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Manuals and User Guides for Ford TRADER. We have
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Ford TRADER manual available for free PDF download: Workshop Manual
Ford TRADER Workshop Manual (906 pages)
truck
Brand:
Ford
| Category:
Automobile
| Size: 29.14 MB
Table of Contents
General Information
2
Table of Contents
2
Important Information
3
Basic Assumptions
3
Safety Risk
3
Warning on Lubricants and Greases
3
Possible Loss of Warranty
3
How to Use this Manual
4
Preparation
4
Repair Procedure
4
Symbols
5
Fundamental Procedures
5
Protection of the Vehicle
5
Notes, Cautions, and Warnings
5
A Word about Safety
6
Special Tools
6
Removal of Parts
6
Disassembly
6
Preparation of Tools and Measuring Equipment
6
Reassembly
7
Adjustments
8
Rubber Parts and Tubing
8
Jack and Safety Stand (Rigid Rack) Positions
9
Towing, Identification Number Locations
10
Units, Abbreviations
11
Electrical Troubleshooting Tools
12
Caution
12
Caution with Electrical Parts
13
Installation of a Mobile Two-Way Radio System
15
Pre-Delivery Inspetion and Scheduled Maintenance
16
Pre-Delivery Inspection Table
17
Scheduled Maintenance Services
18
Tightening of Exhaust Manifold
26
Inspection and Adjustment of Drive Belts
26
Replacement of Engine Oil
28
Replacement of Oil Bypass Filter
29
Inspection of Cooling System
29
Replacement of Engine Coolant
30
Replacement of Fuel Filter
31
Inspection of Air Cleaner Element
31
Inspection of Injection Timing
32
Inspection of Battery
37
Inspection of Clutch Pedal
40
Inspection of Vacuum Tank and Hoses
40
Inspection of Parking Brake Lever
41
Inspection of Kingpin Oil
44
Lubrication of Front Wheel Bearings
44
Inspection of Wheel Lug Unit
44
Engine
45
Index
46
HA Index
46
SL Engine
47
TF Engine
48
Outline, Troubleshooting Guide
49
Specifications
49
Engine Tune-Up Procedure
51
Preparation
51
Sst
51
Engine Oil Inspection
51
Engine Coolant
51
Drive Belt
52
Valve Clearance
53
Injection Timing
55
Idle Speed
59
Air Bleeding
60
Compression
62
Inspection
62
Preparation
62
Cylinder Head Gasket
63
On-Vehicle Maintenance
64
Front Oil Seal
64
Cylinder Head Gasket
65
Front Oil Seal
72
Rear Oil Seal
75
Removal
77
Preparation
77
Procedure
77
Fuel Hose
95
Parking Brake Cable
96
Tie-Rod
96
Engine Stand Mounting
100
HA,SL Engine
100
Procedure
100
Preparation
100
Disassembly
102
Cylinder Head
104
Cylinder Head Bolt
105
Valve Keeper
105
Valve Guide
105
Valve Seal
105
Combustion Chamber Insert
106
Cylinder Block (Internal Parts)
109
Flywheel
110
Front Oil Seal (HA)
114
Camshaft Gear and Friction Gear
115
Connecting Rod Cap
118
Connecting Rod
118
Piston Ring
118
Piston Pin
118
Main Bearing Cap
119
Crankshaft
119
Cylinder Liner
119
Inspection/Repair
120
Valve Mechanism
120
Cylinder Head
120
ROCKER ARM Assembly
123
Cylinder Block
124
Piston, Piston Ring, and Piston Pin
125
Connecting Rod
127
Crankshaft
128
Main Journal Diameter Undersize
129
Crankpin Journal Diameter Undersize
129
Main Bearing and Connecting Rod Bearing
129
Camshaft
129
Tappet
131
Oil Jet
131
Idler Gear
131
Assembly
132
Preparation
132
Torque Specifications
134
Cylinder Block
134
Oil Clearance
137
Piston and Connecting Rod
138
Side Clearance
140
End Plate (TF)
141
Timing Gear Case
142
Fuel Injection Pump
142
Crankshaft Timing Gear
142
Idler Gear
142
Oil Strainer and Oil Pipe
143
Oil Pan Upper Block
144
Oil Pan
144
Oil Pressure Switch
146
Oil Cooler
146
Water Pump
146
Timing Gear Train
147
Stiffening Plate
148
Oil Cooler, Oil Filter
151
Rear Oil Seal Cap
151
Water Inlet Pipe
151
Left Engine Mount
152
Clutch Disc and Clutch Cover
152
Crankshaft Pulley
152
Oil Filter Assembly
154
Injection Pump Oil Pipe
154
PCV Chamber
154
Combustion Chamber Insert (HA)
158
Fuel Filter Body
162
Injection Nozzle and Nozzle Holder
162
Injection Pump Oil Pipe (SL)
162
Valve, Valve Spring and Valve Spring Seat
164
Water Outlet Housing
166
Intake Manifold Assembly
166
Engine Stand Dismoiunting
169
Installation
171
Engine and Transmission Assembly
173
Clutch Release Cylinder
189
Steps after Installation
194
Lubrication System
195
Index
196
Oil Pressure
200
Preparation
200
Inspection
200
Engine Oil
201
Recommended SAE Viscosity
201
Replacement
201
Oil Filter, Oil Bypass Filter
202
Replacement
202
Oil Cooler
203
Removal J Installation
203
Oil Pan
205
Removal Installation
208
Oil Pump
208
Removal Iinstallation
208
Disassembly Iinspection Iassembly
209
Cooling System
213
Index
214
Troubleshooting Guide
217
Engine Coolant
218
Inspection
218
Radiator Cap
218
Preparation
218
Coolant Protection
219
Antifreeze Solution Mixture Percentage
219
Radiator Cap
220
Radiator Cap Valve
220
Negative Pressure Valve
220
Inspection
220
REMOVAL F INSTALLATION
221
Thermostat
222
Water Pump
223
Removal Iinstallation
223
Cooling Fan
223
Cooling Fan
224
Inspection
224
Removali Installation
224
Fuel and Emission Control Systems (HA Engine)
225
Intake Devices
226
Index
226
Exhaust Devices
227
Fuel Devices
228
System Diagram
229
Outline
229
TROUBLESHOOTING Guide
231
Engine Tune-Up
232
Basic Inspection
232
Preparation
232
Air Cleaner Element
233
Adjustment
233
Adjusting Injection Pump
234
Intake Air System
235
Components
235
Fuel System
237
Preparation
237
Fuel Tank
237
Injection Pump
238
Draining Water
240
Sedimentor Sensor (Detector)
240
Fuel Filter
241
Inspection of Priming Pump
241
Injection Nozzle
243
Leakage of Injector
244
Atomizing Condition
244
Checking Injection Nozzle
245
Accelerator Pedal, Accelerator Cable
246
Fuel Cut Control System
247
Fuel Cut Solemoid Valve
247
System Operation
247
Idle Speed Control System
248
Structural View
248
Idling Knob, Idling Cable
248
Exhaust System
250
Components
250
Fuel and Emission Control Systems (SL, SL Turbocharged Engine)
251
SL Turbocharged Engine
253
Exhaust Controlled Heating Devices
255
Exhaust Devices
256
Outline
257
Vacuum Hose Routing Diagram
261
TROUBLESHOOTING Guide
262
Engine Tune-Up
263
Basic Inspection
263
Adjustment
264
INTAKE AIR System
268
Fresh Air Duct
270
Intake Manifold
270
On-Vehicle Inspection
271
Turbocharger Boost Pressure
271
Wastegate
271
Preparation
271
Intercooler
277
Fuel System
279
Fuel Tank
279
Injection Pump
280
Sedimentor
284
Sedimentor Sensor (Detector)
284
Fuel Filter
285
Injection Nozzle
287
Accelerator Pedal, Accelerator Cable
290
Fuel Stop Cable
291
Fuel Cut Control System
291
System Operation
291
Idle Speed Control System
293
STRUCTURAL View
293
Idling Knob, Idling Cable
293
Exhaust System
295
Exhaust Controlled Heating System
296
STRUCTURAL View
296
Exhaust Brake Unit
297
Intake Shutter Valve Actuator
297
Solenoid Valve (for Intake Shutter Valve)
297
Exhaust Heating Switch
297
Clutch Switch
297
10. Neutral Switch
297
'12. Exhaust Brake Switch
297
Exhaust Heating Control Unit
298
Exhaust Brake Unit (Power Chamber)
299
Magnetic Valve
300
Intake Shutter Valve
301
Intake Shutter Valve Actuator
301
Exhaust Heating Switch
303
Accelerator Switch
303
Clutch Switch
304
Neutral Switch
304
Exhaust Brake Switch
305
Fuel and Emission Control System (TF Engine)
306
Intake and Fuel Devices
307
Exhaust and Exhaust Controlled Heating Devices
309
Sedimentor Sensor
327
Injection Starting Pressure
331
Engine Electrical System
350
Charging System
354
Alternator
355
Checking No-Load Adjustment Voltage
355
Checking Output
355
Brush Hoder Ans IC Regulator Assembly
357
Front Bearing
359
Rear Bearing
359
Starter
360
Field Coil
363
Brushes and Brush Holder
363
Replacing Brush
364
Brush Holder
364
Yoke
364
No-Load Test
364
Sub-Starter System
365
Installation Starting System
365
Air Heater System
366
Circuit Diagram
367
Water Thermosensor
370
Standard Resistance
370
Glow Indicator Lamp
370
Quick Start System (QSS)
371
Glow Plug Relay
374
Clutch
375
Clutch Fluid
378
Clutch Pedal Height
379
Assist Spring (Except Vacuum Power Assist)
381
Clutch Master Cylinder
382
Clutch Hose
383
Clutch Pedal Height and Free Play
384
Piston and Secondary Cup Assembly
386
Vacuum Power Assist
387
Function Check
387
Vacuum Loss Check
387
Vacuum Loss Check (Loaded Condition)
387
Overhaul
390
Clutch Unit
391
Clutch Cover and Disc
393
Pilot Bearing
394
Clutch Disc
394
Clutch Cover
395
Release Bearing
395
Manual Transmission (W5M-R)
397
Powerflow
404
Transmission
412
Ground Wire
412
Housing Components
413
Center Brake Drum
414
Ball Bearing
414
On-Vehicle Replacement
414
Sub-Transmission Parts
416
Output Shaft Bearing
417
Locknut
417
Mainshaft Bearing
420
Countershaft Assembly
421
Countershaft Front Bearing
421
Spacer
422
Countershaft Rear Bearing
422
Top Cover
423
Roll Pin
424
Interlock Pin
424
Each Gear and Main Drive Gear
424
Mainshaft
424
Countershaft
425
Shift Rod End and Change Lever
425
Inner Shift Lever and Shift Fork
425
Clutch Hub Assembly
425
Synchronizer Ring
426
Double Cone
426
Clutch Hub
427
Mounting Bolt
435
Adjustment Shim Thickness
435
Thrust Lock Washer
435
Main Drive Gear Bearing
436
Shift Mechanism
443
Manual Transmission (Z5M-R)
446
Top Cover Components
466
Shift Components
470
Clutch Hub Assembly (5Th/Reverse)
473
Countershaft Bearing
474
Selection Arm and Change Lever
476
Mainshaft Components
481
Sub-Transmission Components
485
Input Shaft
486
Bearing (Counter High Gear)
487
Adjustment Shim (Rear)
491
Adjustment Shim (Front)
491
Clip
493
Shift Cable Ball Joint
493
Shift Knob
493
Propeller Shaft
495
Sliding Joint
501
Snap Ring
501
Bearing Cup
501
Center Companion Flange
501
Propeller Shaft
501
Assembly Note
502
Propeller Shaft
502
Center Bearing Rubber
503
Lubrication
505
Front and Rear Axles
506
Wheel Hub, Steering Knuckle
510
Preinspection
510
Wheel Bearing Play
510
Preload Adjustment
510
Wheel Hub
511
Hub Nut
512
Hub Bolt
514
Bearing Outer Race
514
Oil Seal
514
Steering Knuckle
515
Brake Backing Plate
516
Kingpin Cap
516
Lock Pin
516
Kingpin Bushing and Kingpin Clearance
516
Kingpin Oil Level Gauge
518
Kingpin Bushing
519
Rear Axle
520
Brake Drum
522
Bearing Outer Race (Inner)
524
Differential
525
For W and y Type
525
For W Type
525
Differential Oil
528
Differential Assembly
532
Inspect for Damage and Wear of Splines
534
Differential Gear Assembly
535
Side Bearing Outer Race
535
Drive Pinion
536
Pilot Bearing Inner Race
536
Rear Bearing Inner Race
536
Pilot Bearing Outer Race
537
Front Bearing Outer Race
537
Rear Bearing Outer Race
537
Ring Gear
537
Gear Case
537
Adjustment of Pinion Height
538
Adjustment of Drive Pinion Preload
542
Companion Flange
542
Bearing Housing
543
Gear Case
543
Ring Gear
544
Side Bearing Inner Race
544
Adjusting Screw
544
Adjustment of Backlash
544
Inspection and Adjustment of Teeth Contact
545
Lock Plate
546
Steering System
547
Manual Steering
548
Power Steering
549
Boot
554
Tie-Rod End
555
Tie-Rod End Boot
555
Drag Link
555
Dust Seal
555
End Plug
556
Looseness or Play of Steering Wheel
557
Steering Wheel Play
557
Steering Wheel Effort
557
Steering Lock Assembly
560
Steering Shaft
560
Adjusting Plug
563
Worm Ball Nut Assembly
563
Gear Housing
564
Sector Shaft
564
Adjustment of Preload
566
Power Steering Fluid
570
Steering Wheel and Column
573
Pitman Arm Disassembly Note
575
Side Cover Disassembly Note
575
Sector Shaft Disassembly Note
575
Adjusting Plug Disassembly Note
575
Worm Ball Nut Assembly Disassembly Note
575
Gear Housing Disassembly Note
575
Sector Shaft, Side Cover
576
Valve Housing, Worm Ball Nut Assembly
577
Valve Housing
579
Hermetic Inspection
581
Measurement of the Backlash
582
Pitman Arm
582
Woodruff Key
587
Cam Ring
588
Rotor
588
Vane
588
Pressure Plate
588
Braking System
593
Lining and Drum Dimensions
596
Brake Hydraulic Line
599
Brake Fluid
600
Vacuum Line
601
Pedal-To-Floor Clearance
602
Master Cylinder
604
Stopper Screw
606
Secondary Piston Assembl
607
Power Brake Unit Function Check
607
Function Check (Method-Using Tester
608
Loaded Condition
608
Inspection of Check Valve
609
Front and Rear Shell Assembly
612
Rear Diaphragm Plate
612
Retainer (Center Plate)
612
Retainer (Front Diaphragm)
612
Assembly Note
612
Center Plate
613
Retainer (Rear Diaphram)
613
Stop Key
613
Vacuum Pump
614
Load-Sensing G-Valve (LSGV)
617
Front Brake (Drum)
619
Lining Thickness and Drum Inner Diameter
619
Brake Pipe
621
Brake Shoe
622
Wheel Cylinder
623
Rear Brake (Drum)
624
Parking Brake System
629
Center Brake
632
Center Brake Shoe
634
Wheels and Tires
635
Single Tire
636
Dual Tires
636
Tire Wear
638
Visual Inspection
639
Wheel Runout
639
Wheel Lug Nut
639
Abnormal Tire Wear
640
Tire Rotation
641
Wheel Balance Adjustment
642
Suspension
643
Front Suspension
644
Rear Suspension
645
Leaf Spring Dimensions
647
Front Leaf Spring
647
Rear Leaf Spring
647
Leaf Spring Applications
648
Wheel Alignment
650
Front Wheel Alignment
651
Camber/Caster/King-Pin Angle
651
Adjustment (Caster)
652
Total Toe-In
653
Front Suspension (Leaf Spring)
654
Front Shock Absorber
655
U-Bolt
657
Spring Pin and Shackle Pin
657
Shackle Pin Bushing
657
Spring Bushings (Front Side)
657
Sring Bushing (Rear Side)
658
Caster Wedge
658
Rear Suspension (Leaf Spring)
659
Rear Shock Absorber
660
Body
664
Exterior
667
Interior
669
Front Fender Panel
670
Front Door
671
Door Lock Striker
672
Front Window Regulator and Glass
673
Regulator Handle
674
Front Door Glass
674
Front Door Lock and Opener
675
Rear Door
676
Rear Window Regulator and Glass
678
Rear Window Regulator
679
Rear Window Glass
679
Rear Door Lock and Opener
680
Front Bumper
681
Rear Bumper
682
Radiator Grille/Front Grille
683
Step
684
Mirror
685
Windshield Wiper and Washer
686
Windshield Wiper Link Assembly
693
Washer Nozzle
694
Wiper Arm Height
695
Washer Spray
695
Wiper Motor
696
Wiper and Washer Switch
697
Intermittent Wiper Relay
697
Roof Ventilator
698
Windshield
699
Windshield and Weatherstrip
700
Back Window
701
Back Window and Weatherstrip
702
Tilt Lock System
703
Cabin Mount
705
Damper
705
Front Cabin Damper
705
Rear Cabin Mount
707
With Damper
707
Without Damper
711
Console
712
Instrument Panel
713
Heater Control Wire
715
MODE Wire
715
REC-FRESH Wire
715
MIX Wire
715
Seat
716
Front Seat
716
Rear Seat (Crew Cabin)
717
Driver Seat
718
Passenger Seat (with Seatback Tray)
719
Passenger Seat
720
Insulator
721
Rubber Seal
721
Seat Belt
722
Front Seat Belt
722
Rear Seat Belt
723
Clock
724
Floormat
725
Headliner
726
Except Crew Cabin
726
Crew Cabin
727
Trim
731
Underbody Dimensions
732
Body Electrical System
738
Relay, Fuse, Switch
739
Exterior Light, Interior Lamp
741
Instrument Cluster (Meter)
743
Others
744
Test Light
747
Jumper Wire
747
Voltmeter
747
Ohmmeter
747
Electrical Symbols
748
Switches and Relays
748
Other Electrical Symbols
748
Fuse
749
Main Fuse Block
749
Fuse Box
750
Fusible Link
750
Relay
751
Stoplight Checker Relay
752
Switches
753
Engine Switch
754
Combination Switch
755
Exterior Lighting System
757
Aiming
759
Headlights
760
Turn and Hazard Warning Light
762
Small Light Control System
765
Back-Up Light
767
Stoplight
769
Fog Light
771
Front Combination Light
774
Rer Combination Light
776
License Plate Light
778
Interior Lighting System
779
Interior Lamp
780
Warning System
784
Warning Lamp
785
Brake Warning Lamp
786
Alternator Warning Lamp
787
Oil Pressure Warning Lamp
788
Stoplight Warning Lamp
789
Sedimentor Warning Lamp
791
Vacuum Warning Lamp
793
Warning Buzzer
794
Warning and Indicator Lamp
795
Coolant Warning Unit
796
Coolant Level Sensor
799
Speedometer Does Not Operate or Indication Incorrect
802
Tachometer Does Not Operate
802
Water Temperature Gauge Does Not Operate
803
Fuel Gauge Does Not Operate
804
Tachometer
807
Speedometer
807
Fuel Gauge
807
Water Temperature Gauge
807
Fuel Gauge Sender Unit
808
Pickup Sensor
809
Horn
810
Backing Warning Horn
811
Audio
812
AM Radio
813
AM/FM Radio
814
Causes of Noise
823
FM Multi Path
823
Noise Suppression Chart
824
Audio Unit
825
Speaker
826
Instrument Panel Speaker
826
Door Speaker
826
Antenna Feeder
828
Air Conditioner System
829
Front Heater
835
Front Heater Unit
836
Front Blower Unit
838
Blower Motor
840
Resister Assembly
840
Heater Control Unit
841
Steering Wheel
842
Technical Data
845
General Models (RHO)
846
Measurements
846
Australia Models
846
Steering
858
Special Tools
864
Parts Index
874
Logical Symbols
882
Graphic Symbols
882
Ground Circuit
884
Electrical Wiring Schematic
885
Wiper & Washer
894
Heater
900
Common Connector List
903
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