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.

FUNDAMENTAL PROCEDURES GI 9MUGIX·OO3 9MUGIX-038 'pp,_1.'" 47UOGX·005 47UOGX·OO6 9MUGIX·039 A WORD ABOUT SAFETY The fol/owing precautions must be followed when jacking up the vehicle. 1. Block the wheels. 2. Use only the specified jacking positions. 3. Support the vehicle with safety stands. Start the engine only after making certain the engine compart- ment is clear of tools and people. PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that al\ necessary tools and measuring equipment are available before starting any work. SPECIAL TOOLS Use special tools when they are required. REMOVAL OF PARTS While correcting a problem. try also to determine its cause. Begin work only after first learning which parts and subassem- blies must be removed and disassembled for replacement or repair. DISASSEMBLY If the disassembly procedure is complex. requiring many parts to be disassembled. all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently. GI-5

GI GI-6 FUNDAMENTAL PROCEDURES SMUGIX-040 47UOGX-010 SMUGIX-004 SMUGIX-042 1. Inspection of parts When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. 2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. 3. Cleaning parts for reuse All parts to be reused should be carefully and thorotJghly cleaned in the appropriate method. REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. Refer to STANDARD BOLT AND NUT TIGHTENING TORQUE in Section TD for tightening torques not mentioned in the main text. If removed, these parts should be replaced with new ones: 1. Oil seals 2. Gaskets 3. a-rings 4. Lock washers 5. Cotter pins 6. Nylon nuts Depending on location: 1. Sealant should be applied to gaskets. 2_ Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed. locations (such as oil seals) before reassembly.

FUNDAMENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and/or testers when making adjustments. 67UOGX·002 RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing. 9MUGIX-OOS GI-7

G I JACK AND SAFETY STAND (RIGID RACK) POSITIONS JACK AND SAFETY STAND (RIGID RACK) POSITIONS FRONT END Jack position: At the center of the front axle REAR END Jack position At the center of differential GI-8 9TFGIX.()()2 9TGGIX.()()6 Safety stand positions: On both sides of the front axle 9TGGIX.Q03 Safety stand positions Spring clamps at both sides of the differential 9TGG1X-007

TOWING, IDENTIFICATION NUMBER LOCATIONS GI 9TGGIX·008 REAR 9TGGIX·OO9 TOWING Proper towing equipment is necessary to prevent damage to the vehicle. Laws and regulations applicable to vehicles in tow must always be observed. If the transmission, rear axle and steering system are not damaged, the vehicle may be towed on all four wheels. If they are damaged, use a towing dolly. Caution • The gearshift lever must be set a NEUTRAL, the engine key in the "ACC" position and the parking brake released. Remember that power brake assist will not be available when the engine is inoperative. IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER (YIN) ENGINE MODEL AND NUMBER ENGINE NUMBER 9TGGIX-Ql0 GI-9

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

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