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1997 Ford F-250/ 350/ Super Duty Steering Knuckle REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 13-06-2012

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Steering Knuckle Removal 1. Remove the front wheel spindle (3105) and the right and left shaft and joint assembly. Refer to Spindle, RH and LH Shaft and Joint Assembly in the Removal and Installation portion of this section. 2. Disconnect the steering linkage, if necessary, from the knuckle. Refer to Section 11-03 in the Body, Chassis Manual. Steering Knuckle Installation 3. Remove the cotter pin from the stud of the front suspension upper ball joint (3049). Loosen the nut on the top stud and the bottom nut inside the steering knuckle. Remove the top nut. 4. Sharply hit the top stud with a plastic or rawhide hammer to free the knuckle from the axle arm. Remove and discard bottom nut. 5. NOTE: Note the orientation of the camber adjuster to make sure of the same camber setting. Remove camber adjuster by hand or, if difficulty is encountered, use Pitman Arm Puller T64P-3590-F. 6. Place steering knuckle in vise and remove snap ring from bottom ball joint socket if so equipped. 7. Remove plug from U-Joint Tool T74P-4635-C and replace with Plug T80T-3010-A4 (part of 4WD Ball Joint Tool Set T80T-3010-A). 8. Assemble U-Joint Tool T74P-4635-C and Receiving Cup T80T-3010-A2 (part of 4WD Ball Joint Tool Set T80T-3010-A). 9. NOTE: Always remove front suspension lower ball joint first. Turn forcing screw clockwise until front suspension lower ball joint is removed from steering knuckle. 10. Repeat procedure and remove front suspension upper ball joint. Installation 1. Clean steering knuckle bore and insert front suspension lower ball joint as straight as possible. 2. NOTE: If ball joint cannot be installed to the proper depth, realign Receiving Cup T80T-3010-A3. To replace the front suspension lower ball joint, assemble U-Joint Tool, Receiving Cup T80T-3010-A3 (part of 4WD Ball Joint Tool Set T80T-3010-A) and Installing Cup from Ball Joint Adapter Set D81T-3010-A or equivalent. 3. Turn forcing screw clockwise until front suspension lower ball joint is firmly seated. 4. Install the snap ring on the front suspension lower ball joint. 5. To install front suspension upper ball joint, assemble the C-Frame, Receiving Cup T80T-3010-A3 and Replacer T80T-3010-A1 (both part of 4WD Ball Joint Tool Set T80T-3010-A). 6. Turn forcing screw clockwise until front suspension upper ball joint is firmly seated. 7. Assemble knuckle to axle arm assembly. Install camber adjuster on the stud of the front suspension upper ball joint with the arrow pointing outboard for positive camber, pointed inboard for negative camber. 8. Install new nut on bottom socket finger-tight. Install and tighten nut on top socket finger-tight. Tighten bottom nut to 47 Nm (35 lb-ft). 9. CAUTION: If the tightening sequence is not followed in this step and Step 10, ball joint life will be reduced. NOTE: Do not loosen top nut to install cotter pin. Tighten top nut to 136 Nm (100 lb-ft), then advance nut until castellation aligns with cotter pin hole. Install cotter pin. 10. Retighten bottom nut to 123-149 Nm (91-110 lb-ft). 11. Install the front wheel spindle and the right and left shaft and joint assembly as described in this section. 12. Connect steering linkage, if necessary, to the knuckle. Refer to Section 11-03 in the Body, Chassis Manual.

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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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Coil Spring Spacer Installation Instructions

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

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1. Check to see that the spacer kit you purchased matches the year and model of your vehicle. Spacer kits two inches or taller may require a spring compressor to install. Ball joint and tie rod forks may also be useful. 2. A good portion of your front suspension will be disassembled so this would be a good time to replace any worn parts (i.e. tie rod ends, ball joints, idler arm and any bushings) Replace bushings with polyurethane replacement parts. 3. Jack up vehicle as high as possible using jack stands for support at all times. 4. With vehicle safely off the ground remove front tires. It is advisable to disassemble on side at a time so that you can use the other side as a reference for re-assembly in the event you get side tracked. 5. Remove the brake caliper from the rotor (attached with 2 bolts inside the caliper or with press-in clips depending on the vehicle). Do not remove the brake line from the caliper unless you intend to bleed the brakes at this time. Set the caliper aside or tie it up to the frame rail. Avoid pinching the brake line. 6. Remove the tie rod from the spindle using the proper tools. Do not hit the tie rod itself or the nut on the threaded portion of the tie rod or it may cause damaged and need replacing. 7. Remove the anti-sway bar from the lower control arm. This would be a good time to replace the end link bushings with polyurethane replacement bushings. 8. If your vehicle is equipped with anti-lock brakes you must now disconnect the front rotor sensor from the dust shield or spindle and set it aside. 9. Disconnect your shock absorber completely from the vehicle whether it is mounted inside the coil spring or not. 10. Support the lower control arm with jack just touching the arm. This will prevent it from dropping when the ball joint is disconnected. 11. The use of a coil spring compressor is recommended before the following steps are taken. 12. Disconnect the upper ball joint from the top of the spindle using the proper tools. Do not hit the ball joint or the threaded end of the ball joint. Once the ball joint is free the spindle should move easily. 13. Be careful when lowering the lower control arm. The coil spring is under high compression and may shoot out when released. Do not stand near the side of the truck during this step. Lower the jack so that the lower control arm swings down. If the coil spring has not fallen out on it’s own you may need to use a pry bar from the front of the vehicle to remove it. 14. Note which end of the coil spring is “bottom” for installation. Also note the depression in the lower control arm. It is important that the last winding of the coil spring fit into the indentation completely so that the vehicle will sit level. Do not switch coil springs from side to side as some vehicles have a specific “right” and “left” coil spring. 15. Check the coil spacer for proper fitment into the coil spring mount in the frame. The flat part of the spacer should face up and touch the top of the spring mount. Some vehicles have guiding tabs to center the coil spring in its top mount. These tabs may have become bent and need to be bent back to allow the spacer to properly fit in the mount. 16. Install the coil spring with the spacer on top of it. If used the coil spring compressor should still be on the spring in a compressed state. If it is not you may need to compress the spring before re-installing. Make sure the spacer is centered in the upper mount and the bottom of the spring is properly nested in the receptor groove on the lower control arm. If you are installing a two-inch or taller spacer you may need a spring compressor. Follow all safety rules when installing the coil spring as it will be under extreme compression. 17. Raise the lower control arm with a jack once the coil spring and spacer are properly lined up. Raise until the spindle is high enough to bolt on the upper ball joint. Before bolting on the upper ball joint make sure the brake caliper and brake line are where they need to be since some brake lines run inside the spindle and outside the coil spring. 18. With the upper ball joint tight and a cotter pin re-installed you may now remove the jack from under the lower control arm. 19. Assemble all of the components previously removed (sway bar with new polyurethane bushings, tie rod ends with polyurethane grease boot, brake caliper and anti-lock sensor). Don’t forget the shock with a new colored boot while it is off. 20. Repeat instructions for other side. 21. After properly installing both spacers you can install your front tires and lower vehicle back to the ground. 22. Your vehicle may sit too high at first because the suspension needs to settle. Carefully back the vehicle up and drive forward a few times using the brakes frequently. Park on level ground and check out your lift. 23. The vehicle will now require a front wheel alignment. Failure to do so may result in severe wear on your tires and may pull to one direction

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1991 Infiniti G20 AXLE SHAFTS – FRONT REMOVAL AND INSTALLATION MANUAL

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

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

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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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Ball Joint Spacers for IFS Suspension

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Filed Under (More Manuals) by admin on 20-12-2011

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1) Block rear wheels, place front end of truck on jack stands supported on the frame and remove the front wheels. 2) Remove the original upper ball joint hardware. 3) Knock the studs out of the ball joint with a small hammer. This is done most easily if the joint is pressed against the arm supported with a floor jack. 4) Remove the factory shock. 5) Trim the lip. An angle grinder with a cut-off wheel or a small reciprocating saw works well. Trim enough to allow installation of the spacer. 6) Put the spacer in place, NOTCH FACING DOWNWARD and, using a floor jack to control arm height, align the ball joint and install the hardware. The notch acts as a weep hole to let any water that gets in from above drain out to prevent the ball joint from rusting out. 7) Tighten ball joint hardware using the provided nylon lock nuts. 8) Install new extended length shock. 9) Repeat for other side. 10) Re-install the wheels. 11) If the end of the upper control arm is too close to the tire at this point, there are a few options: • You can replace your wheels with a higher off-set. • You can add a 1/4″ wheel spacer to move the wheel/tire away from the suspension. 12) Put the vehicle back on the ground. 13) For low profile bump stops only: • Shim them approx. 1/2″ with some washers or use stock bump stops. • Failure to do so could result in damage to CV joints, shocks, or other components 14) Even with stock bump stops, you may experience some CV axle binding. • To check, let the suspension hang’ at full droop. • Rotate each CV axle shaft by hand and check for any binding at the CV joints. • If felt, several options to fix it are available: o Add some shims for the low profile bump stops. o Or install a front differential drop kit to lower the differential and thus lessen the CV joint angles.

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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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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2003-2007 Accord V6 Power Steering Moans or Whines Repair Manual

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Filed Under (Toyota Manuals) by admin on 02-06-2012

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SYMPTOM A moan or whine is heard when turning the steering wheel when the engine is cold. There may be air bubbles or foam in the power steering reservoir. The noise usually goes away when the engine warms up. PROBABLE CAUSE Air enters the power steering pump through the inlet joint O-ring. CORRECTIVE ACTION Replace the O-ring on the power steering pump inlet joint. PARTS INFORMATION O-ring: P/N 91345-RDA-A01, H/C 8811010 REQUIRED MATERIALS Honda Genuine Power Steering Fluid: P/N 08206-9002, H/C 3747284 (One container repairs about 12 vehicles.) WARRANTY CLAIM INFORMATION In warranty: The normal warranty applies. Operation Number: 5121B5 Flat Rate Time: 0.3 hour Failed Part: P/N 91345-PAA-A01 H/C 5430681 Defect Code: 07408 Symptom Code: 04201 Template ID: 07-086A Skill Level: Repair Technician Out of warranty: Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work. REPAIR PROCEDURE 1. Remove the bolt holding the inlet joint to the power steering pump housing. 2. Place a shop towel under the inlet joint. 3. Twist the inlet joint back and forth until it is loose, then carefully disconnect the joint and point the hose upward to minimize fluid loss. 4. Remove the inlet joint O-ring. 5. Apply power steering fluid to a new O-ring, and install it on the inlet joint. 6. Install the inlet joint, and torque its bolt to 11 N. m (8 lb-ft). 7. Top off the power steering fluid, if needed. Start the engine, and let it idle. Confirm that the noise is gone and that the system is operating properly

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2006-2009 Dodge Ram 1500 4×4 Installation Instructions

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

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2006-2009 Dodge Ram 1500 4×4 1. Jack the truck up and support with jack stands. 2. Remove the wheels 3. Remove the sway bar link from below the control arm, remove the tie rod end, and the upper ball joint. 4. Remove the strut 5. Install the leveling kit on the strut 6. Reinstall the strut into the truck 8. Re-attach the tie rod end before the upper ball joint. 9. Using a floor jack, apply pressure to the lower ball joint and reattach the upper ball joint Align and adjust headlights

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