Repair 7

The GM and Hydra-Matic made TH400 is an automatic transmission. Also erred to as the "Turbo 400," the TH400 is considered very durable and of high quality, according to the auto experts at Novak-Adapt.com.

History

The TH400 started out in 1964 when it was used in Buicks and Cadillacs. After a few years in cars, GM began putting the Turbo 400 in trucks in the 1970s. In 1990 GM changed the name to the 3L80, though the transmission is still being used in GMs heavy-duty vehicles and in military applications.

Specifications

The TH400 weighs 135 lbs and is 24.37 inches long. Encased in smooth cast aluminum casing, the Turbo 400 is GMs largest automatic transmission and features a 3.48, 1.48 and one gearing.

Variations

GM created two alternate variations of the TH400. The TH475 was used in GMs most heavy-duty trucks starting in 1971. The TH375, used between 1972 and 1976, was used in cars with small displacement.

Potential

According to Novak-Adapt, the Turbo 400 is a popular transmission often used in Jeep conversions. Theyve also been used in GM vehicles, Rolls-Royces, Jaguars and even Ferrari models.

The EGR sensor is an automotive engine component designed to work with an exhaust gas recirculation system. Exhaust gas recirculation systems are part of many newer makes of automobiles, which must comply to more stringent environmental standards. The EGR sensor detects temperature and oxygen levels and determines whether the system is functioning properly.

Benefits

An EGR system offers two primary benefits to an automobile engine. The primary benefit is a reduced level of environmentally damaging emissions. The second benefit is a more efficient use of fuel, leading to better energy efficiency and more thorough combustion.

How EGR Systems Improve Engine Systems

An automotive engine without an EGR system releases gaseous emissions with hydrocarbon waste that has not been fully consumed by the combustion process. An EGR system recycles this partially combusted waste gas back into the combustion system to be used a second time for an overall cleaner emission.

EGR Sensor Warning

An EGR sensor fault warning on the vehicles indicator panel can indicate either that the sensor itself is damaged or that the exhaust gas recirculation system is not functioning within factory designated parameters. The best way to tell the difference between the two potential problems is to take the vehicle in for maintenance and have the sensor replaced.

Cars need to breathe. Too much or too little air will cause big problems for your engine. Make sure you know what a remanufactured air flow sensor is, how it helps your vehicle breathe and when you may need one.

Air Flow Sensor Basics

The air flow sensor (AFS) measures how much air enters the engine on vehicles that have an electronic fuel-injection system. The sensor allows the vehicle to let more or less air into the engine, which controls idle speed and acceleration.

Remanufactured Definition

A remanufactured part is different from a rebuilt part. When you rebuild a part, you only replace the broken pieces. When something is remanufactured, the entire piece, called the core, is taken apart. All pieces are then cleaned, repaired or replaced.

When Your AFS Fails

If your vehicle begins to stall, misfire or accelerate slowly or not at all, you might need to replace your AFS. In this case, a remanufactured sensor will cost less than a new one. Have your vehicle checked by a certified mechanic before buying or trying to replace it yourself.

For 2000 Ford F-250 trucks, the horns are mounted behind the radiator grille. Removing the horns requires detaching one retaining bolt. An electrical connector also links the horns themselves to the horn pad inside the vehicle.

Replacement

Generally, car horns are not off-the-shelf items. To obtain a replacement, a F-250 owner would need to order through a dealership or an online retailer. The mechanical replacement process should only take a few minutes. Once the F-250s hood is opened, the horn can be located behind the grille. After the wiring is disconnected, only one bolt needs removal.

The Steering Wheel

The F-250s horn can be sounded by pressing a component on the steering wheel. The horn also has components within the steering wheel, and getting to them requires partially dismantling the steering wheel itself. The horns electrical connections and wiring are near the airbag module. For reasons of safety, the F-250s airbag system should be disarmed before attempting to dismantle the steering wheel.

Disarming the Air Bags

Disarming the F-250s air bag system requires opening the trucks hood. Remove the negative cable from the batterys negative terminal. Then, remove the positive cable from the positive terminal. Wait five minutes or more. The F-250 will have residual power within the vehicle. It needs to drain out or the air bags could still deploy.

The orifice tube on a Ford truck is a hard debris filter for the air conditioning system. If a component in the system fails, the orifice tube prevents the debris from the failure from spreading throughout the system.

Location

The orifice tube resides in the liquid line between the receiver/dryer and the evaporator. The liquid line brings rigerant into the evaporator, the component that removes heat from the air in the passenger compartment.

Purpose

The rigerant flows through the AC system, outward from the AC compressor, through the manifold hose, condenser, receiver/dryer and evaporator before returning to the compressor.

Purpose

When performing a full AC system inspection, after evacuating the system with a rigerant service machine, remove the orifice tube and visually inspect it. If you note any signs of debris in the line, the AC compressor is most likely coming apart inside and requires replacement.

Torx-heads screws are used in auto manufacturing and machinery because they provide the best grip for application and removal. Reverse torx are less common but are also used in automotive manufacturing.

Tightening & Loosening

Reverse torx bolts are particularly capable of handling torque. The deep-set grooves prevent slippage and stripping often encountered with flat-head or Phillips-head screws. Increased torque means that screws and bolts will hold tighter in locations with high tension and strong vibrations.

Setting the Bolt

Anyone who works on cars knows the difficulty of threading a bolt or screw in a hard-to-reach place. Torx are designed to be easier to start because they do not move on the end of the ratchet or wrench when held up to a thread. This is also a result of the deep notches.

Common Uses

The most common use of torx bolts requiring a female bit is as a wheel lock on American automobiles. Typically one of the lug nuts on each wheel is replaced with a torx bolt to prevent thieves from removing the wheel easily.

The exhaust gas recirculation (EGR) system is used in car engines to reduce exhaust emissions. Though EGR problems are often blamed on the EGR valve, its the tube that can become clogged and will require cleaning.

How It Works

The EGR system works by allowing a small amount of exhaust to return to the combustion chamber. The gases cause a reduction in ignition temperature, which prevents the formation of NOx and other pollutants. The EGR system uses a valve that opens and closes to maintain the proper temperature.

Components

The primary component of the EGR system is the valve. Valves can be controlled either by vacuum pressure or electronics. When the gas is needed to cool combustion, the valve is opened. The exhaust gases move through the open valve and pass through a small tube or channel back to the intake manifold.

Tube Cleaning

The exhaust gases often carry small particles. These particles can become deposited inside the EGR valve or tube and clog the system causing it to fail. EGR tube cleaning simply ers to the process of cleaning this sediment from the tube. Most sediment will accumulate in the tube near the valve and can be removed with a small wire. Larger deposits will require the manifold to be removed for cleaning.

A wide variety of Ford vehicles come with a program, controlled by the vehicles computer, whose function is to reduce the vehicle to minimal performance standards, in the case of a vehicle component being at risk of failure. This programs informal name is a "limp mode."

Benefits

Limp mode engages when a vehicle sensor indicates that a vital component is not working properly. By modifying the vehicles acceleration and shifting capabilities, limp mode allows drivers to navigate their Ford vehicles home, or to a nearby service station. By allowing the vehicle to continue with limited operation capability, limp mode helps eliminate the cost of towing and dangers of roadside breakdowns.

Solutions

Once a Ford vehicle has begun to operate in limp mode, a driver can rectify its malfunction by taking the vehicle to a mechanic who has the ability to plug into the vehicles diagnostic port and read any problem codes put out by the vehicles computer. After diagnosing the issue and repairing the vehicle, the mechanic will be able to reset the limp mode program.

Warning

Ford vehicles operating in limp mode will not perform according to their normal standards and will be slow to accelerate and maintain speed. Use caution while driving a vehicle in limp mode to avoid causing a traffic hazard and seek assistance to remedy the vehicles performance problems as soon as possible.

Made of steel, a ball joint acts as a pivot between a car or trucks suspension and its tires. Vehicle manufacturers developed them for specific models, so theyre not interchangeable.

Function

Ball joints support the weight of the truck and, in some cases, also help set its alignment. Located on the front end of the truck, a ball joint stays inside a steel casing to prevent dirt and water from reaching it.

Types

Some trucks contain an upper and lower ball joint. Others use a MacPherson strut system, which has a lower ball joint and an upper strut bearing. With this system, the upper strut bearing acts as the pivot, making an upper ball joint unnecessary.

Maintenance

When inspecting a trucks suspension, the owner or mechanic should also check the ball joints. If the truck doesnt have its original joints, they will require lubrication regularly, as the original seal is broken. Worn out joints can cause uneven wear on tires and steering problems.

The Jeep is an all-purpose off-road vehicle. There are several reasons why a Jeep could stall and not start back up. You may have a bad battery or a bad starter. You can troubleshoot to find out what is wrong with your Jeep and try to get it up and running before resorting to a mechanic.

Instructions

Battery

1

Turn the ignition and turn on your headlights.

2

Get out of the Jeep and look to see if your headlights come on.

3

Open your hood if the lights do not come on.

4

Look over your battery for any corrosion. Use a screwdriver to scrape the corrosion off the battery. Use caution when doing this. Battery acid can harm your skin and clothes.

5

Tighten the connections from your battery to the terminals. Turn your Jeep back on.

Jump Start

6

Get another vehicle and pop the hoods on your Jeep and the other vehicle.

7

Connect the red end of your jumper wires to the red connection on your Jeep. Connect the other red end to the red connection on the other car.

8

Connect the two back ends to the black connections on the cars.

9

Turn the other car on.

10

Start your Jeep and let it run for at least 5 minutes to give the battery a good charge.

Starter

11

Pop the hood on your Jeep and follow the red cable coming from your battery to the starter. This is shaped like a soda can but larger.

12

Use a screwdriver to connect the two poles on the starter. Lay the screwdriver across the two poles to form a circuit.

13

Listen for the starter to let off a sound. If you hear the starter run then the starter is OK. If it is not running, you need to replace the starter.

14

Make sure the connection from the starter to the battery is complete. Tighten the connection if needed.

15

Test the alternator at an auto parts store if the starter is working but the Jeep still will not turn on.

The Chrysler transmission bump shift describes a condition when Chrysler transmissions shift harshly from one gear to another when downshifting, for example, from fourth to third or third to second gear. It may be simple to fix or require extensive work.

Causes

In some cases, the wrong type of transmission fluid can cause Chrysler transmissions to bump shift. In other cases, it may be a computer malfunction or a problem with the underdrive clutch.

Fluid Replacement

Changing transmission fluid to one of Chryslers recommended types may be enough to solve some bump shift problems. Sometimes, however, the fluid is only a part of the problem and a more complicated fix is required.

Retraining

Sometimes, Chrysler transmissions with bump shift problems need to have the computer retrained to correctly recalibrate the shift points. This requires disconnecting the battery to erase the computers memory and then repeatedly driving the vehicle with steady throttle position as it accelerates through all four gears, then performing kickdowns -- downshifts caused by pushing the accelerator to the floor -- to help the transmission relearn the correct shift points.

Rebuilding

When the bump shifts in a Chrysler transmission are the result of a problem with the underdrive clutch, changing the transmission fluid or retraining the transmission will not alleviate the problem. In this case, rebuilding the transmission is required.

Finding a Toyota thermostat depends on the year and the engine motor you are dealing with. However, there are a few standard guidelines to follow when locating and servicing the thermostat.

Follow the Flow

Follow the upper radiator hose from the top of the radiator. Where the hose ends and clamps on is called the thermostat housing. This housing will be either on the intake manifold or the engine block.

Housing Removal

Sometimes in newer Toyotas this housing in under a plastic engine cover. This cover is easily removed, as it is held on by either a couple of bolts or a couple plastic clips. Once removed, the thermostat housing will be visible. Remove the radiator cap and unclamp the upper hose from the thermostat housing. This housing is held in place by two or three bolts.

The Thermostat

Once the housing is removed, the thermostat will be revealed. It should pull out easily at this point. Thermostats have either a rubber O-ring or a fiber gasket to keep the housing from leaking. Be sure to replace this gasket if the thermostat if replacing the device.

A cars power steering depends on a constantly-moving belt to supply it with power. This belt, also known as a serpentine belt, typically supplies power to several other components as well.

Description

The power steering or serpentine belt consists of flexible synthetic material with a flat outer side and a grooved or ribbed inner side. This belt winds through a series of pulleys, with a device called a tensioner maintaining a precise amount of stress on the belt at all times, according to 2 Car Pros.

Function

The belt conveys power to various important engine components, including the power steering system, water pump, air conditioner compressor and alternator. Some cars, mostly older models, divide these tasks between two or more belts, according to Samarins.

Potential Problems

Power steering belts tend to fray and weaken through years of constant use. If this belt breaks the power steering will fail; any other parts the belt powers will also stop working. AA1 Car recommends inspecting belts at regular service intervals and replacing worn ones as needed.

Vehicle engine problems can be extremely costly. But, instead of scrapping the car, many options are available for repairing or replacing the engine, including the use of a rebuilt engine core.

Identification

When an engine is replaced with one urbished by the dealers manufacturer, normally the original damaged engine is returned to the factory for analyzing and possible urbishment, erred to as an engine core or rebuilt engine core.

Causes

Engines can fail for a variety of reasons. For these reasons, manufacturers keep rebuilt engine cores available to serve their customer base so that if a replacement is needed, a more expensive new engine isnt the only purchase option. Key failure points of an engine are due to age, overheating issues and inadequate maintenance or lubrication.

Significance

Using rebuilt engine cores has helped keep people in their vehicles longer, saving them money and avoiding the need to scrap them. A typical cost of a core, between $2,250 and $4,000 (as of 2010), is much less than purchasing a new car outright.

Fuel tanks have built-in mechanisms to control the flow of gas and gas vapors into the engine. One such assembly is the fuel module assembly, which helps prevent vapors from escaping into the atmosphere as well as pumping fuel where it belongs.

Fuel System

The gas tank module assembly aids in the hard acceleration of vehicles and filters out junk that can clog up the carburetor. In the book "Classroom Manual for Automotive Fuels and Emissions," author Barry Hollembeak writes, "The fuel pump module assembly incorporates the fuel pump, fuel filter, fuel gauge sending unit, and fuel temperature sensor (if used) in a single assembly."

Gas Tank Pickup Tube

The fuel tank pickup tube isnt always a part of the module assembly. When it is, it is attached by a fuel line. Its job is to pick up dirt, grime, rust and water before they clog up the fuel tank filter, causing the car to sputter along.

Liquid Vapor Separator

Inside of the tank are liquid vapor separators that also stop liquid fuel from invading the engine crankcase. It also stops liquid fuel from entering the area in which fuel vapors are stored. Fuel vapors are ignited, causing the combustion that actually powers the car.

A tune up ers to preventive maintenance that focuses on the cars engine. At the most basic level, a tuneup is replacing specific parts in a specific time frame.

What is a tune up?

A tune up will always replace: spark plugs, fuel filter, spark plug wires, ignition rotor and distributor cap (if the car is so equipped). Additionally, the throttle bore and throttle plate should be cleaned and adjusted. Performing this maintenance keeps clean air and fuel moving into the engine, in addition to ensuring that the spark plugs ignite the fuel at optimal levels.

When do I perform a tune up?

It depends on how your car is equipped. Platinum tipped spark plugs can last up to 100,000 miles. Cheaper plugs may last only 30,000 miles.

Can I do this myself?

There are many guide books and websites that can teach you to perform your own tune ups. A tune up is about as simple as modern car maintenance can get. A tune up is also fairly cheap to have done at a reputable auto shop. Doing your own tune up depends on your individual comfort level.

A catalytic converter greatly reduces the amount of emissions that your vehicle produces. However, when this part has gone bad it can mean trouble for your vehicle as well as the environment. Certain clues will help you determine whether your catalytic converter is failing.

Driveability

Your ability to drive your vehicle normally will be affected if the catalytic converter is bad. The speed and the power of a vehicle will fall below their normal performance levels. If your vehicle starts to have trouble with stalling, this could be a sign of bad catalytic converter.

Emissions

A rise in vehicle hydrocarbons and carbon monoxide emissions is a sure sign that a catalytic converter has gone bad. An exhaust analyzer, which costs $3,000 to $5,000, can inform you whether the converter is bad by reading the emissions levels as they exit the exhaust pipe.

Exhaust

The color of the smoke coming from your exhaust is another way to determine whether a catalytic converter is bad. Blue smoke indicates that the converter might be contaminated with phosphorus, which is found in motor oil. White smoke usually indicates that coolant is leaking internally.

Sophisticated computers that continuously adjust critical engine parameters control almost all modern car and truck engines. The crankshaft sensor is one of the numerous sensors that feed information to the computer.

Function

The crankshaft sensor sends information to the engine computer about the precise position and speed of the crankshaft. Because the crankshaft is attached to the pistons, information about its position allows the computer to determine the relative positions of all critical engine components, including pistons, belts and valves. This makes it possible to time the injection of fuel and the spark plug ignition for optimum performance and fuel economy.

Principle of Action

The crankshaft sensor consists of a metal disk positioned on the crankshaft and a detector that covers a magnetic coil. The metal disks movement past the coil causes a disturbance in the magnetic field, creating a stream of electric pulses that the computer uses to determine the speed and position of the crankshaft. The sensor does not produce direct data about the location and speed of the crankshaft; it sends raw data to the engine computer, which then calculates the desired values.

Malfunction

A malfunctioning crankshaft sensor can cause various disturbances including extended crank time during start-up, rough running, bucking, compromised fuel economy and stalling. If your vehicle is equipped with an on-board diagnostic computer, a malfunction of the crankshaft sensor will trigger an error code to inform you about the problem.

Your catalytic converter is the part of your vehicles exhaust system designed to reduce the amount of toxic emissions of gases that leave your car and enter into the environment. Because of increasing concerns about pollution, catalytic converters are among the most heavily legally regulated parts of your vehicle. It is illegal to modify or alter your catalytic converter in any way, so the only way to legally repair your clogged catalytic converter is to have an exhaust shop or certified mechanic replace it.

Instructions

1

Take your car to mechanics shop that specializes in exhaust problems and repairs. Have a certified professional mechanic evaluate your vehicles problem and determine definitively that its the catalytic converter causing it. The mechanic is not allowed to replace the catalytic converter unless he is able to thoroughly document a problem with it. No individual or mechanic is legally allowed to tamper with the converters mechanical workings in any way, theore the converter must be replaced. If your car has failed emissions test or state inspection, you should keep the documentation related to that as proof that there is a problem with the catalytic converter.

2

Determine if your car is still covered by the federally mandated catalytic converter warranty. This means if your car is less than eight years old or has fewer than 80,000 miles on it, the original manufacturer is responsible for replacing the catalytic converter free of cost. In this case, you should take all the documentation of the problem to your local dealers parts and service department and have them replace the catalytic converter free of charge under the warranty.

3

Have mechanic replace catalytic converter with an identical model. Youre not allowed to alter the design or change models from the original manufacturer installed catalytic converter. Once the converter has been installed, make sure your mechanic correctly fills out and submits the federally required warranty card. Keep all documentation for catalytic converter in case a problem arises later during emissions testing.

The 1999 Ford F-250 is a diesel truck that many people use to haul heavy items with good fuel economy. If your F-250 is having a hard time starting, there are a few things that you can do before you get it towed to a repair shop. You dont have to be a car mechanic to get your diesel working again. You can do it yourself with little hassle and minimal knowledge of truck repair.

Instructions

1

Insert your key into the F-250s ignition and then try to start the truck. Check the electrical panel on the dashboard. Look at the battery meter and the gas gauge on the dashboard. If your truck does not have enough gas to start, fill the tank with diesel.

2

Use the applicable fuel for the truck. If you are using winter diesel in the summer, you will need to change the fuel. Summer diesel should not be used in the winter. Use a siphon to pump the gas out of the trucks gas tank.

3

Insert one end of the hose into the gas tank. Insert the other end into an empty container. Pump the siphon hose to siphon the gas out of the tank and into the container. Fill the gas tank with the applicable diesel.

4

Check the battery connections to the battery if your gauge indicated that there was a low charge. Open the hood and locate the battery next to the engine. Make sure that the battery connections are properly connected to the terminals. The red cable should be on the positive (+) terminal and the black cable should be on the negative terminal (-). Use a pair of channel locks to secure the connections.

5

Place the terminal leads of the voltmeter to your batterys connections. The diesel truck uses a 12-volt battery. You should get an 11 to 12 volt reading on the voltmeters display. If you dont get an 11 to 12 volt reading from the voltmeter, replace the battery.

6

Jack the front end of the truck up with a jack and then locate the small black box on the bottom of the engine. This is the starter. Have a friend turn the ignition and listen to the starter. If you hear buzzing or clicking coming from the starter, you need to have it replaced by a certified technician.