General maintenance practices are given in this section. All special tools and torque values are noted at the point of use and all required parts or materials can be found in the appropriate sections of your service manual.

 

Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Don’t just do the job – do the job safely.

 

 

 

Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel, and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air. Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation.

 

 

If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, filters and covers are used in this vehicle to keep out environmental dirt and dust. These items must be kept in good condition to ensure satisfactory operation. Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed. Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris.

 

 

Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when finished. Be sure that everything is done. Operate the vehicle to perform any final check or adjustments. If all is correct, the vehicle is ready to go back to the customer.

 

 

 

To check the torque on a fastener that has a lock patch:

 

1. Set the torque wrench for the lowest setting in the specified torque range.

2. Attempt to tighten fastener to set torque. If fastener does not move and lowest setting is satisfied (torque wrench clicks), then the proper torque has been maintained.

 

 

 

 

Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding specified torque. Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable tap or die. Replace all damaged or missing lubrication fittings. Use Teflon tape on pipe fitting threads.

 

 

Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specifications.

 

 

Replace broken or defective instruments and gauges. Replace dials and glass that are so scratched or discolored that reading is difficult.

 

 

Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. Wash bearings in a non-flammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again. Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings. 

 

Coat bearings with clean oil. Wrap bearings in clean paper. Be sure that the chamfered side of the bearing always faces the shoulder (when bearings installed against shoulders). Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part. Always use the proper tools and fixtures for removing and installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary.

 

 

Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out bushings that must be replaced. When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, flat end. Never use a hammer to drive bushings. Inspect the bushing and the mated part for oil holes. Be sure all oil holes are properly aligned.

 

 

Always discard gaskets after removal. Replace with new gaskets. Never use the same gasket twice. Be sure that gasket holes match up with holes in the mating part. If a gasket must be made, be sure to cut holes that match up with the mating part. Serious vehicle damage can occur if any flange holes are blocked by the gasket. Use material that is the right type and thickness.

 

 

Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applications. Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement. Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings. Always discard seals after removal. Do not use the same seal twice.

 

 

Always discard O-rings after removal. Replace with new Orings. To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation.

 

 

Always check gears for damaged or worn teeth. Remove burrs and rough spots with a honing stone or crocus cloth before installation. Lubricate mating surfaces before pressing gears on shafts.

 

 

If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force. Shafts fitted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly. Clean all rust from the machined surfaces of new parts.

 

 

Always replace worn or damaged parts with new parts.

 

 

 

Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof barrier material. Remove the rubber part if it cannot be properly protected.

 

 

Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before repainting.

 

 

Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing crocus cloth on highly polished parts that are rusted.

 

 

Remove shields and seals from bearings before cleaning. Clean bearings with permanent shields and seals in solution. Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine. Let bearings stand and dry. Do not dry using compressed air. Do not spin bearings while they are drying.