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2000 Chevy Truck S10/T10 Blazer Transfer Case Removal And Installation Manual

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Filed Under (Chevy Manuals) by admin on 18-05-2011

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Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the front propeller shaft. Refer to Propeller Shaft Replacement- Front. 3. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement-Rear. 4. Remove the vent hose from the transfer case. 5. Disconnect the vehicle speed sensor electrical connectors. 6. Remove the electrical connectors from the transfer case motor/encoder. 9. If equipped with a manual transmission, remove the bolt securing the left side support brace to the transmission. 10. If equipped with a manual transmission, remove the bolt and stud securing the left side support brace to the transfer case 11. If equipped with a manual transmission, remove the two bolts securing the right side support brace to the transmission and transfer case. 12. For vehicles equipped with a manual transmission, remove the six nuts securing the transfer case and bracket to the transmission 13. Remove the transfer case. * Start by pulling the transfer case straight back from the transmission. * After the transfer case is pulled out from the transmission turn and lower the transfer case. 14. For vehicles equipped with a automatic transmission, remove the six nuts securing the transfer case and bracket to the transmission adapter. 15. Remove the transfer case. * Start by pulling the transfer case straight back from the transmission. * After the transfer case is pulled out from the transmission turn and lower the transfer case. 16. Remove and discard the gasket. Installation Procedure 1. Install a new gasket to the transmission. Use sealer GM P/N 12346004 in order to hold the gasket in place. 2. Raise and position the transfer case to the vehicle Notice: Refer to Fastener Notice in Service Precautions. 3. For vehicles equipped with a automatic transmission, install the six nuts securing the transfer case and bracket to the transmission adapter. * Tighten the nuts to 47 Nm (35 lb ft) . 4. For vehicles equipped with a manual transmission, install the six nuts securing the transfer case and bracket to the transmission. * Tighten the nuts to 47 Nm (35 lb ft)

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Toyota V6 Adapter Plate Installation Manual

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Filed Under (Toyota Manuals) by admin on 30-03-2012

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Apply silicone to face of single or dual transfer case assembly. Install adapter plate on face of transfer case, using 4 M10-1.25×35 bolts (provided). We recommend applying blue LocTite® to threads before installation. Torque four plate bolts to 30 ft. lbs. Step 2 Install M-10-1.25×30 allen head bolt using blue Loc- Tite® torque to 30 ft. lbs. Step 3 Remove rear transmission seal using a seal remover or claw hammer. Step 4 Step 5 Install M-10-1.25x 35 bolt using blue LocTite® torque to 30 ft. lbs. Using degreaser, clean the rear transmission seal sur- face. Step 6
Ensure two dowels are in place in the transmission. If dowels are in the transfer case move them to the trans- mission. Step 8 Step 11: Apply silicone to rear face of transmission Slide coupler into place on the back of the transmis- sion. Step 7 Step 9 Step 10 Apply silicon to smaller end of seal adapter Install Seal Adapter into rear of transmission. Gently seat seal adapter into place using rubber mallet Step 11 After Assembling Adapter Plate & T/Case(s): Install replacement v6 dual transfer case crossmember Reconnect 4 wheel drive indicator (This may require cutting and splicing connector from original case) 1988-1991 Application, reconnect speedometer cable (Use speedometer extension cable for dual case applications) 1992-1995 Application will need a replacement VSS for the transfer case Reattach front and rear drive shafts (drive shaft lengths may need to be changed) Fill transfer case with 90W GL5 gear oil, check gear oil level in transmission Reinstall transfer case shifter and boot Drain and replace transfer case oil after first 1,000 miles and every 30,000 thereafter Full synthetic gear oil may be used. Step 12 Using 6 of the 9 stock bolts, 1 allen head bolt and 2 M10-1.25×35 bolts, attach transfer case to transmission. Use blue LocTite® on all bolts. Tighten bolts to 30 ft. lbs. The second allen head bolt should be installed in position shown on the upper right (passenger) side. Step 13 These instructions are designed as a general installation guide. Installation of many Trail-Gear Products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 559-252-4950 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Trail-Gear Inc are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use.

1995-1997 FORD EXPLORER TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP

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Filed Under (Ford Manuals) by admin on 20-01-2012

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TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP ISSUE to the Data Link Connector (DLC) underneath The diagnostic procedure for binding or shudder the steering wheel. Monitor for any Diagnostic from transfer case in slow, tight turns while in 4 Trouble Codes (DTCs) set by the transfer case Auto mode may be inaccurate for some vehicles. that could indicate incorrect speed sensor function. Codes could include, but are not ACTION limited to: Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure. •P1836 – Front propshaft sensor circuit failure •P1837 – Rear propshaft sensor circuit failure DIAGNOSTIC PROCEDURE •P1874 – Hall effect sensor power short circuit to battery 1997 EXPLORER •P1875 – Hall effect sensor power circuit 1. Test drive the vehicle in 4 Auto, 4 High and 4 failure Low. Evaluate the vehicle in each of these NOTE modes. The vehicle should bind in turns in both ADDITIONAL CODES COULD BE SET AS WELL. 4 High and 4 Low, but not in 4 Auto. The 4 PLEASE REFER TO THE APPROPRIATE YEAR High mode is intended for severe winter EXPLORER SERVICE MANUAL FOR COMPLETE weather or off-road driving only. It is not LISTING AND EXPLANATION. intended for use on dry or merely wet pavement. 3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and 2. Verify the instrument panel has the proper 4X4 replace accordingly. Drive the vehicle to verify if selection label (Figure 1). Proceed to 1995-97 the shudder/binding has been eliminated. Send Explorer heading, Step 1. replaced speed sensor to the Ford Warranty 1995-97 EXPLORER Parts Return Center, Canton, MI. NOTE 4. Using NGS Tester, monitor the Parameter 4 AUTO IS THE FAR LEFT SWITCH POSITION Identification Display (PID) on the transfer case ON 1997 MODELS AND IS THE MIDDLE clutch duty cycle. If the 4 Auto mode reads POSITION ON 1996 MODELS. something higher than one (1), verify speed sensors have not set any Generic Electronic 1. If during test driving, the vehicle shudders or Module (GEM) DTCs and follow the speed binds in 4 Auto during slow forward or reverse sensor diagnostic procedure in the above Step parking lot maneuvers, proceed to Step 2. 2. Verify the following while checking PID: Mode Duty Cycle Indicator 4 Auto 0 or 1 4 High 13 4 Low 38 at 5 MPH 5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil

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4WD Switch Indicator Lights Flashing, 4WD Inoperative, DTCs C0327, P0500, P0836, P1875 Set (Replace Encoder Motor Sensor, Reprogram TCCM, Inspect Front Drive Axle Engagement Sleeve for Damage/Repair if Necessary)

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Filed Under (More Manuals) by admin on 22-06-2012

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Correction Important: For ease of reassembly, shift the transfer case assembly to 2HI for the NV263 (NP1), or Neutral for the NV246 (NP8) prior to removing any components. For information on placing the NV246 (NP8) transfer case in NEUTRAL, see the procedure at the end of this bulletin. 1. Remove the transfer case and front axle/engine skid plates (if equipped). 2. Disconnect and position the front propeller shaft aside. 3. Disconnect the transfer case encoder motor wiring harness. 4. Remove the three (3) bolts that retain the encoder motor to the transfer case. 5. Separate the encoder motor assembly from the transfer case and place it on a work bench. Important: DO NOT REMOVE THE SCREWS INDICATED WITH THE (1) IN THE ABOVE ILLUSTRATION. 6. Remove the four screws on the outer perimeter of the encoder motor housing. Important: For proper timing and ease of reassembly, hold the gear in place as your remove the cover from the encoder motor assembly with your thumb or finger. 7. Carefully remove the cover from the encoder motor assembly. The cover has a seal on the bottom side. Place the cover in a position to protect this seal from damage and/or contamination. Important: Observe the location of the punch mark on the large gear in relation to the timing mark on the housing if the transfer case was placed in the 2HI for the NV263 (NP1), or Neutral for the NV246 (NP8). The timing marks should be within one tooth of proper alignment. If not, you must note the timing mark positions for reassembly. 8. Locate the two shims; one on the small gear and another on the larger gear. Set them aside on a clean surface for reuse. Important: After removing the large gear from the housing, a dark gray phenolic spacer should remain in the casting where the bottom of the large gear resides. Locate this spacer and save for reuse. 9. Carefully lift the large gear from the housing. The sensor and wiring harness will come with the gear. 10. Disconnect the wiring from the sensor. 11. Separate the sensor from the large gear.

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TOYOTA LC70 HYDRAPNEU LTPTO INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 01-12-2011

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INSTALLATION INSTRUCTIONS ` Raise the vehicle on a hoist to a workable height. Remove the front drive shaft (C) at the transfer case flange (D). In order to easily install the LTPTO, the cross member (E) must be lowered from the main chassis (F) by approximately 30mm. Using a 14mm socket loosen the eight bolts (g) supporting the cross member (E) . Use the appropriate safety equipment to support the cross member and prevent it from falling. Remove the rear backing plate (I) from the transfer case (t/case) (H) with a 14mm socket. Use a container to collect any oil that may leak from the t/case after the rear backing plate is removed. Remove all old gasket glue from around the mounting face (M) of the t/case (H) ensuring not to damage the mounting face. Then replace the rear backing plate (I) to prevent possible contamination during future steps. Parts of the t/case (H) must be modified in order to allow the units engagement cable to be mounted correctly. As illustrated in the picture, (looking from front of vehicle), remove the small amount of the material on the rib and lip as shown. The amount can be checked by loosely mounting the LTPTO unit and checking that the cable sheath does not foul on the case. While the rear backing plate is installed use a die grinder to complete this task, remove the backing plate to test the unit. A second rib may have to be modified, in order to determine this; loosely mount the LT PTO unit (1) and check to see if the rib (J) shown will prevent the unit from seating correctly with the transfer case. Then, if required, die grind a small amount of material from the rib (J) to ensure the correct mating of the two faces. A gap of at least 3mm between t/case (H) and LTPTO (I) should be sufficient to ensure a correct seal is created between the two faces. If the backing plate (18) on the LTPTO is installed at this stage remove it by undoing the nine x M5 Socket Head Cap (3) Screws (SHCS) – with a 4mm Allen key.

2007 Chevrolet Impala V6-3.9L – A/T 4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration

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

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This service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover ( Channel Plate ) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, other gaskets not included in this service kit will also be needed to complete the repair – a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering gasket kit 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to-Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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1998 Chevy Truck S10/ T10 Blazer 2WD Evaporator Core Service and Repair Manual

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Filed Under (Chevy Manuals) by admin on 14-05-2012

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Manual A/C REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the right side instrument panel sound insulator. 3. Remove the instrument panel storage compartment. 4. Disconnect the passenger side SIR. 5. Remove the lower right instrument panel mounting bolt. 6. Remove the left and right front speaker grilles. 7. Remove the center instrument panel sound insulator. 8. Remove the left side instrument panel sound insulator. 9. Disconnect the park brake release cable. 10. Remove the knee bolster. 11. Remove the lower left instrument panel mounting bolt. 12. Remove the BCM. 13. Disconnect the driver side SIR. 14. Remove the instrument panel cluster. 15. Remove the radio. 16. Remove the HVAC control assembly. 17. Remove the steering column retaining retaining nuts. 18. Lower the steering column. 19. Remove the instrument panel carrier. 20. Remove the left and right cowl vent grille panels. 21. Disconnect the underhood lamp electrical connector, if equipped. 22. Remove the hood. 23. Remove the VCM. 24. Remove the coolant recovery tank. 25. Remove the heater hoses. 26. Disconnect the electrical connectors from the grille mounted lamps. 27. Remove the right front headlamp assembly. 28. Remove the front bumper. 29. Remove the right wheelhouse panel. 30. Disconnect the radio antenna cable. 31. Disconnect the electrical connector for the horn. 32. Remove the right fender. 33. Remove the evaporator case heat shield, if equipped. 34. Remove the blower motor resistor. 35. Remove the evaporator case bolts and screws. 36. Remove the accumulator. 37. Remove the condenser to the evaporator line fitting. 38. Remove the bolts which retain the evaporator case to the bulkhead. 39. Pull back lightly on the heater case to remove the evaporator case. 40. Remove the evaporator case retaining screws. 41. Disassemble the evaporator case sections, and remove the evaporator core. NOTE: If replacing the evaporator core, remove the expansion (orofice) tube and install it into the new core. INSTALLATION PROCEDURE 1. Install the evaporator core. 2. Assemble the evaporator case sections. 3. Install the evaporator case retaining screws. Tighten to 2.5 N.m (24 in lb) . 4. Install the evaporator core assembly to the vehicle. 5. Install the bolts which retain the evaporator case to the bulkhead. Tighten the bolts to 4.5 N.m (40 lb in) . 6. Install the condenser to the evaporator line fitting. 7. Install the accumulator. 1998 Chevy Truck S10/T10 Blazer 2WD 8. Install the evaporator case bolts and screws. Tighten to 2.5 N.m (24 In in) . 9. Install the blower motor resistor. 10. Install the evaporator case heat shield, if equipped. 11. Install the right fender. 12. Connect the electrical connector for the horn. 13. Install the radio antenna cable. 14. Install the right wheelhouse panel. 15. Install the front bumper. 16. Install the right front headlamp assembly. 17. Connect the electrical connectors to the grille mounted lamps. 18. Install the heater hoses. 19. Install the coolant recovery tank. 20. Install the VCM. 21. Install the hood. 22. Connect the underhood lamp electrical connector, if equipped. 23. Install the left and right cowl vent grille panels. 24. Install the instrument panel carrier. 25. Reposition the the steering column, and install the steering column retaining nuts. 26. Install the HVAC control assembly. 27. Install the radio. 28. Install the instrument panel cluster. 29. Connect the driver side SIR. 30. Install the BCM. 31. Install the lower left instrument panel mounting bolt. 32. Install the knee bolster. 33. Connect the park brake release cable. 34. Install the left side instrument panel sound insulator. 35. Install the center instrument panel sound insulator. 36. Install the left and right front speaker grilles. 37. Install the lower right instrument panel mounting bolt. 38. Connect the passenger side SIR. 39. Install the instrument panel storage compartment. 40. Install the right side instrument panel sound insulator. 41. Connect the negative battery cable. 42. Inspect the system for leaks.

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2003 Ford F-Super Duty 250-550/ Excursion Differential Case and Ring Gear Removal And Installation manual

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Filed Under (Ford Manuals) by admin on 07-02-2012

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1. Remove the differential case. For additional information, refer to Differential Case in this section. 2. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, for additional information, refer to Differential Case in this section. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. ? If required, remove the ring gear and anti-lock speed sensor ring. 3. NOTE: This tool does not have the 1/2-inch drive hole. Install the special tool in a suitable vise. 4. Install the differential case on the special tool 5. Install the special tool in the bottom side gear bore. ? Apply a small amount of grease to the centering hole of the special tool. 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate 7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened. 8. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert the special tool in the pinion shaft bore and turn the differential case to “walk” the differential pinion gears and differential pinion thrust washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs and tag them RIGHT and LEFT with the shim. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Separate the differential clutch discs and clutch plates for cleaning and inspection. Refer to the disassembled view of the limited slip differential case in the Description and Operation portion of this section.

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Edelbrock Rebuildable Race Muffler Repack Kit Installation Manual

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Filed Under (More Manuals) by admin on 22-02-2012

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DISASSEMBLY 1. Using the drill motor and the 3/16 drill bit, drill out all of the rivets in the muffler case being cautious not to enlarge the rivet holes. 2. Disassemble the muffler assembly. 3. Remove what is left of the old packing, clean were needed, be sure to remove any pieces of the old rivets that may be remaining in the outer case. ASSEMBLY 1. Slip on the new steel wool sleeve (Note: On the 3 ½” diameter muffler, a piece of 3″ diameter tubing flared to 3 ½” I.D. on one end will make this job much easier). 2. Wrap the ceramic packing around the installed steel wool sleeve. 3. Wrap the ceramic cloth material around the outside of the ceramic packing. Note: Position the seam or the end of the packing and the cloth on opposite sides of the muffler. Rubber bands or masking tape can be used to hold the packing in place. 4. Slide the outer case over the outside of the ceramic cloth and packing. Stand the muffler on the outlet end, gently squeeze the packing at the top and begin working down while the outer case slips down over the new packing. Note: Make sure the packing and ceramic cloth stay in place as the outer case is worked down. The better the repack job the longer it will be between repacks. 5. When the outer case has been completely slipped down, install the inlet end of muffler and align the rivet holes. Using the rivet gun install the rivets. Note: After the muffler goes through a number of repacks it may be necessary to drill additional or new holes to hold the muffler case securely together

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