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Toyota Front Coil Spring Spacer Lift Kit Installation Manual

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Filed Under (Toyota Manuals) by admin on 22-12-2011

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INSTALLATION INSTRUCTIONS FRONT 1. Read complete instructions before beginning installation, the following special tools are recommended: Coil spring compressor, floor jack, ball joint separator, jack stands, bench vise, and metric hand tools. 2. Jack the vehicle in the center of the front cross member. 3. Support the vehicle by placing jack stands on the frame cross member so that the front tire/wheels are off the ground. 4. Remove the front tires/wheels. 5. Disconnect the sway bar end links and remove the upper ball joint cotter pin and nut. 6. Separate the upper ball joint from the spindle. (Using ball joint separator or a suitable tool, be careful NOT to damage the ball joint boot) 7. Remove upper strut tower nuts holding strut assembly to strut tower (3) on each side of vehicle. 8. Remove the lower strut bolt from the lower control arm and remove the strut assembly from the vehicle. (Note the direction of the bolt for reinstallation) 9. Compress the coil spring on the strut assembly with a suitable coil spring compressor so that the coil spring has about 3/8″ play in the strut and remove the upper strut isolator mount nut. 10. Remove the coil spring isolator from the upper strut mounting plate. 11. Replace the upper strut mounting plate studs with the supplied studs with a bench vise and a deep well socket. (3 on each side) 12. Reinstall the factory coil spring isolator to the upper strut mounting plate. 13. Reinstall the compressed coil spring onto the strut assembly and reattach the upper strut mount plate using the stock hardware. See diagram. Torque upper strut mounting plate nut to 18 foot-pounds. 14. Decompress the coil spring in the strut assembly. Make sure that the spring is seated correctly into the strut assembly alignment indentation at the bottom of the strut and the top isolator. 15. Slide the coil spring spacer onto the top of the strut assembly over the 10mm studs. 16. Install the strut assembly into the strut tower and start the upper three 10mm lock nuts. (Make sure that the bottom of the strut is aligned as well) 17. Install the lower strut bolt in the original position and torque to 100 foot- pounds. (Step 8) 18. Using the floor jack, raise the lower control arm and connect the upper ball joint on the upper control arm to the spindle. Torque nut to 80 ft lbs. and make sure that you replace the cotter pin. (Not supplied) 19. Install the front tires/wheels. 20. Lower the vehicle onto the ground and tighten the upper strut tower 10mm nuts. Torque to 35 foot-pounds. (3 on each side) 21. RETORQUE ALL BOLTS AFTER 500 MILES.

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2007-Up Toyota Tundra 2WD/4WD ADJUSTABLE UPPER STRUT FRONT LIFT/ LEVELING KIT INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 28-03-2012

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Step 1: Measure current front ride height. Take a measurement from the bottom of the wheel/rim to the lip of the fender on each side of the vehicle. Write down measurements to help in determining ride height after new kit is installed. (Figure A) Step 2: Position vehicle on a flat surface or automotive lift. Suspend front wheels , lifting by the frame with a floor jack or lift jack. Secure using jack stands and wheel chocks. Be sure engine is turned OFF and vehicle is in PARK. Remove tire/wheel assembly on ONE side of vehicle . Step 3: Support Spindle to protect ABS system and brake lines! LOOSEN, but don’t completely remove upper ball joint nut, outer tie rod nut and sway bar link nut at the lower control arm. Step 4 : Break Outer tie rod and ball joint from their tapers using tools specific to this procedure. CAREFULLY, while supporting the spindle assembly, completely remove upper ball joint nut & tie rod nut, leaving the loosened sway bar link nut in place. ( Figure B) Step 5: Remove strut assembly from the vehicle. Remove LOWER strut bolt first, followed by the three (3) upper strut nuts. CAUTION! BE EXTREMELY CAREFULL TO SUPPORT STRUT ASSEMBLY WHEN REMOVING UPPER STRUT NUTS! The Strut/Spring assembly is heavy and can cause injury to technician or damage to other components if released too quickly! (Figure C) Step 6: Apply 50% of the INCLUDED Synthetic Grease to the TOP of the THREADED INNER ADJUSTMENT SCREW, as illustrated. (Figure D) Step 7: Using the original OEM stud nuts , secure new Adjustable Upper Strut Kit to OEM upper strut studs and torque to manufacturer’s specifications. (Figure E) IMPORTANT! Be sure the Threaded Adjustment Screw Rotates FREELY after securing kit to OEM top of strut! If not, slightly loosen the three upper stud nuts and reposition Threaded Adjuster Screw UPWARD slightly. Retorque upper stud nuts to manufacturer’s specifications and recheck that Inner Adjuster Screw rotates freely. Step 8: Install the Top Connection Plate ONLY, studs directed UPWARD, into position in the strut tower, and secure with the NEW Nylock stud nuts supplied with this kit. Torque stud nuts to OEM specifications. (Figure F) Step 9: Reinstall strut assembly . Be sure the new Adjustable Upper Strut Kit is THREADED DOWN in the MOST COMPACT POSITION for easiest reassembly, then pass exposed threaded area of the kit THROUGH the center of the Top Connection Plate already installed. HINT: The use of a pry bar or breaker bar may simplify reinstallation of the Strut Assembly. (Figure G) Step 10: Install Large 1-1/4-12 Adjustment Locking Jam Nut included with this kit and tighten until snug to Top Connection Plate. Install Snap Ring included with kit.

1999-2006 TOYOTA TUNDRA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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1. To begin installation, block the rear tires of the vehicle so that the vehicle is stable and can’t roll backwards. Safely lift the front of the vehicle and support the frame with jack stands. Place jack stands on both the driver and the passenger sides of the vehicle. Next remove the wheels from both sides. 2. Using a 17mm socket, remove the lower sway bar link bolt from both sides. HINT: If the stud turns together with the nut use a hex wrench or vice grips to hold the stud . 4. Next remove the strut’s lower mounting bolt with a 19 mm socket and wrench. NOTE: Once the nut is removed, it may be necessary to use a punch and hammer to free the bolt. 5. Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 6. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the steel strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 7. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the steel spacer the strut will be rotated 180° when reinstalled. 8. Place strut back into upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 9. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. 10. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 11. Repeat Steps 3 through 10 on the opposite side of the vehicle. 12. Reattach the sway bar link assembly on both sides of the vehicle. Torque to OEM specs. For 2wd trucks skip Step 13. 13. For 4×4 models only it is necessary to lower the differential using the provided spacers and bolts. Install the spacers following the instructions provided with the spacers. 14. Reattach the wheels. Torque to OEM specs. 15. Lower vehicle to the ground and torque strut mounts to OEM specs. 16. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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1996-2004 TOYOTA TACOMA FRONT LEVELING SYSTEM FOR THE 6-LUG SUSPENSION INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 27-10-2011

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Remove the nuts from the three upper strut mounting bolts with a 14 mm ratchet. Be sure to support the strut assembly as the nuts are removed to prevent it from falling. 96-04 Tacoma 11/07 5. Remove the strut assembly from the vehicle and mount it in a bench vise. Install the provided strut extension on the top of the strut assembly. ** Caution: Use the factory nuts with the factory studs** 6. Run down nuts snug with end wrench. Torque to OEM specs. NOTE: Because of the shape of the provided spacer the strut will be rotated 180° when reinstalled. 7. Place strut back into the upper strut mount. Tighten provided nuts snug with a 14mm wrench or ratchet (after install, you will torque to OEM specs). 8. Use a pry bar to position the lower control arm and the strut mount, and then reinstall the mounting bolt. Torque to OEM specs. HINT: It may be helpful to use a pry bar to press down on the steering knuckle for reinstalling the mounting bolt. 9. Place a jack under the lower control arm. Raise the lower control arm to reattach the lower ball joint bolts. Torque the ball joint nuts to OEM specs. 10. Repeat Steps 2 through 9 on the opposite side of the vehicle. 11. Reattach the wheels. Torque to OEM specs. 12. Lower vehicle to the ground and torque strut mounts to OEM specs. 13. Align the vehicle. A certified alignment technician that is experienced with lifted vehicles is recommended to perform the alignment

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1995-2004 TOYOTA TACOMA 4 X 4 AND PRERUNNER 3″ SUSPENSION LIFT KIT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 29-02-2012

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Tacoma 4WD & PreRunner Installation Instructions Page 3 of 7 09/09/08 INST-425F.DOC FRONT OF VEHICLE 1. Park vehicle on level concrete surface. 2. Center and lock the steering wheel. 3. Block the rear wheels of the vehicle to prevent vehicle from moving in either direction. 4. Jack up the vehicle from the lift point in Figure “A.” 5. Support the vehicle with jack stands from the points in Figure “A.” 6. Remove the front wheels. 7. Remove the nut (14mm) and the hardware from the anti-sway bar. See Figure “B.” 8. Remove the nut (19mm) and bolt (14mm) from the bottom of the strut. See Figure “C.” 9. Remove the three nuts (14mm) from the top of the strut. See Figure “D.” 10. Remove the strut from the vehicle. NOTE: AT THIS TIME, IF YOU DO NOT HAVE A SUITABLE SPRING COMPRESSOR, IT IS HIGHLY ADVISED TO EITHER TAKE THE STRUT TO A QUALIFIED SERVICE CENTER OR PURCHASE THE REVTEK SC-1 SPRING COMPRESSOR. 11. Compress strut assembly and remove the nut (17mm) on the top of the strut shaft in Figure “E.” 12. Release the compressor. 13. Remove the spring top plate from the strut. 14. Remove and discard the rubber spacer. 15. Remove (hammer) the studs from the spring top plate. See Figure “F.” 16. Install (hammer) the LONGER STUDS (10MM) (provided) in the spring top plate. See Figure “G.” 17. Install the PRELOAD SPACER between the spring and the spring top plate with the small diameter facing toward the spring. See Figure “H.” 18. Compress the strut assembly, making sure you center the strut shaft through the spring top plate hole and that the STUDS line up with the PRELOAD SPACER reliefs. Replace nut on the top of the strut shaft and torque to spec. (Figure “E”). (Torque specs can be found on page 1.) 19. Install the TOP OUT EXTENDER over the STUDS (Figure “H”). 20. Reinstall the strut by reversing the removal procedure; torque to spec. (Torque specs on page 1.) 21. When properly installed, PRELOAD SPACER relief and Revtek Industries logo should face outward. (Figure R) 22. Reinstall hardware and nut on anti-sway bar; torque to spec. 23. Replace the wheels; torque to spec.

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2007-2009 Chevy GM Truck 6-LUG Models Installation Instructions

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Filed Under (Chevy Manuals) by admin on 24-12-2011

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1. Place the vehicle on a flat surface and using a floor jack and jack stands lift the front of the vehicle by the frame so the wheels are off the ground. 2. Remove the front wheel on the driver-side of the vehicle. 3. Remove the sway bar end link. 4. Loosen the three upper strut mounting nuts, but DO NOT REMOVE them. 5. Locate the ABS line and unhook it from the upper control arm. 6. Remove the two lower strut mounting bolts. 7. Loosen the nuts on the upper ball joint, but DO NOT REMOVE them. Note: A hammer may be needed to break the ball joint free. 8. Now remove the ball joint nut, the three upper mounting nuts and remove the strut from the vehicle. 9. With the strut removed from the vehicle, place the leveling spacer on top of the strut assembly, then reinstall the strut assembly in the stock location with the new nuts provided in the kit. 10. Reinstall the upper ball joint nut and sway bar end link. Note: It may be necessary to use a pry bar to aid installation of the strut assembly. It may also be necessary to use a floor jack to raise the lower A-arm to get the ball joint nut installed. 11. Verify that all fasteners have been torqued to factory specs. 12. Reinstall the wheel, and torque to OEM specs. 13. Repeat the above steps on the passenger-side of the vehicle. 14. Adjust your headlights and get the vehicle aligned by a Certified Alignment Technician that is experienced with lifted vehicles. PROFESSIONAL INSTALLATION BY A CERTIFIED MECHANIC IS RECOMMENDED

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2001 Ford Taurus/ Sable Strut and Spring Assembly Four Door Workshop Manual

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Filed Under (Ford Manuals) by admin on 03-02-2012

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Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed if installation becomes necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified to make sure of correct retention of these parts. 1. Remove the parcel tray. For additional information, refer to Section 501-05. 2. Loosen the nuts. 3. NOTE: It is not necessary to remove the stabilizer bar links from the stabilizer bar. Remove the stabilizer bar, if so equipped. For additional information, refer to Stabilizer Bar and Connecting Link — Four Door in this section. Remove the jack stands after the stabilizer bar is removed. 4. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 5. Remove the bolt and detach the rear wheel brake hose 6. Remove the nut, washer and bushing. Detach the tension strut from the spindle. ? Discard the nut. 7. CAUTION: Care should be taken when removing the strut and spring assembly so the rear wheel brake hose is not stretched. Remove and discard the pinch bolt. Detach the spindle from the strut and spring assembly. ? To aid in removal, use a large screwdriver to spread the pinch joint. 8. Partially lower the vehicle. 9. Remove the nuts and the strut and spring assembly. ? Discard the nuts. Installation 1. Position the strut and spring assembly and install new nuts. ? Do not tighten the nuts at this time. 2. Partially raise the vehicle. 3. Position the spindle on the strut and install a new pinch bolt. 4. NOTE: Make sure the cupped side of the washer is facing away from the bushing. Position the tension strut in the spindle and install the bushing, the washer and a new nut. 5. Position the rear wheel brake hose and install the bolt. 6. Install the stabilizer bar, if so equipped. For additional information, refer to Stabilizer Bar and Connecting Link — Four Door in this section. 7. Install the wheel and tire assembly. For additional information, refer to Section 204-04. 8. Tighten the nuts. 9. Install the parcel tray. For additional information, refer to Section 501-05

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1985 – 1989 Toyota MR2 3SGTE Engine Mount Kit Installation Manual

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Filed Under (Toyota Manuals) by admin on 04-12-2011

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You can now temporarily set the new mounts onto the frame rails and see if you need to grind any additional paint or sealer off the rails. You want at least one inch of clean metal on all sides o the new mount for proper weld pen Do not rush the preparation of the frame rails or new mounts! The weld fixture installs using the upper strut mount studs. Remove the 6 nuts, and carefully slide f etration. the fixture over the studs. If one side is tight because of the height of the studs, lower the strut on that side until the fixture goes into place, and then push the strut up. Snug the nuts up onto the weld fixture. Please do not force the weld fixture in any way! I cannot stress this enough, the weld fixture needs to stay straight and true so that the next person can properly install their mount kit! With the weld fixture installed, you can slide the mounts into place and test the fit against the frame rail and inner fender sheet metal. You may have to grind a little off the edges of the new mounts to get the bolthole to line up perfectly. You want the bolt to slide through easily, without having to force it in any way. You can now put a bolt through the mounts and weld fixture, and prepare to weld! The preferred method is to MIG weld the mounts, but you can also stick weld them to the frame rails. Tack the mounts to the frame, 2 tacks on either side of each mount. Then REMOVE the weld fixture to finish weld the mounts. The fixture will get in the way of you finish welding it, and you do not way to risk twisting it if the mounts move from heat as you weld it. If you properly weld the mounts, they should look like this picture.special Instructions For Returning the Weld Fixture 1. Please place the fixture back into the case when not in use, and close the latches completely. 2. Put a zip tie through each latch to secure it during shipment, just as it arrived to you. 3. Remove the old label from the top of the case. 4. Be available for the FedEx Driver to pick the case up and place the Call Tag on the label plate. 5. Please be very careful with the weld fixture, it should be treated as a precision instrument!

1989-1996 Dodge Dakota Trucks COIL Ignition Tests Manual

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Filed Under (Dodge Manuals) by admin on 18-06-2012

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Dakota Trucks 1989-1996 Ignition Tests COIL The ignition coil for the vehicles covered by this guide is in the following locations: • 1989-92 engines: mounted to the firewall • 1993-96 2.5L engines: mounted on the thermostat housing in front of the coolant temperature sensor • 1993-96 V6 and V8 LDC engines: mounted to a bracket bolted to the right engine cylinder head • 1993-96 5.9L HDC engines: mounted to a bracket bolted to the air injection pump (AIR pump) mounting bracket. Fig. 2: Ignition coil mounting-all 1989-92 models Fig. 3: Ignition coil wiring and mounting hardware-1993- 96 2.5L engine 1. Inspect the ignition coil for arcing while the engine is running. If the engine will not start, this can be performed while the engine is cranked by either an assistant or a remote starter. Look at the coil in dim or low light to aid visibility of any arcing. Fig. 4: Ignition coil mounting-1993-96 3.9L and 5.2L/5.9L LDC engines 2. Arcing at the tower will carbonize the wire boot, which, if it is connected to a new ignition coil, will cause the coil to fail. In such cases, clean all the carbonization away or replace the components as necessary. Fig. 5: Ignition coil mounting-1993-96 5.9L HDC engine 3. Using a coil tester or ohmmeter according to the manufacturer’s instructions, test the primary and secondary resistance. Replace any coil that does not meet the specifications indicated in the accompanying chart. 4. Inspect the secondary coil wire for any sign of damage. Replace if any damage is found. Carbon tracking on the old wire can cause arcing and the failure of a new ignition coil. REMOVAL & INSTALLATION 1989-92 Models See Figures 6 and 7 1. Disconnect the negative battery cable. 2. Disconnect the three wires from the coil. Mark them to identify for installation. Fig. 6: Remove the coil bracket bolt at the cowl Fig. 7: Unscrew the coil mounting hardware, then remove the coil from the vehicle 3. Unplug the condenser suppressor connector from the coil, if equipped. 4. Unbolt and remove the coil. To install: 5. Bolt down the coil with old bolts. 6. Connect wires to coil making sure that the proper wires are connected where they should be. 7. Connect the condenser suppressor, if equipped. 8. Connect the battery negative cable Removal and Installation V6 AND V8 ENGINES 1. Disconnect the negative battery cable. 2. Disconnect the primary wiring from the ignition coil. 3. Disconnect the secondary spark plug wire from the coil. 4. Remove the two bolts and withdraw the coil from its mounting bracket. To install:
5. Position the coil on its bracket and install the two bolts. Tighten them to 100 inch lbs. (11 Nm). If the bracket has been tapped for coil mounting bolts, these fasteners require less torque, so tighten them to 50 inch lbs. (5 Nm). 6. Connect all wiring to the ignition coil. TESTING See Figure 1 The only test you can perform without a DRBII scan tool, or equivalent, is a basic check of the sensor only.

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2008 Honda Accord L4-2.4L Knuckle/ Hub Bearing Unit Replacement

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Filed Under (Honda Manuals) by admin on 19-11-2011

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Hub Bearing Unit Replacement 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel nuts, and the rear wheel. 3. Remove the brake hose mounting bolt (A). 4. Remove the brake caliper bracket mounting bolts (B), then remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose excessively. 5. Remove the two washers (A). NOTE: During installation, make sure the washers are installed between the brake caliper bracket and the knuckle. 6. Remove the rear brake disc. 7. Remove the hub bearing unit (A) and O-ring (B). 8. Check the hub bearing unit for damage and cracks. 9. Install the hub bearing unit in the reverse order of removal, and note these items: * Use a new O-ring on reassembly. * After installing the brake caliper, make sure the clearance between lower arm B and the parking brake cable is more than 5 mm (3/16 in.). * Before installing the brake disc, clean the mating surfaces of the hub bearing unit and the brake disc. * Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel. * Check the wheel alignment, and adjust it if necessary. Knuckle Replacement 1. Remove the hub bearing unit. 2. Remove the splash guard (A). 3. Remove the lock pin (A) from the upper arm ball joint, then remove the castle nut (B). NOTE: During installation, install the lock pin as shown after tightening the new nut. 4. Disconnect the upper arm ball joint from the knuckle using the ball joint remover. NOTE: * Be careful not to damage the ball joint boot when installing the remover. * During installation, to connect the ball joint, raise the suspension with a jack. 5. Remove the wheel speed sensor (A) from the knuckle. Do not disconnect the wheel speed sensor connector. 6. Remove the self-locking nut (A) while holding the joint pin (B) with a hex wrench (C), then disconnect the stabilizer link (D) from the knuckle, and remove the brake hose bracket (E). NOTE: Use a new self-locking nut during reassembly. 7. Remove the damper lower mounting bolt (F). NOTE: Use a new mounting bolt during reassembly. 8. Remove the control arm mounting self-locking nut (A) and washer (B). NOTE: Use a new self-locking nut during reassembly 9. Remove the lower arm mounting bolt (A), and the lower arm B mounting bolt (B), then remove the knuckle (C). NOTE: Use new mounting bolts during reassembly. 10. Install the knuckle in the reverse order of removal, and note these items: * First install all the components, and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle’s weight before fully tightening to the specified torque values. * Be careful not to damage the ball joint boot when connecting the knuckle. * Before connecting the ball joint, degrease the threaded section and tapered portion of the ball joint pin, the ball joint connecting hole, and the threaded section and mating surface of the castle nut.

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