Repair 7

Welding hard steel, such as 4140 steel, is a complicated process that involves heating levels that are unusual to achieve in a home workshop. However, in the right shop, it is possible. You will need a good oven and good welding skills to accomplish this task, but as long as you have the right facilities, it will not be a complicated procedure. AISI ers to the American Iron and Steel Institute and its industry-accepted steel standards; AISI 4140 is a versatile alloy steel used in many industrial applications, including plating and shafts, and is easily weldable with traditional methods.

Instructions

1

Heat the damaged steel to about 1,250 degrees Fahrenheit.

2

Match weld material to 4140 metal, including a minimum of 1.25 percent manganese, 1.75 percent nickel, 0.3 percent chromium and 0.25 percent molybdemum. If repairing a crack, this filler metal should be lower in carbon than AISI 4140, which has up to 40 percent carbon content, to prevent development of a brittle layer called martensite and possible future cracks.

3

Use softer filler metal in building up a shaft for re-machining, followed by a harder layer. This buffer layer should be very low in carbon content to prevent carbon from leaching into the hard-facing layer, one of several specialized alloys, causing it to crack quickly. The hard-facing layer should be thin, as thicker layers will, counterintuitively, fail faster than thinner layers. Preheating, as mentioned above, is vital to prevent distortion and failure of the hard facing, which will lead to rapid erosion of the buffer layer.

4

Cool the steel very gradually by placing an insulated welding blanket over the bar or by burying it in sand. Rapid cooling will cause the layers to distort and spoil the job. The piece should not cool more than 150 degrees Fahrenheit per hour; for large parts, this may require a temperature-controlled furnace to cool the part precisely.

Volkswagen produced the first series of Transporters from 1949 to 1967. Also known as the Microbus or station wagon, Transporters utilize a water-cooled engine called a Wasserboxer. Wasser is the German word for water. The pistons oppose one another inside a flat engine and appear to "box." This lead to the term boxer. Vanagon is the third generation of Transporters.

About Vanagons

Volkswagen produced Vanagons from 1980 until 1991. The Vanagon featured body contours that were more square than previous models and large windows and windshield. From 1983 until 1985, Vanagons fuel injection system called Digijet analyzed the engines RPMs and temperature to determine the proper amount of fuel. Modifications to the Digijet system lead to the development of Digifant in 1986. The Vanagon website describes the Digifant system as a less "complicated version of the Bosch Motronic fuel injection used on BMWs and Porsches."

Recalls

According to Motor Trend, before purchasing a Vanagon, you should ensure the previous owner repaired all issues raised by recalls. Vanagons experienced re-occurring issues with the center air flow duct throughout its production. According to Motor Trend, the plastic duct is fastened by two mounting screws to the ceiling of the passenger compartment. It can crack, break, separate and strike passengers. Between 1980 and 1985, Volkswagen recalled and repaired slide-in camper latches, the defroster/defogger system, loose bolts on the front control arm/upper ball joint and door latches. An anchor problem on passenger seats led to a 1987 recall. The seat could break loose and injure the passenger. Possible leaks at the seam of the plastic casing around the in-line fuel filter, shrinkage of the fuel hose on the engines fuel distribution rail, deformation of the sending unit cover, an improperly-seated fuel tank filler neck pipe and stalling caused by high engine load and ambient temperatures lead to recalls. A transmission issue in 1987 resulted from improper welding. The pin in the shift-locking pawl can separate and make the shift lever immovable without pressing the safety-release button. When using cruise control, the accelerator cables tension allowed it to sag and possibly entangle with the water pipe bracket. When this happened, the cable was unable to return to the idle position.

Other Problems

According to the Repair Pal website, leaking O-rings and porous cylinder heads leak and cause overheating. Plastic cooling system components can fail abruptly. Coolant, oxygen and air flow sensor failures and excessive oil use are common. The transmission oil cooler fails and permits coolant to mix with transmission flood resulting in extensive automatic transmission damage. Noise and reverse gear failures are common in manual transmissions.

Power windows are useful and convenient options, and come standard on many vehicle models. Like any piece of machinery, power windows can encounter problems from time to time. Fortunately, many of these problems fall into several major categories, which are usually quite easy to solve. If you own a vehicle with power windows, you may want to make yourself aware of these problems, as this knowledge could save you time, effort, and money later.

Jamming

Jamming is probably the most common problem that crops up with power windows. Jamming is usually a result of problems with weatherstripping, gaskets, or channels. These parts of a power window assembly take a lot of abuse, both from mechanical use and weather. Sometimes, they can bunch up, break apart, or buckle, which will jam the power windows tracks. Sometimes, problems like this can be solved without taking the window apart, but simply spraying in silicon lube or compressed air and/or cleaning with water and a toothbrush. Other times, the door might need to be taken apart and a piece of the channel-liner glued in place.

Fuses

Overloaded fuses are another common problem with power windows. If you cant hear anything when you flip your power windows switch, this is probably the problem. In this case, you simply need to check the power window fuse and replace it. However, sometimes the fuse may blow because there is excessive drag somewhere on the track, so checking for this is a good idea as well.

Switches

Bad switches are a common problem with power windows. Often, switches will have dirty contact points. Sometimes, the power for all of the window switches throughout the vehicles will run through a master switch located at the drivers door, and should one switch up front get stuck in an "off" position, a switch somewhere else in the car could be affected. You can usually clean out the contacts with tuner cleaner and compressed air.

Switch Rocker

Sometimes the switch mechanism itself is fine, but the actual switch handle, called the switch rocker, doesnt work. This often happens with the drivers side switches, as they get by far the most use. While you usually have to buy an entire new switch assembly, it is quite easy to swap out one of the rear window switch rockers. You simply remove the panel and take the switch out.

Traffic accidents, floods, tinkering and dismantling are all ways that your car, a once-drivable on-road machine, could become a salvage vehicle according to Ohio standards. Auto insurance companies will appraise its value and determine whether to call the car a salvage or to put it back on the road. Once your vehicle is declared a salvaged vehicle, you must obtain a salvage title for it within 30 days. If you choose to repair it, you will need to reinstate the title before driving it on the road.

Instructions

Obtaining a Salvage Title

1

Locate the clerk of courts title office for your county and make an appointment.

2

Present your vehicles original title and the salvage certificate or document from the insurance company that states that the vehicle is a salvage vehicle.

3

Exchange the original title for the salvage title. A salvage title makes your car illegal to drive on any highway.

Rebuilt Salvage Title

4

Find the deputy registrars office for your county and ask for an inspection form for your salvaged vehicle.

5

Pay the titling fee and save the receipt, which you will have to show to the inspection facility.

6

Find a nearby inspection facility (see Resources) and make an appointment to have your vehicle inspected.

7

Present the receipts for all major components of the car that you have replaced. Bring the Ohio salvage title and the receipt and inspection form from the deputy registrars office.

8

Take the completed inspection form and Ohio salvage title to the clerk of courts title office in your county. Exchange the salvage title for an Ohio rebuilt salvage title, which makes the vehicle legal to drive on highways again.

Introduced in 1975, BMWs 3 Series is the German automakers best-selling vehicle and currently comes in seven different body styles. Although the 2005 330Ci updated several features lacking on the 2004 model, it suffers from several design and mechanical issues.

Rear Seat & Cargo Room

Cars.com indicated that the 330Ci regular-top and convertible models do not have ample room in the backseat. Taller passengers will not be able to stretch their legs. The 330Ci convertible also suffers from lack of rear cargo room. The 330Ci convertible may not be suitable if you need to transport larger amounts of cargo.

Rear Axle Problem

MSN Autos reports moderate issues with the 330Cis rear axle seals. Damaged rear axle seals can result in oil leakage. Cost to repair a rear axle seal is approximately $135 for parts and labor per rear wheel (as of 2011).

Engine

MSN Autos indicates that the 3-liter engine of the 330Ci suffers from both water pump and valve cover gasket issues. A faulty water pump can cause your cars cooling system to malfunction. Cost to repair the 330Cis water pump is approximately $288 for parts and labor. A damaged valve cover can cause oil leakage. It costs approximately $157 for parts and labor to repair a valve cover gasket. (All prices as of 2011.)

A time-tested technique for removing small car-dents can often be accomplished with a household plunger. Small dents and dings are inevitable for some drivers, but you can quickly remove a dent if the damage is not severe. Keep in mind that the household plunger wont induce a miracle. A plunger will not help with a large dent, or one with extensive paint damage.

Instructions

1

Clean the area around the dent with soap and water, wiping away all dirt and dust. Use your cloth to completely dry the area. This will give you a better view of the dent and help determine whether it can be repaired via the plunger method.

2

Apply a small amount of petroleum jelly to the bottom rim of your plunger; this will allow it to form a better seal when you place the plunger over the dent. The tighter seal allows the plunger to create more suction.

3

Place the plunger directly over the dent and firmly push it into place. Make sure the plunger covers the entire dent.

4

Push in on the plunger to create suction. Quickly pull out with the handle to "pop" the dent.

5

Inspect the area to see if the dent popped out completely. If it is only partially repaired, repeat the process.

A broken harmonic balancer bolt can cost a lot of money to have professionally removed from the threaded hole in which it is stuck. An EasyOut can help you remove the broken section of the bolt without the hassle of bringing your vehicle to a mechanic. Special care needs to be taken to make sure you do not damage the threads in the harmonic balancer or break off the hardened EasyOut inside the bolt. A broken EasyOut requires a professional machinist to remove both the broken bolt and EasyOut.

Instructions

1

Spray penetrating oil on the end of the broken bolt. Allow the penetrating oil to soak in around the bolt for five to six hours.

2

Align the tip of a center punch with the center of the broken bolt. Hit the center punch with a hammer to make a depression on the end of the broken bolt.

3

Secure a 1/8-inch left-hand drill bit in the chuck of a drill motor. Drill a hole at least 1/2-inch deep in the end of the bolt, using the center punch depression as a guide to hold the drill bit in place. Exchange the 1/8-inch drill bit for the drill bit recommended by an EasyOut set for the size of the broken bolt. Enlarge the hole with the larger drill bit.

4

Set the squared end of the recommended EasyOut into the tee-handle wrench supplied with the set. Tighten the handle of the wrench to hold the EasyOut in place.

5

Place the tapered end of the EasyOut in the drilled hole running through the center of the broken bolt. Turn the tee-handle wrench counterclockwise to force the EasyOut into the hole. Continue turning the wrench until the broken section of the bolt backs out of the threaded hole.

Scratches in automotive paint are an eyesore and can allow water to corrode the sheet metal if the scratch continues into the primer underneath the paint. Touching up the scratch will hide the eyesore and provide protection against rust damage. Bottle painters have a brush attached to the lid that allows you to apply automotive touch up paint to a scratch or other blemish without specialized painting tools.

Instructions

1

Add one teaspoon of dishwashing soap to a plastic bucket. Fill the bucket with water. Thoroughly wash the vehicle with the soapy water. Rinse the vehicle with clean water and allow it to dry for one hour. Dispose of the soapy water. Rinse the bucket and fill it with three to four inches of clean water.

2

Place a piece of 600-grit sandpaper in the bucket of clean water. Let the sandpaper soak in the water for 10 to 15 minutes

3

Sand the scratch with the wet 600-grit sandpaper. Place the sandpaper back in the water every one to two minutes to keep the sanding area wet. Rinse sanding debris from the paint with clean water.

4

Remove the cap from the bottle painter. Apply paint to the scratch with the brush attached to the lid of the bottle painter. Allow the paint to dry for 24 hours.

5

Set a piece of 1000-grit sandpaper in clean water. Allow the sandpaper to soak for 10 minutes. Sand the paint until it blends into the surrounding area.

6

Remove the cap from a clear coat bottle painter. Apply clear coat to the scratch with the brush. Allow the clear coat to dry for 24 hours.

Almost all automotive upholstery has a surface dye (or "top coat" dye). This layer of dye often wears off over time, leaving white patches where the vinyl gets the most wear. Repaired cracks also usually need to be recolored. Dye colorant is easy to use and repairs blemished areas in 24 hours.

Instructions

1

Clean the vinyl upholstery with a color prep solution and a vinyl upholstery cleaner. This will remove any stains from the vinyl to ensure an evenly-colored repair. Scrub well with a sponge and dry with a lint-free cloth.

2

Patch any cracks or holes using vinyl filler. Most vinyl fillers need to be heat cured. A heat gun, clothes iron, or vinyl heating tool can be used to heat the filler. Most fillers cure at 350 or 400 degrees Fahrenheit.

3

Clean the vinyl once more to remove any residue before applying the dye. Dry well with a lint-free cloth once again.

4

Apply 2 to 4 light coats of dye colorant as needed to cover the damaged area. Allow the dye colorant to dry completely between coats.

5

Apply a leather protectant and then buff the upholstery with a clean cloth once the dye colorant is completely dry. Vinyl is usually ready to buff after 24 hours.

Using a normal socket with an impact wrench is no different than using an impact socket with an impact wrench. The difference between the two sockets is the thickness and hardness of the material used to make them. Obviously, the impact socket is made to withstand the punishment of the impact wrench, but for projects that require less torque to either attach or remove a fastener, a normal socket will do just fine.

Instructions

1

Attach the air compressor hose to the impact wrench by pulling back the compression ring on the female end of the hose and inserting the male fitting on the handle of the impact wrench into the hose connection and releasing the compression ring when the male fitting is seated.

2

Choose the appropriate size normal socket that will fit the nut or bolt being removed. Align the square hole in the socket with the square drive on the impact wrench and push the square drive of the impact wrench into the square hole of the socket.

3

Remove the nut or bolt by placing the exposed end of the socket over the nut or bolt and pressing the trigger of the impact wrench. Make sure that the impact is set in the reverse position before pressing the trigger. If the nut or bolt is being tightened, place the socket attached to the impact wrench over the nut or bolt and press the trigger while the wrench is in the forward position. Refer to the impact wrench manufacturers manual for directions.

The 2009 Ford F-150 came with a wide array of high-luxury and high-tech options available. One of these options was Fords Microsoft-powered Sync. This system allows the driver to change radio stations, adjust the radio volume, perform basic vehicle diagnostics and even make phone calls by just speaking. Sync utilized Bluetooth technology to access the drivers cell phone, in order to make hands-free calling possible. To make this system function correctly, as with all Bluetooth devices, you must pair the cell phone with Sync.

Instructions

Without Navigation System

1

Turn your cell phones Bluetooth on. This process varies, depending on the phone you have.

2

Insert the ignition key in the F-150s ignition and start the truck. Turn the radio on.

3

Press the button on the radio in the shape of a phone. Observe as "Connecting" or "No Phone Found" shows on the Sync display, depending if you already paired a phone to the F-150.

4

Press the up or down arrow key until "Add Bluetooth Device" appears on the Sync display screen. Press the "OK" button.

5

Listen for Sync to say "Press OK to begin pairing device." Press the "OK" button.

6

Listen for Sync to say "Search for SYNC on your device and enter the PIN provided by SYNC." Locate "Sync" in the Bluetooth devices listed on your phone and select it. Enter the PIN provided by on the Sync display screen. You have three minutes to complete this task, or you must go back to Step 1.

7

Observe as "Device Connected" appears on the Sync display screen, if successfully paired.

8

Press the "OK" button when "Primary" shows up on the Sync display screen. To set this phone as primary, click "OK" when "Yes" appears on the screen. Scroll to "No," using the arrow keys, and press "OK" if you do not want this phone as the primary. The primary phone is the phone that the Sync searches for by default when the F-150 starts.

9

Observe as "Download Phonebook?" appears on the Sync display, if your phone supports this feature. Press the "OK" button. If you would like to download your phonebook to Sync, press "OK" when "Yes" appears on the screen. If not, scroll to "No," using the arrow keys, then press "OK."

10

Observe as "Download Complete" appears on the Sync display when the phonebook download is complete, if applicable.

11

Press the arrow keys until "Exit Phone Menu" appears on the Sync display screen, and press "OK" to exit the system.

12

Turn the ignition off and remove the key.

With Navigation System

13

Turn your cell phones Bluetooth on. This process varies, depending on the phone you have.

14

Start the F-150s engine and turn the radio on.

15

Press the "Phone" button on the F-150s radio. This allows you to access the phone menu.

16

Touch the "Settings" button on the left of the navigation screen.

17

Press the "Add" button on the right side of the navigation screen. Observe as a "Pass-Key" appears on the screen. Locate "Sync" in the Bluetooth devices on your cell phone and add the "Pass-Key" when prompted. This process varies, depending on your model of phone.

18

Observe as "Pairing Successful" appears on the screen; if this does not appear, start over from Step 1.

19

Select "Yes" or "No" when "Set as Favorite Phone?" appears on the screen. Selecting "Yes" means this phone is the one that Sync will connect to when first started.

20

Observe as "Download Phonebook/Call History?" appears on the screen. Select "Yes" to add your phonebook and call history to Sync. Select "No" not to add it.

21

Turn the ignition off and remove the key.

If you can no longer insert your key into the keyhole of your broken car trunk, the only way you can open the lock is to drill a hole in the cylinder. Since you need to replace the entire lock once the keyhole is broken, drilling the cylinder does not do any additional damage to your lock or trunk. A screwdriver or crowbar will help you open the trunk itself if you cannot open it by hand once you drill through the lock.

Instructions

1

Position the end of the drill bit in the keyhole of your trunk lock. Drill all the way through the lock.

2

Turn the reverse switch of the drill to reverse position and press the drill trigger to get the bit out of the lock mechanism. Try to open the trunk door. Insert a screwdriver into the space below the lock and between the trunk door and the rear bumper and pry the trunk open if you cannot open it by hand. Insert the flat end of a crowbar into the space and carefully pry upward against the bumper if the screwdriver does not work. Be careful not to dent the bumper.

3

Position a 2-to-3-foot metal beam between the floor of the trunk and the bottom of the trunk door so that it holds the door open while you clear out the trunk. Have a new lock put in and the latch repaired professionally as soon as possible.

A lot of things that can wrong with your cars engine. Oil pressure, bad batteries, and fuel levels can affect the engines performance. If you have problems with your engine, you can use a vacuum gauge to test the exhaust system or a blown head gasket. You dont have to be a mechanic to perform this task.

Instructions

1

Park your car on a flat surface and then turn it off at the ignition switch. Put the car in neutral with the parking brake engaged if you have a manual transmission.

2

Open the hood to the car and locate the vacuum hose connection on the backside of the engine. This is a T-fitting that connects with the hose on your vacuum gauge.

3

Pull the T-fitting from the engine and then put the vacuum hose into the right side of the T-fitting. Place the other vacuum port onto the left side of the T-fitting. Place the last vacuum line on the last nipple of the T-fitting.

4

Start your cars engine and then look at the reading of the vacuum gauge. Compare the reading on the vacuum gauge to the chart that came with the gauge. This tells you what the problem is with your cars engine.

Conversion vans are ideal for towing because of their large engine size and strong suspension system. You can install a tow package on a conversion van yourself or take it to a shop or moving company such as UHaul to install the hitch for you. Make sure you check the conversion vans owners manual for the towing capacity and overall load weight that the engine can handle. Take into consideration the weight of the unloaded trailer and how many people will be riding in the van when calculating weight load.

Instructions

1

Look over the installation instruction sheet provided with your hitch. Check your vans owners manual to ensure you have the right size hitch for your engine size. Park your van on level ground. Engage the emergency brake. Put blocks in front of the front tires. Hoist the vehicle off the ground using a jack or ramps.

2

Locate the part of the frame at the rear of the van that the draw bar will attach to. Make sure you find the exact center of the frame so the hitch will not be pulling in an unbalanced manner.

3

Hold draw bar up to the frame at the desired location. Use the C-clamps to clamp the draw bar in place against the frame. You can use a scissor jack to support the weight of the draw bar if you dont have access to C-clamps.

4

Drill any holes in the frame if the draw bar has holes that dont line up with those already in the frame of the van. Use the electric drill to make the holes. Insert any reinforcement plates provided with the hitch between the draw bar and frame. Place bolts through all the holes in the draw bar and fasten with nuts. Hardware should be provided with hitch.

5

Tighten the nuts with a wrench to the recommended torque levels suggested in the hitch instructions.

6

Insert ball into the hitch located at the end of the draw bar. Insert cotter pin into the hitch to secure the ball to the hitch.

Your 1999 Ford F-150, a sturdy vehicle with a 5.4-liter engine, can tow a trailer on camping trips or other vacations -- or when you simply want to move the trailer. The F-150 comes equipped with a towing ball, which allows you to attach cable to the trailers towing hitch. Once youve made the connection, drive the speed limit and avoid sharp or sudden turns in your Ford F-150.

Instructions

1

Drive your F-150 to a point in front of the box trailer where you can attach the tow ball and hitch.

2

Place the F-150 in park, and engage your emergency brake.

3

Exit the truck, and walk to the tow ball. Wrap the cable in place around the tow ball, and clamp it shut so it stays in place. Test the connection to ensure it wont come undone easily.

4

Tie the other end of the cable to the tow hitch of the box trailer, taking special care to clamp it in place to stabilize it.

5

Turn on the hazard lights of your box trailer if it has them, which will alert drivers of other vehicles to take caution when driving behind you and your trailer.

A strut is a suspension component that dampens an automobiles movements and prevents it from bouncing on its springs. Struts are often expensive to replace, but driving on a broken strut is not a good idea.

Suspension Damage

When a strut is broken, one area of the vehicle is free to move farther and faster than the others. This increases the wear on the other suspension components and may cause the failure of these components. Damage to other suspension components may greatly increase the cost of needed repairs.

Steering Damage

The increased movements allowed by the broken strut may also increase the strain on the steering system and cause it to become damaged. Also, suspension and steering system components are typically mounted close to each other. When a strut breaks, the strut itself may strike and damage steering components.

Loss of Control

The suspension system is responsible for keeping the wheels in contact with the road, this is especially important on rough road surfaces and during emergency braking. Without a properly operating strut, the vehicle will tend to bounce, causing a wheel to not properly contact the road. This can cause a driver to lose control of the vehicle.