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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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2003 Ford F-Super Duty 250-550/ Excursion Rear Drive Axle/Differential/ Ford 10.50-Inch Ring Gear Installation Manual

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Filed Under (Ford Manuals) by admin on 30-06-2012

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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. 2003 F-Super Duty 250-550/Excursion Workshop Manual 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 Plat 2003 F-Super Duty 250-550/Excursion Workshop Manual 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. 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

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TOYOTA 87/ 8 ” LANDCRUISER FULL FLOATING INSTALLATION MANUAL

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

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Removing the Existing Differential 5 2.1 Vehicle Support Safely secure the vehicle on a hoist. We recommend supporting the vehicle on a chassis hoist to keep the differential area at a convenient working height and to leave the wheels and axles free to be rotated and removed. Once supported off the ground, release the parking brake and leave the vehicle in neutral. Chock the wheels if necessary. 2.2 Differential Fluid Drain Clean around the differential drain plug to prevent dirt from entering the differential. Position a fluid drain reservoir under the differential and loosen the differential drain plug. Completely drain all differential fluid. HINT : This is a good time to check for metal particles in your oil and in the bottom of the housing which may indicate a worn bearing or differential component. 2.3 Removal of the Axles and Differential Remove the axles according to your vehicle’s service manual. HINT : When removing the axles try not to damage the paper gaskets behind the axle flanges. Disconnect the drive shaft from the flange of the differential. Remove the third member from the differential housing. Refer to your vehicle’s service manual. IMPORTANT : Collision damage or heavy off-road use of your vehicle in the past may have resulted in some degree of bending in the axle. Any misalignment of the axle tubes may result in excessive wear and/or failure of your differential and axle shafts. ARB strongly recommends that you have your axle assembly inspected for concentricity and straightness before installing your Air Locker 2 Removing the Existing Differential 6 2.4 Marking the Bearing Caps Using a small pointed center punch, gently mark the bearing caps in a way that will enable you to know which cap is ‘LEFT’ and which cap is ‘RIGHT’, which way is ‘UP’ and which way is ‘DOWN’. (Fig. 1. ) Mark the right hand cap in a similar way. HINT : Many installers choose to make one punch mark on the left hand side of the left hand bearing cap and a similar mark on the housing at close proximity to the cap mark. The right hand side is then designated with two punch marks on the right hand side of the cap and two similar punch marks on the housing

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1997-2001 HONDA CR-V (4WD) Noise From the Rear Differential REPAIR PROCEDURE

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Filed Under (Honda Manuals) by admin on 06-01-2012

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REPAIR PROCEDURE 1. Drain and refill the rear differential with Dual Pump Fluid. 2. Check the tires for proper inflation (recommended cold inflation front and rear is 26 psi) and any variation in tire size or type. 3. Test-drive the vehicle in a parking lot. Make tight, low-speed turns. If the noise is eliminated, return the vehicle to the customer. If the noise is still present, go to step 4. 4. Remove the rear differential assembly (see page 15-16 of the 1997-01 CR-V Service Manual). 5. Remove the torque control differential case, then remove and discard the 30 mm shim and the clutch assembly (see steps 1 thru 10 on pages 15-20 thru 15-22 of the service manual). 6. Remove the thrust needle bearing, the oil pump driveshaft, and the oil pump body assembly (see steps 11 and 12 on page 15-22 of the service manual). 7. Install the new flow collar over the drive pinion shaft. Make sure the tabs of the flow collar align with the oil pump pin. 8. For 1997 models: Assemble the new oil pump (spring, O-rings, piston, and pump body assembly). 9. Align the rear oil pump grooves with the oil pump pin and the flow collar tabs, then install the oil pump body assembly on the differential carrier. 10. Tighten the oil pump body assembly bolts to 12 N·m (8.7 lb-ft). 11. Align the oil pump driveshaft tabs with the grooves of the front oil pump in the oil pump body assembly, then install the oil pump driveshaft. 12. Install the thrust needle bearing with the outer race facing up.

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2000 Dodge Dakota & Durango Power Windows ADJUSTMENTS

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

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ADJUSTMENTS WINDOWS Remove door trim panel. See DOOR TRIM PANEL under REMOVAL & INSTALLATION. Loosen bolts holding window to regulator. Raise window fully, seating window in frame. Tighten bolts. Install door trim panel. TROUBLE SHOOTING POWER WINDOWS On Dakota, inspect circuit breaker No. 20 (20-amp) in junction block. On Durango inspect circuit breaker No. 21 (25-amp) in junction block. On all models, junction block is located on left end of instrument panel. Inspect fuse No. 9 (40-amp on Dakota, 50-amp on Durango) in Power Distribution Center (PDC). PDC is located in left front corner of engine compartment. Inspect power window system ground circuit. See WIRING DIAGRAMS . SYSTEM TESTS ALL WINDOWS INOPERATIVE Dakota 1. Check circuit breaker for power window system. See TROUBLE SHOOTING . Replace circuit breaker as necessary. If circuit breaker is okay, go to next step. 2. Disconnect negative battery cable. Remove driver’s front power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. Check for continuity between ground and terminal No. 3 (Black wire) at driver power window switch wiring harness connector. If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between driver power window 2000 Dodge Durango 2000 ACCESSORIES & EQUIPMENT’ ‘Power Windows – Dakota & Durango 2000 Dodge Durango 2000 ACCESSORIES & EQUIPMENT’ ‘Power Windows – Dakota & Durango switch connector and ground. See WIRING DIAGRAMS . 3. Connect negative battery cable. Turn ignition on. Measure voltage between ground and terminal No. 5 (Tan wire) at driver’s power window switch wiring harness connector. If battery voltage is present, check driver power window switch. See POWER WINDOW SWITCH under COMPONENT TESTS. If battery voltage is not present, repair open Tan wire between driver power window switch connector and ignition switch. See WIRING DIAGRAMS . See POWER DISTRIBUTION article in WIRING DIAGRAMS. Durango 1. Check circuit breaker for power window system. See TROUBLE SHOOTING . Replace circuit breaker as necessary. If circuit breaker is okay, go to next step. 2. Disconnect negative battery cable. Remove driver’s front power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. 3. Check for continuity between ground and terminal No. 5 (Black wire) at driver’s power window switch wiring harness connector. If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between driver’s power window switch connector and ground. See WIRING DIAGRAMS . 4. Reconnect negative battery cable. Turn ignition on. Measure voltage between ground and terminal No. 4 (Tan wire) at driver’s power window switch wiring harness connector. If battery voltage is present, check driver’s power window switch. See POWER WINDOW SWITCH under COMPONENT TESTS. If battery voltage is not present, repair open Tan wire between driver power window switch connector and ignition switch. See WIRING DIAGRAMS . See POWER DISTRIBUTION article in WIRING DIAGRAMS. ONE WINDOW INOPERATIVE

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HONDA CR-V Moan or Groan From the Rear Differential REPAIR PROCEDURE

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Filed Under (Honda Manuals) by admin on 15-07-2012

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REPAIR PROCEDURE: 2002-04 MODELS 1. Replace the rear differential fluid: •Refer to page 15-13 of the 2002-04 CR-V Service Manual , or •Online, enter keywords REAR DIFF, and select Rear Differential Fluid Inspection and Replacement (4WD) from the list. 2. Raise the vehicle on a lift until all four wheels are completely off the ground and can rotate freely. 3. Start the engine, and let it idle until the radiator fan cycles on and off twice. 4. Burnish the rear differential clutches: Automatic transmission models – •Set the parking brake, and shift the transmission to D. Let the engine idle for 5 minutes. •With the shift lever in D, release the parking brake, keep the wheel speed at 10 mph, and let all four wheels rotate freely for 5 minutes. •Apply the brakes to stop the wheels, repeat the bulleted steps one more time, then go to step 5. Manual transmission models – •With the engine idling and the parking brake released, shift the transmission into 1st, release the clutch, and let the wheels rotate for 5 minutes. •Disengage the clutch, and apply the brakes to stop the wheels. Shift the transmission into reverse, release the clutch, and let the wheels rotate for 5 minutes. •Shift the transmission into neutral, then apply the brakes to stop the wheels. •Repeat the bulleted steps one more time, then go to step 5. 5. Shift the transmission to P (A/T) or neutral (M/T), and turn off the engine. 6. Let the rear differential cool for 10 minutes

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1999 Chevrolet Silverado The service engine soon light is on with trouble code P1416 present

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Filed Under (Chevrolet Manuals) by admin on 07-05-2012

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Tests/Procedures: 1. Use a scanner and command the air pump on with the engine running at idle. Check if the O2 sensors go lean. 2. If the O2 sensor does not go lean on one bank, see if the check valve at the exhaust manifold is stuck closed, not allowing air into the manifold. Potential Causes: Defective Check Valve Diagnostic Codes: P1416 Author: Christopher Pittman Average Reported Mileage: 85812 Confirmed Fix Summary Confirmed Fix 18 – Air Injection Reaction (AIR) Check Valve 1 – Air Injection Reaction (AIR) Check Valve, Air Injection Reaction (AIR) Pump Confirmed Fix Details Tech Reported Fix Details Confirmed Fix Lee Stroup Sr. November 15, 2007 2001 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * A.I.R. Check Valve – removed check valves, found one rusted closed, one restricted, replaced both valves. Moisture from exhaust seems to have rusted both valves. Air Injection Reaction (AIR) Check Valve Paul Puleo August 20, 2009 1999 Chevrolet Camaro, Z28 5.7L * Replaced Both Air Injection Reaction (AIR) Check Valves – bank 2 AIR check valve restrticted, bank 1 slightly restricted replaced both Air Injection Reaction (AIR) Check Valve SouthGate January 05, 2009 2000 Chevrolet Silverado 1500, 4.8L, Vin V, Eng Cfg V8 * Replaced Air Injection Reaction (AIR) Check Valve – replaced boht check valves. fix the code. Air Injection Reaction (AIR) Check Valve Dwight Heckman July 31, 2008 2000 Chevrolet Blazer, 4.3L * Check Valve – replacing the check valve and cleaning out the lines repaired the problem. Air Injection Reaction (AIR) Check Valve Nick Secchitano June 16, 2009 2000 Chevrolet Silverado 1500, 5.3L, Vin T, Eng Cfg V8 * Replaced Both Air Injection Reaction (AIR) Check Valves – Air injection check valves Air Injection Reaction (AIR) Check Valve Mark Bertelsen 1998 Chevrolet Camaro, Z28 5.7L * Replaced Air Injection Reaction (AIR) Check

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2004 Chevrolet Silverado 1500 WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) MANUAL

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Filed Under (Chevrolet Manuals) by admin on 27-06-2012

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WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Remove the rotor. Refer to Brake Rotor Replacement – Front in Disc Brakes. Fig. 62: View Of Retaining Bolts For Brake Hose And Wheel Speed Sensor Brackets Courtesy of GENERAL MOTORS CORP. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 2004 Chevrolet Silverado 1500 2004 SUSPENSION Front Suspension – Sierra & Silverado Fig. 63: Removing The Wheel Drive Shaft Nut Retaining Cover (4WD) Courtesy of GENERAL MOTORS CORP. 5. Remove the wheel drive shaft nut retaining cover. IMPORTANT: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Fig. 64: Removing Wheel Driveshaft Assembly Retaining Nut And Washer (4WD) Courtesy of GENERAL MOTORS CORP. 6. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent Fig. 65: Disengaging The Wheel Drive Shaft From The Wheel Hub And Bearing (4WD) Courtesy of GENERAL MOTORS CORP. 8. Remove the wheel hub and the 15-series bearing mounting bolts

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FORD 1983-1990 BRONCO II 1983-1995 RANGER 1991-1994 EXPLORER 4X4 system diagnosis can be difficult at times due to system complexities

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Filed Under (Ford Manuals) by admin on 19-06-2011

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HUBLOCK DIAGNOSTICS torque. As this torque attempts to turn the other axle shaft through the differential gears, that WHEEL END CONTAMINATION: shaft’s hublock will attempt to engage which will •All compact vehicle hublocks have an O-ring seal result in a ratcheting or buzzing noise. between the hublock and wheel hub to prevent •This type of noise concern is usually found on contamination. Whenever the hublock is removed, axles that have incorrect front axle differential the O-ring seal should be checked for damage. lubricant or very few 4X4 miles on them. •If contamination is found in the wheel end, the •Verify that the front axle differential lubricant is path must be determined and corrected. Path F1TZ-19580-A. If incorrect lubricant is detected, possibilities are through the hublock seal, the extract the old lubricant using a suction gun. wheel bearing seals or the axle spindle seals. NOTE BREAKING THE CARRIER SEAL IS NOT A RECOMMENDED METHOD OF EXTRACTING THE LUBRICANT. 1. Refill the front axle with 56 oz (1.66 L) of lubricant F1TZ-19580-A using a suction gun. 2. As the front axle accumulates 100-200 miles (161-322 km) of locked hublock operation, the axle will break-in, thus reducing the amount of differential motoring torque significantly. 3. If a front axle requires breaking in, refer to the Front Axle Break-In Procedure in this article

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1986-1995 TOYOTA 4-5″ KIT FRONT INSTALLATION INSTRUCTIONS

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Filed Under (Toyota Manuals) by admin on 14-05-2011

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1. Chock the rear tires and lift the front of the truck with a floor jack. Place jack stands under the frame rails . Lower the vehicle on the jack stands. Never work under an unsupported vehicle. 2. Remove the tires and wheels. 3. Remove the stock shock absorbers using a 21 & 22 wrench. 4. Remove the brake caliper bolts from the knuckle using a 17mm wrench and secure out of way. Do not let the brake caliper hang by the brake line. Doing so could cause damage to the brake line. 5. Remove sway bar from the frame rail using a 12mm wrench and from the factory lower control arm using a 14mm wrench. See PHOTO 1 & 2 .Remove the front skid plate. (if equipped). 6. Remove the cotter pin on the tie rod and remove nut using a 19mm wrench. Strike the end of the knuckle to dislodge the tie rod. Retain the hardware for reuse 7. Remove the cotter pins from the upper and lower ball joint castle nuts and loosen the lower ball joint nuts using a 22mm wrench, but do not remove. Using a hammer, strike the knuckle as shown in PHOTO 3 & 4 to dislodge the ball joint on the upper and lower ball joints. PHOTO 1 PHOTO 2 8. Using a 17mm wrench remove the 6 nuts that secure the front half shaft to the differential. See PHOTO 5 . 9. Remove the tie rod mount from the knuckle by removing the two bolts as shown in PHOTO 6 .Using a 19mm wrench. 10. Remove the axle/knuckle assembly from the vehicle. PHOTO 3 PHOTO 4 PHOTO 5 PHOTO 6
11. Loosen and remove lower control arms using a 22mm & 24mm wrench as shown in PHOTO 7 & 8 . Retain the hardware for reuse. Remove the lower control arms from the vehicle. PHOTO 7 PHOTO 8 12. On the front cross-member, remove the 4 bolts securing the cross-member to the frame using a 17mm wrench as shown in PHOTO 9 . Retain hardware for reuse. 13. Remove the differential bolt as shown in PHOTO 10 using a 15mm wrench. Retain hardware for reuse. Remove the factory cross-member and retain for reuse. PHOTO 9 PHOTO 10 14. Remove driveshaft from the differential as shown in PHOTO 11 using a 13mm wrench. Retain hardware for reuse. Secure driveshaft out of harms way. PHOTO 12 15. Remove the two factory bump-stops from the frame using a 14mm wrench as shown in PHOTO 12 & 13. 16. Support the differential with a floor jack and remove the hardware on the drivers side as shown in PHOTO 14 using a 17mm wrench.

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