1989-2000 Mazda T-Series (T3000 / T3500 / T4000) Service & Repair Manual

TRADER Workshop Manual

GENERAL INFORMATION IMPORTANT INFORMATION ..................... GI- 2 BASIC ASSUMPTIONS ............................ GI- 2 SAFETY RiSK ••.•.•••••••.•••••••••••••••.••••••••••• GI- 2 POSSIBLE LOSS OF WARRANTY •••••.••••••• GI- 2 WARNING ON LUBRICANTS AND GREASES .••••••••••••••••••••••••••••••••••• GI- 2 HOW TO USE THIS MANUAL .................... GI- 3 PREPARATION ...................................... GI- 3 REPAIR PROCEDURE •.••••••••••••.••••••.••••••. GI- 3 SyMBOLS ••••••••••••••••••••••••••••••••••••••••••••• GI- 4 NOTES, CAUTIONS, AND WARNINGS ••••••• GI- 4 FUNDAMENTAL PROCEDURES ............... GI- 4 PROTECTION OF THE VEHICLE ••••••.••••••• GI- 4 A WORD ABOUT SAFETY ....................... GI- 5 PREPARATION OF TOOLS AND MEASURING EQUIPMENT ••••••••••••. GI- 5 SPECIAL TOOLS •••••••••••••••••••••••••••••••••••• GI- 5 REMOVAL OF PARTS ••••••••••••••••••••••••••••• GI- 5 DISASSE M BL Y •••••••••••••••••••••••••••••••••••••• GI- 5 REASSEMBLy ••••••...•••••••••.•••.•••••••••••••••• GI- 6 ADJUSTMENTS .............. •••••••••••••••••••••• GI- 7 RUBBER PARTS AND TUBING •••••••••••••••• GI- 7 JACK AND SAFETY STAND (RIGID RACK) POSiTIONS •••••••••••••••••••••••••••••••••••••••••••• GI- 8 TOWiNG ..................... ............................. GI- 9 IDENTIFICATION NUMBER LOCATIONS ...... GI- 9 UNITS ......... ............................................ GI-10 ABBREViATIONS ..................... ................ GI-10 CAUTION ................................................ GI-11 ELECTRICAL TROUBLESHOOTING TOOLS GI-11 CAUTION WITH ELECTRICAL PARTS •••••••• INSTALLATION OF A MOBILE TWO-WAY RADIO SYSTEM ................................... GI-14 9TGGIX-OO' GI

GI IMPORTANT INFORMATION IMPORTANT INFORMATION BASIC ASSUMPTIONS This repair manual assumes that you have certain special tools that are necessary for the safe and efficient performance of service operations on Ford vehicles and that you know how to use them properly. It also assumes that you are familiar with automobile systems and basic service and repair procedures. You should not attempt to use this manual unless these assumptions are correct and you understand the consequences described below. SAFETY RISK This manual contains certain notes, warnings, and other precautionary information that you should carefully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper service that may damage the vehicle or render it unsafe. If there is no such information in regard to any specific service method, this does not mean there is no possibility that personal safety or vehicle safety will be jeopardized by the use of incorrect methods or tools. POSSIBLE LOSS OF WARRANTY The manufacturer's warranty on Ford vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Authorized Ford Dealer. WARNING ON LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service (e.g .• engine sump oils) are more irritating and more likely to cause serious effects. including skin cancer. in the event of gross and prolonged skin contact. Wash skin thoroughly after work involving oil. Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not use gasoline. paraffin, or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if nE?cessary. Particu- lar care should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil. Dry clean or launder such clothing at regular intervals. 9TFGIX·001 GI-2

HOW TO USE THIS MANUAL GI HOW TO USE THIS MANUAL PREPARATION PREPARATION points out the needed SST for the service operation that follows. It is best to gather all necessary SST before beginning work. Example: N TIE-ROD END BOOT AND STEERING GEAR BOOT SST NUMBER TIE·ROD END BOOT AND STEERING GEAR BOOT PREPARATION 49 0118 850C Puller. ball joint REPAIR PROCEDURE 49 H028 301 Installer. boot SST NAME SST ILLUSTRATION 9MUGIX-033 1. Most repair operations begin with an overview illustration. It identifies the components. shows how the parts fit together. and visual parts inspections. If a damaged or worn part is found, repair or replace it as necessary. 2. Expendable parts, tightening torques, and symbols' for oil, grease, and sealant are shown in the overview illustration. . 3. Pages related to service procedures are shown under the illustration. Refer to this information when ser- vicing the related part. Example: SHOWS EXPENDABLE PARTS SHOWS APPLICATION n-'07 (7.4-10.'. Sot-1IJ \ \ \\p"1 ./ SHOWS TIGHTENING TORQUE SPECIFICATION *2 POINT OF ETC. __ .,..--________ TIGHTENING TORQUE UNIT SHOWS RELATED PAGE FOR SERVICE 1.Bott 2. Lock plate 3. Beanng cup 4. Adjusting screw 5. Beanng outer race S.Locknut 7. Washer a.Com 1S. Bearing inner race ... I: tot· or «ICBIOn HOWS VISUAL InstallatIOn... . . ............ page 1.1-24 INSPECTION INFORMATION .. .......... page M-21 Inspect splines and teeth for wear or damage AdjUSlment of heIght. page M-22 Ad oe M- 9MUGIX·034 *1: The numbering (ex. G)) shows service procedure. *2: Units shown in N-m (m-kg, ft-Ib) unless otherwise specified. GI-3

G I HOW TO USE THIS MANUAUFUNDAMENTAL PROCEDURES SYMBOLS There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. Symbol Meaning Kind y Apply oil New engine oil or gear oil as appropriate " .. II Apply brake fluid Only brake fluid - Apply automatic transmission fluid Only ATF 1 Apply grease Appropriate grease ... Apply sealant Appropriate sealant • Apply petroleum jelly Appropriate petroleum jelly 05UGIX-OOS Note • When special oil or grease is needed, this is shown in the illustration. NOTES, CAUTIONS, AND WARNINGS As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS you should follow when you work on a vehicle.' GI-4 9MUGIX.Q36 FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats. and floor areas before starting work.

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1989-2000 Mazda T-Series (T3000 / T3500 / T4000) Service & Repair Manual

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