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The major cause of clutch failure is excessive heat. Excessive heat generated between the flywheel, driven discs, intermediate plate and pressure plate can cause the metal to flow and the material to be destroyed. If this occurs, the clutch can burst which can cause property damage, serious bodily injury or death. In order to prevent clutch failure resulting from excessive heat: 1. Do not exceed recommended vehicle loads. 2. The clutch should only be used for the recommended applications. 3. Drivers should be properly trained in starting, shifting and operation of the clutch. 4. Drivers should report erratic clutch operation as soon as possible to permit maintenance personnel to inspect, adjust or lubricate as required. 5. The removal and installation procedure described for each component may vary for your vehicle. For Solo and Heavy-Duty ECA clutches only, install shipping bolts before removing clutch assembly from the flywheel. IMPORTANT For service information and assistance, call the Roadranger Help Desk at 1-800-826-HELP (4357) (Mexico: 01-800-826HELP (4357). You may also find more information about Eaton Clutches at www.Roadranger.com. Mechanics must be familiar with proper clutch adjustment, linkage adjustment, lubrication and other maintenance troubleshooting procedures outlined in the Failure Analysis Guide. Every effort has been made to ensure the accuracy of the information contained in this manual. However, Eaton Corporation makes no warranty, expressed or implied, based on the information provided.
Be sure to connect the Xbox LIVE communication cable in the proper order: 1. ... PARTS NEEDED FROM PACKAGE CONTENTS (REFERENCE PAGE 3). 1. 2. 1 Mic Mute: Slide the mic mute switch down to mute the microphone so others cannot hear you. 2 Master Volume and Mute: Use to adjust the master volume of game audio. Push in to mute all game sound. 3 Breakaway In-line Connector 4 Xbox LIVE Port: Use to connnect to Xbox LIVE. 5 Voice Communication Volume and SVM Control: Use to adjust the volume of the voices of other players. SVM = Selectable Voice Monitoring. SVM allows the user to hear his or her own voice through the headset. Push in to turn SVM ON/OFF.Headset Microphone Insertion Directions Insert the microphone into the headset by lining up the small dot on the microphone with the small dot on the headset. Firmly press the microphone into place. Rotate the microphone in a clockwise direction until it stops.
Rugged or refined: whatever you need Whether it’s cruising on paved surfaces or heading off-road, the Amarok is equipped to deliver the performance for all environments and terrains D riv ing te ch ex pla ine d Permanent 4MOTION® Permanent is great for convenient oﬀ-roading. It keeps the four-wheel-drive system engaged whether you’re on- or oﬀ-road, so that power is always sent to the wheels with the most oned on South America’s rough mountain Sure-footed on any terrain grip. It’s available on the terrain, it’s no surprise that the Amarok is Designed to tackle the toughest off-road terrains, Amarok Highline – the such a formidable off-roader. With its powerful the Amarok has an Electronic Stabilisation Programme manual model comes with 2.0-litre TDI engines and the dynamic all-terrain benefits (ESP) fitted as standard – part of an impressive range the standard leaf-spring of the intelligent 4MOTION four-wheel-drive, it will take of safety features, which include on- and off-road suspension. The automatic you anywhere you need to go. On-road performance is anti-lock braking systems, an Electronic Differential has the heavy-duty leaf just as composed, thanks to the Amarok’s refined ride. Lock, and Trailer Stability Control. suspension system. Dependable four-wheel drive steep inclines when pulling away, while Hill Descent Selectable At the heart of the Amarok’s off-road performance is Control regulates engine speed and applies the brakes 4MOTION® Selectable Volkswagen’s advanced 4MOTION system, which if necessary, so that you can drive down slopes in a safe is ideal for rugged helps maintain optimum traction on all road surfaces.
To suit: Voklswagen Amarok 2010-on Since 1950 Pedders has been designing and manufacturing suspension products specifically for Australian conditions to ensure your vehicle is always performing at its best. That’s why at Pedders Suspension we’re proud of our range of totally integrated 4WD suspension systems – TrakRyder. Pedders’ TrakRyder suspension range includes thousands of quality components that have all been designed to improve the ride and handling characteristics of specific vehicles. The range includes coil and leaf springs, torsion bars, shock absorbers, suspension bushes, brakes, alignment kits, u-bolts, shackles, airbags and more. Following is our range of tailor made kits to suit the aforementioned vehicle. TrakRyder Touring Kits: The spring and shock absorber rates were developed to provide an improved ride quality, a reduction in body roll and improved stability. This kit is primarily designed to return the vehicle’s ride height to it’s original specification ( up to 0.5”/13mm lift ) and to reenergise the suspension capabilities through the addition of new shock absorbers.
Removal (Diamante) 1) Remove hood. Drain cooling system. Remove radiator. Release fuel system pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain engine oil and transaxle oil. Remove front exhaust pipe. Remove transaxle assembly. See appropriate CLUTCHES or TRANSMISSION SERVICING article. 2) Disconnect accelerator cable, brake booster vacuum hose, fuel supply and return lines, and heater hoses. Disconnect EGR temperature sensor (if equipped). Unplug vacuum hose connector. Remove drive belts. Remove power steering pump and A/C compressor, leaving hoses attached. 3) Unplug all harness connectors. Remove bolt from body ground connection. Disconnect alternator wiring inside relay box. Remove relay box and engine wiring harness connection. On models with ABS, remove radiator overflow tank and bracket. 4) Attach engine hoist. Raise engine enough to take weight from mounts. Remove engine mount bracket. Remove damper. Remove rear roll stopper bracket mount bolt. Remove front roll stopper bracket mount bolt. Carefully lift engine from car. Installation (Diamante) To install, reverse removal procedure. Install engine mount bracket so that arrow points away from engine, toward body. Install new "O" rings on fuel lines. Install new exhaust gaskets and nuts. Adjust throttle cable. See TORQUE SPECIFICATIONS TABLE at the end of this article. Replenish fluids. CAUTION: DO NOT allow foreign material into turbocharger air intake hoses or pipes.
Spacer - Brake Pedal Support to Body....................6.00 Gasket - Rear Wheel Bearing Retainer......................95 . NOW AVAILABLE: Brake drums made with detailed features per original specifications, balanced, and MADE IN THE USA. These are the best brake drums available! 1125A Front Brake Drum - 55/56....................................131.95 1125B Front Brake Drum - 57.........................................131.95 1126A Rear Brake Drum - 55/56.....................................131.95 1126B Rear Brake Drum - 57..........................................131.95 NOTE: BRAKE DRUMS SHIPPED AT ACTUAL COST 1193 Gasket - Front Brake Grease Baffle.........................1.05 2001 Disc brake pads.....................................................34.95 2004B Master Cylinder Repair Kit 1" Dia..........................25.98 . 2005 Booster Assy. - Power Brake - requires 2005D to convert to 56/57 T-Bird - Does not come with 2365A check valve . ..................................499.00 2005A Power Brake Booster Vacuum Line - 55................ 11.50 2005ASS Same As Above - Stainless Steel Line.................17.22 2005B Power Brake Booster Vacuum Line - 56................ 11.50 2005BSS Same As Above - Stainless Steel Line.................17.25 2005C Power Brake Booster Vacuum Line - 57................12.25 2005CSS Same As Above - Stainless Steel Line.................18.25 2005CE Power Brake Booster Vac Line - Dual 4...................8.35 2005CESS Same As Above - Stainless Steel Line.................10.45 2005D Power Brake Booster Line - To Convert Pass. Car Booster to T-Bird - 56/57.....................10.45 2005DSS Same As Above - Stainless Steel Line.................14.65 2005E Clip - To Hold 2005B & C to 9180 Brkt.....................1.85 2005F Rebuild Kit - Power Brake Booster (Does Not Include 2394)....................................178.00 2005G Vacuum Line - Flex - Power Brake Booster.............2.10 2005GE Vacuum Line - Flex Powr Brk Boostr - 57 "E"..........3.15 2005GF Vacuum Line - Flex Powr Brk Boostr - 57 "F"..........3.68 . Disc brakes now available See page 11 for details...
BRAKE BOOSTER REMOVAL OF BRAKE BOOSTER 1. REMOVE MASTER CYLINDER (See page BR–10) 2. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3. REMOVE PEDAL RETURN SPRING 4. REMOVE CLIP AND CLEVIS PIN 5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS BR–17 BRAKE SYSTEM – Brake Booster INSTALLATION OF BRAKE BOOSTER (See page BR–16) 1. ADJUST LENGTH OF BOOSTER PUSH ROD (a) Install the gasket on the master cylinder. (b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737–00010 (c) Turn the SST upside down, and set it on the booster. SST 09737–00010 (d) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) (e) Adjust the booster push rod length until the push rod lightly touches the pin head. 2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS (a) Install the booster and gasket. (b) Install the clevis. (c) Install and torque the booster mounting nuts. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf ) 3. CONNECT CLEVIS TO BRAKE PEDAL Insert the clevis pin into the clevis and brake pedal and install the clip to the clevis pin. 4. INSTALL PEDAL RETURN SPRING 5. INSTALL MASTER CYLINDER (See page BR–15) 6. CONNECT HOSE TO BRAKE BOOSTER 7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–8) 8. CHECK FOR FLUID LEAKAGE 9. CHECK AND ADJUST BRAKE PEDAL (See page BR–6) 10. PERFORM OPERATIONAL CHECK (See page BR–7)
• Check for engine vacuum, make sure manifold is open and clear of carbon build up. • Use a vacuum gauge to check the vacuum at the booster, do not guess. • Check vacuum hoses for soft spots, deterioration or collapse (replace hose if in doubt.) • Check brake pedal for binding. • Check the condition of the foundation brakes, drums, linings, and brake shoes for binding. • Check for air in Hydraulic System. • Check for any line restrictions. PEDAL KICKBACK • Check for dirt or foreign matter in Hydraulic System. • Before replacing the booster, remove the master cylinder to clean any dirt out. Also; Clean out the rest of the Hydraulic System. BRAKE WILL NOT RELEASE • Be sure a brake booster with residual check valve is not used with master cylinder with check valve. • On remote mountd boosters, disconnect the line between the master cylinder and the brake booster. • If the brakes release, the trouble is in the master cylinder (possibly the brake pedal is binding.) • If brakes do not release, disconnect the line from the booster to the wheel cylinders. • If the brakes release, the problem will be in the booster. • If brakes still do not release, the problem is in foundation brakes. • If brakes will not release on firewall mounted brake booster, disconnect the hydraulic line to the wheels. • If brakes release, the problem is in the booster or master cylinder (be sure the brake pedal is not binding.) LOW BRAKE PEDAL • Make sure master cylinder reservoir is full. • Check for air in the hydraulic system. • Make sure there are no leaks in the wheel cylinders, lines or fittings. • Check the foundation brakes for proper adjustment, cracked or over-sized drums. SPECIAL NOTES: Common Causes of Booster Failure
9. Brake Booster A: REMOVAL 1) Remove or disconnect the following parts at engine compartment. (1) Disconnect the connector for brake fluid level indicator. (2) Remove the brake pipes from master cylinder. (3) Remove the master cylinder installing nuts. (4) Disconnect the vacuum hose from brake booster. 2) Remove the following parts from pedal bracket. (1) Snap pin and clevis pin (2) Four brake booster installing nuts • Use care when placing the brake booster on floor. • Do not change the push rod length. If it has been changed, reset the projected length “L” to standard length. Standard L 10.05 mm (0.40 in) L BR-00074 (1) CAUTION: If external force is applied from above when the brake booster is placed in this position, the resin portion as indicated by “P”, may be damaged. (1) (2) P (3) BR-00075 (4) (1) Force BR-00073 (1) (2) (3) (4) B: INSTALLATION Nuts Clevis pin Snap pin Operating rod 1) Adjust the operating rod of brake booster. 3) Remove the brake booster while shunning brake pipes. Standard L 144.6 mm (5.69 in) If it is not within specified value, adjust it by adjusting the brake booster operating rod. NOTE: • Be careful not to drop the brake booster. The brake booster should be discarded if it has been dropped. • Use special care when handling the operating rod. If excessive force is applied to the operating rod, sufficient to cause a change in the angle in excess of ±3°, it may result in damage to the power piston cylinder. BR-38 L BR-00076 BRAKE BOOSTER BRAKE 2) Mount the brake booster in position. 3) Connect the operating rod to brake pedal with clevis pin and snap pin. CAUTION: Be careful not to rotate the stop light switch. Stop light switch clearance: A 0.3 mm (0.012 in) (1) A BR-00079
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