”) on steering intermediate shaft and the steering sliding yoke and temporarily install them with bolt B. Torque: 35 Nm (360 kgfcm, 26 ftlbf) B. Ensure the wheels are straight. C. Install the No. 2 intermediate shaft and the intermediate shaft with bolt A. Torque: 35 Nm (360 kgfcm, 26 ftlbf) 10. Install the column hole cover silencer sheet. A. Install the column hole cover plate with the 2 clips. B. Install the floor carpet. 11. Remove the steering wheel holder from the vehicle. 12. Road test the vehicle to verify the repair and confirm that the steering wheel is centered.

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1994 Ford Explorer SPINDLE AND SHAFT ASSEMBLY REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 01-02-2012

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Removal 1. Raise and support vehicle. Remove wheel assembly. Remove caliper from rotor. Remove locking hub. See AUTOMATIC LOCKING HUBS or MANUAL LOCKING HUBS under REMOVAL & INSTALLATION. 2. Remove wheel bearings, lock nuts, hub and rotor. Remove spindle-to-steering knuckle nuts. Tap spindle with plastic hammer to free spindle from steering knuckle. See Fig. 9 . Remove spindle, spindle seat (if equipped) and splash shield. 3. On right side applications, remove and discard keystone clamp from shaft assembly and stub shaft. Slide rubber boot onto stub shaft. Remove shaft assembly from right axle. See Fig. 9 . 4. Remove left shaft assembly (if required). On all applications, wrap spindle in protective cloth and place second step of spindle in soft-jawed vise. 5. On Explorer and Ranger, remove oil seal using slide hammer and Seal Remover (TOOL-1175-AC). Remove needle bearing from spindle. Press seal from shaft assembly. See Fig. 9 . 6. On Bronco and F150, remove needle bearing and oil seal using slide hammer and Cup Puller (T77F- 1102-A). Press seal from shaft assembly. Installation 1. Clean all dirt and grease from spindle bearing bore. Ensure bearing bore is free of nicks and burrs. On Explorer and Ranger, install seal on shaft assembly using press and Seal Installer (T83T-3132-A). 2. On Bronco and F150, install seal on shaft assembly, with seal lip toward spindle. On right side applications, install rubber boot and NEW keystone clamps on stub shaft. Install right shaft assembly into stub shaft, with stub shaft missing spline aligned with shaft assembly. 3. Ensure splines are fully engaged. Install rubber boot over assembly and tighten keystone clamps. On left axle applications, install shaft assembly through steering knuckle, and engage in splines. 4. Install needle bearing in spindle, with manufacturer identification mark facing away from spindle bore. For bearing installation, use Handle (T80T-4000-W), and Bearing/Seal Installer (T83T-3123-A for Explorer and Ranger; T80T-4000-S for Bronco and F150).

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1994 Nissan Maxima SE FWD Axle Shafts Removal And Installation Manual

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Filed Under (Nissan Manuals) by admin on 21-05-2011

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FWD AXLE SHAFT Removal 1. Raise and support vehicle. Remove wheel. Remove wheel bearing lock nut from end of drive axle. Remove disc brake caliper and suspend out of way. DO NOT allow caliper to hang by hydraulic hose. 2. Separate tie rod end from steering knuckle. Remove axle shaft from steering knuckle hub using a soft mallet. On models with ball and cage type right axle shaft, remove support bearing retainer-to-block bolts. See Fig. 4 . 3. On all models, pry right axle shaft from transaxle using screwdriver. See Fig. 1 . On M/T models, pry left axle shaft from transaxle using screwdriver. On A/T models, insert screwdriver through right axle shaft hole in differential, and drive out left axle shaft. See Fig. 2 1. Place axle shaft in soft-jawed vise with inner joint facing up. Remove boot clamps. See Fig. 4 . Mark slide joint housing and inner race in relation to axle shaft for reassembly reference. 2. Remove and discard snap ring “A”. See Fig. 3 and Fig. 4 . Remove slide joint housing. Remove snap ring “C”. Remove cage, inner race and balls as an assembly. Remove snap ring “B”. Cover axle shaft splines with tape. Remove boot. 3. To disassemble support bearing and retainer assembly on right axle shaft, remove dust shield and snap ring “D”. See Fig. 4 . Press axle shaft out of support bearing and retainer assembly. Remove snap ring and dust shield from retainer. Using bearing driver and hammer, drive support bearing out of retainer.

1999 Ford Windstar Instrument Panel and Console REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals, Uncategorized) by admin on 23-04-2012

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Instrument Panel Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Remove the steering wheel. Refer to Section 211-04 . 2. Remove the passenger side air bag module. Refer to Section 501-20B . 3. Disconnect the antenna in-line connector. 4. Remove the RH instrument panel reinforcement bolt. 5. Close the glove compartment. 6. Remove the utility compartment. 1. Remove the four two part pin type retainers. 2. Remove the utility compartment. * Disconnect the power point electrical connector. 7. If equipped, disconnect the compact disc changer electrical connector. 8. Release the compact disc changer electrical connector locator. 9. Remove the LH and RH scuff plates. 10. Remove the LH and RH A-pillar lower trim panels. 11. Position the LH and RH front door weatherstrip seals aside. 12. Remove the RH ground bolts. 13. If equipped, remove LH and RH instrument panel lower insulators. 14. Remove the instrument panel lower steering column opening cover. 1. Remove the screws. 2. Remove the instrument panel lower steering column opening cover. 15. Remove the instrument panel opening cover reinforcement. 1. Remove the bolts. 2. Remove the instrument panel opening cover reinforcement. 16. Disconnect the LH wiring harness electrical connectors. 17. Disconnect the electronic crash sensor (ECS) electrical connector. 1. Release the locking clip. 2. Disconnect the ECS electrical connector 18. Disconnect the automatic transmission shift cable. 1. Disconnect the cable from the steering column shift tube lever. 2. Disconnect the cable from the steering column bracket. 19. Separate the intermediate shaft from the steering column. 1. Remove the pinch bolt. 2. Separate the intermediate shaft from the steering column. 20. Disconnect the climate control harness electrical connector. 21. Disconnect the climate control vacuum harness connector. 22. Disconnect the fuse junction panel electrical connectors. 23. Remove the LH instrument panel reinforcement bol 4. Remove the four instrument panel center support bolts. 25. Remove the instrument panel defroster opening grille. * If equipped, disconnect the sunload sensor electrical connector. 26. Remove the cowl top bolts. 27. Remove the RH cowl side bolts. 28. Remove the LH cowl side bolts. 29. NOTE: Two technicians are required to carry out this step. Remove the instrument panel. Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. NOTE: Two technicians are required to carry out this step

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