Cub Cadet Challenger Series User manual

SERVICE MANUAL
Challenger 500
Challenger 700

Foreword
Brief Introduction to the Service and MaintenanceHandbook
500/700 Challenger Utility Vehicles
This manual gives methods to check, maintain and repair the Cub Cadet 500 &700
utility vehicles (UV’s), and supplies some relevant techniques and performance
data.
Please read the handbook through and fully understand it; otherwise, any
improper repairing could cause problems, and/or an accident mayoccur.
Proper use and maintenance will reduce malfunctions, and help the vehicle
remain at its best performance level.
The standards, procedures and specifications mentioned in this manual are basedon
the sample in design, and they are subject to changes according to theproduct’s
improvement without prior notice.

INDEX
Chapter 8
Troubl eshooti ng
Wi ri ng
Di agram
Chapter 6
El ectri cal
Chapte
r
7
Engi ne
Management
S
y
stem
Chapte
r
4
Engi ne
Chapte
r
5
Chassi s
Chapter 2
Speci ficati ons
Chapter 3
Peri odi c
Mai ntenance
and
Adj ustments
I ndex Chapter 1
General

INDEX
General Information
Chapter 1
Warning, Caution, Note
Description
Vehicle Identification Code, Engine
Number
Safety
Handling Gasoline, Cleaning Parts
Warning Labels, Serial Numbers,
Fasteners
Self-Locking Fasteners, Washers,
Cotter Pins, Snap Rings and E-
clips
Shop Supplies
Lubricants and Fluids,
Engine Oils, Greases, Brake Fluid
Coolant, Cleaners, Degreasers,
and solvents
Gasket Sealant, Gasket Remover,
Thread Locking Compound
Basic Tools
Screwdrivers
Wrenches
Adjustable Wrenches, Sockets,
Ratchets, and Handles
Impact Drivers
Allen Wrenches
Torque Wrenches, Torque
Adapters
Pliers, Snap Ring Pliers
Ignition Grounding Tool
Precision Measuring Tools
Feeler Gauge, Calipers
Micrometers
Adjustment and Care
Metric Micrometer
Standard Micrometer
Telescoping and Small Bore
Gauges
Dial Indicator, Compression Gauge
Multimeter
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-11
1-11
1-12
1-13
1-14
1-15
1-15
1-16
1-17
1-17
1-18
1-19
1-20
1-20
1-21
1-22
1-23
1-24
Electrical System Fundamentals
Voltage
Resistance, Amperage
Basic Service Methods
Removing Frozen Fasteners
Removing Broken Fastener
Stud Removal, Removing Hoses
Bearings
Removal
Installation
Interference Fit
Seal Replacement
Storage
Area Selection
Preparing the UV for storage
Returning the UV to Service
Specifications
Chapter 2
General Specifications
Engine Torque Specifications
Chassis Torque Specifications
General Torque Specifications
Chassis Lubrication points
Periodic Maintenance
Chapter 3
Periodic Maintenance Table
Periodic Maintenance
Engine
Valve Clearance
Spark Plug
Compression Test
Engine oil
Oil Change
Air Filter cleaning
Coolant Change
V-Belt Inspection
Replacement
Cleaning the Spark Arrester
Adjustment of the Parking Brake
Brake Fluid Level check
1-24
1-24
1-25
1-25
1-27
1-27
1-28
1-28
1-29
1-30
1-31
1-32
1-32
1-33
1-33
2-1
2-13
2-16
2-18
2-19
3-1
3-3
3-4
3-6
3-7
3-8
3-9
3-11
3-12
3-15
3-16
3-16
3-17
3-18

INDEX
Brake lines, Bleeding the Brake
Select Lever Shift Rod adjustment
Brake light switch adjustment
Final Gear oil Change
Tow In adjustment
CV Boot inspection
Steering system Inspection
Rear Shock adjustment
Tire inspection
Headlight Bulb replacement
Tail Light Bulb replacement
Engine
Chapter 4
Special Notes
Engine removal
Cylinder Head and Cover
Inspection, installation
Rocker Arm and Camshaft
3-19
3-20
3-20
3-21
3-22
3-23
3-23
3-24
3-24
3-24
3-25
4-1
4-2
4-3
4-4
4-6
Crankcase, Starter Motor and Oil
Filter
Crankcase
Bearings
Inspection
Assembly
Crankshaft and Oil Pump
Oil Pump
Inspection
Installation
Transmission
Drive Axle Assembly
Inspection
Installation
Middle Gear, Middle Drive Shaft
Middle Driven Shaft
Inspection
Installation
Chassis
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
4-41
4-42
4-43
4-44
4-45
4-46
Inspection 4-7
Chapte
r
5
Installation 4-8
Val
v
es and Valve springs 4-9 Inspection 5-1
Inspection 4-10 Steering S
y
stem 5-4
Installation 4-11 Steering Wheel
A
ssembly 5-5
C
y
linde
r
and Piston 4-12 Disassembl
y
, Inspection 5-6
Inspection 4-13 Installation 5-8
Installation 4-14 B
r
ake S
y
stem Inspection 5-8
Engine Cooling Fan and
A
.C. 4-15 B
r
ake Line Removal 5-10
Magneto B
r
ake Disc Removal 5-11
Inspection 4-16 Inspection 5-12
Installation 4-17 B
r
ake Pad Removal 5-13
Balance
r
Gea
r
s and Oil Pump 4-18 Installation 5-14
Gea
r
sF
r
ont B
r
a
k
eCalipe
r
Remo
v
al 5-15
Inspection 4-19 B
r
ake Calipe
r
Disassembly 5-16
Installation 4-19 Installation 5-17
Prima
r
y and Seconda
r
y Sheaves 4-20 Rea
r
B
r
ake Disc Remo
v
al 5-19
Prima
r
y Shea
v
e4-21 Inspection 5-20
Seconda
r
y Shea
v
e4-22 Rea
r
B
r
ake Calipe
r
and Pads 5-21
Inspection 4-23 Rea
r
B
r
ake Pad Replacement, 5-23
Installation 4-24 Inspection 5-23
Clutch 4-26
A
ssembly and Installation 5-24
Disassembly 4-27 B
r
ake Mas
t
e
r
C
y
linde
r
5-26
Inspection 4-28 Inspection, Ins
t
allation 5-27
Installation 4-29 Foot
r
est
A
ssembly 5-28

INDEX
Front Wheel and Tire
Rear Wheel
Inspection, Installation
Transmission Front Bridge
Front Bridge Removal
Disassembly
CV Joint Inspection
Differential Gear and Gear Motor
Operation
U-Joint Assembly
Differential Gear Motor Adjustment
Front Bridge Installation
Rear Bridge
Rear Differential Removal
Gear Shift Mechanism
Adjustment
Front Suspension and A-Arm
Inspection, Installation
Rear Suspension
Rear A-Arm
Inspection, Installation
Cooling System
Inspection, Coolant replacement
Water Pump Assembly
Disassembly, Inspection
Assembly
Seat Assembly
Fuel System
Fuel Pump Inspection
Electrical
Chapter 6
Components
Battery
Lead Acid Battery Charging
Maintenance Free Battery
Charging
Checking Fuses
Switch Inspection
Switch Locations
Bulbs and Sockets
Ignition Circuit Diagram
Ignition Troubleshoot
Starting Circuit Diagram
5-30
5-31
5-32
5-33
5-34
5-37
5-37
5-38
5-39
5-39
5-40
5-41
5-42
5-45
5-46
5-47
5-49
5-50
5-51
5-52
5-53
5-55
5-56
5-58
5-59
5-60
5-62
5-66
6-1
6-3
6-4
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-15
Brake Master Cylinder
Inspection, Installation
Footrest Assembly
Starter Motor Troubleshoot
Starter Motor Removal
Charging Circuit Diagram
Charging System Troubleshoot
Lighting Circuit Diagram
Signaling Circuit Diagram
Cooling Circuit Diagram
2WD / 4WD Select Circuit Diagram
Engine Management
System Chapter 7
Components
E.C.U.
Fuel Injectors
Installation Guidelines
Replacement
Cleaning Procedure
Throttle Body
Engine Coolant Temperature
Sensor
Oxygen Sensor
Fuel Pump Module
Inspection
Removal, Installation
Fuel Leak Check
E.M.S. Fault Codes
Troubleshooting
Chapter 8
Spark Test
Fuel System Check
Compression Test
Engine Overheating
Engine Noises
Cylinder Leak Down
Electrical checks
Intermittent Problems
E.C.U.
5-26
5-27
5-28
6-16
6-17
6-18
6-19
6-20
6-21
6-22
6-23
7-1
7-2
7-3
7-3
7-5
7-6
7-7
7-7
7-8
7-8
7-9
7-10
7-10
7-11
8-1
8-2
8-2
8-3
8-4
8-5
8-7
8-8
8-9

Vehicle Identification Number
LWG MD SZ 44 E B 123456
LWG
MD
MH
Manufacturer
UV below 750 cc
UV above 750 cc
SZ
TZ 500cc
YZ
700cc
44 DOT Check Digits
A 2010 Model Year
B 2011 Model year
C 2012 Model Year
D 2013 Model Year
E 2014 Model Year
A Manufacturing Plant A
B Manufacturing Plant B
123456 Sequential Serial
Number

General Information
1‐1
This manual provides complete information on maintenance, tune-up, repairand
overhaul. Hundreds of photographs and illustrations created during the complete
disassembly of Utility Vehicles (UV) guide the reader through every job. All
procedures are in step by step format and designed for the reader who maybe
working on the UV for the first time.
Warnings, Cautions and Notes
The terms Warning, Caution and Note have specific meanings in thismanual.
Warning
Emphasizes areas where injury or even death could resultfrom
negligence.
Caution
Emphasizes areas where equipment damage could result.
Disregarding a Caution could cause permanent
mechanical damage, although injury isunlikely.
Note
Provides additional information to make a step or procedureeasier
or clearer. Disregarding a Note could cause inconvenience, but
would not cause equipment damage orinjury.

General Information
1‐2
Description
Note
The vehicle you have purchased may
differ slightly from those in the
figures of this manual.
1. Headlights
2. Frontshockabsorberadjustingring
3. Brakefluidreservoir
4. Airfilterelement(insideairintakeduct)
5. V‐beltcase
6. Driverseat
7. Driverseatbelt
8. Sparkplug
9. Cargobed
10. Tail/brakelights
11. Rearshockabsorberadjustingring
12. Cargobedreleaselever
13. Sparkarrester
14. Passengerseatbelt
15. Passengerseat
16. Oilfilter
17. Engineoildipstick
18. Battery
19. Fuses
20. Coolantreservoir
21. Radiatorcap
22. Fuelcap
23. Lightswitch
24. Steeringwheel
25. Choke
26. Ignitionswitch
27. On‐commandfour‐wheeldriveand
Differentiallockswitches
28. Multi‐functiondisplayunit
29. AuxiliaryDCoutlet
30. Driveselectlever
31. Parkingbrakelever
32. Acceleratorpedal
33. Brakepedal

General Information
1‐3
Identification Code
Vehicle Identification Number
Vehicle Identification number is
stamped in the lower right side of
the frame.
Engine Number
Engine number is printed on a
white tag on top of the clutch
cover.

General Information
1‐4
Safety
Professional mechanics can work for
many years and never sustain a serious
injury or mishap. Follow these
guidelines and practice common sense
to safely service the utility vehicle.
1. Do not operate the UV in an
enclosed area. The exhaust
gasses contain carbon monoxide,
which is an odorless, colorless
and tasteless poisonous gas.
Carbon monoxide levels build
quickly in small confined areas
and can cause unconsciousness
and death in a short time. Make
sure to properly ventilate the work
area or operate the UV outside.
2. Never use gasoline or any
extremely flammable liquid to
clean parts. Refer to cleaning
parts and handling gasoline
safely in this section.
3. Never smoke or use a torch in
the vicinity of flammable liquids,
such as gasoline or cleaning
solvents.
4. If welding or brazing on the UV
move the fuel tank to a safe
distance, at least 50ft away.
5. Use the correct type and size
tools to avoid damaging
fasteners.
6. Keep tools clean and in good
condition. Replace or repair worn
or damaged equipment.
7. When loosening a tight fastener,
be guided by what would happen
if the tool slips.
8. When replacing fasteners, make
sure the new fasteners are the
same size and strength as the
original ones.
9. Keep your work area clean and
organized.
10. Wear eye protection anytime the
safety of the eyes is in question.
This includes procedures that
involve drilling, grinding,
hammering, use of compressed
air, and chemicals.
11. Wear the correct clothing for the
job. Tie up or cover long hair so it
does not get caught in moving
equipment.
12. Do not carry sharp tools in
clothing.
13. Always have an approved fire
extinguisher available. Make sure
it is rated for gasoline (class B)
and electrical (class C) fires.
14. Do not use compressed air to
clean clothing, the UV, or the
work area. Debris may be blown
into the eyes or skin. Never direct
compressed air at anyone. Do
not allow children to use or play
with any compressed air
equipment.
15. When using compressed air to
dry parts, hold the part so it does
not rotate. Do not allow the force
of the air to spin the part. The air
jet is capable of rotating parts at
extreme speed and the part may
disintegrate or become damaged
possibly causing injury.
16. Do not inhale the dust created by
brake pad and clutch wear. These
particles may contain asbestos.
Some types of insulating
materials and gaskets may also
contain asbestos. Inhaling
asbestos particles is hazardous to
your health.

General Information
1‐5
Handling Gasoline
Safely
Gasoline is a volatile flammable liquid
and is one of the most dangerous items
in the shop. Because gas is used so
often, many people forget about the
hazards associated with its use. Gas
should only be used for fuel in a
gasoline internal combustion engine.
Keep in mind when working on the UV
that gasoline is always present in the
fuel tank, fuel lines and carburetor. To
avoid an accident when working around
a fuel system, carefully observe the
following precautions.
1. Never use gas to clean parts.
Refer to cleaning parts in this
section.
2. When working on the fuel
system, work outside or in a well
ventilated area.
3. Do not add fuel to the fuel tank or
service the fuel system while the
UV is near open flames, sparks or
where someone is smoking.
Gasoline vapor is heavier than air
and it collects in low areas, and is
more easily ignited than liquid
gasoline.
4. Allow the engine to cool
completely before working on any
fuel system component.
5. Do not store gasoline in glass
containers. If the glass breaks, a
serious explosion or fire may
occur.
6. Immediately wipe up spilled gas
with rags. Store the rags in a
metal container with a lid until
they can be properly disposed of,
or washed.
7. Do not pour water onto a
gasoline fire. Water spreads the
fire and makes it more difficult to
put out. Use a class B, BC or
ABC fire extinguisher to
extinguish the fire.
8. Always turn off the engine before
refueling. Do not spill fuel onto
the engine or exhaust system. Do
not overfill the fuel tank. Leave an
air space at the top of the tank to
allow room for the fuel to expand
due to temperature fluctuations.
Cleaning Parts
Cleaning parts is one of the more
tedious and difficult service jobs
performed in the home garage. Many
types of chemical cleaners and solvents
are available for shop use. Most are
poisonous and extremely flammable. To
prevent chemical exposure, vapor
buildup, fire and serious injury, observe
each product warning label and note the
following.
1. Read and observe the entire
product label before using any
chemical. Always know what type
of chemical is being used and
whether it is poisonous and/or
flammable.
2. Do not use more than one type of
cleaning solvent at a time. If
mixing chemicals is required,
measure the proper amounts
according to the manufacturer.
3. Work in a well ventilated area.
4. Wear chemical resistant gloves.
5. Wear safety glasses
6. Wash hands and arms thoroughly
after cleaning parts.
7. Keep chemical products away
from children and pets.
8. Wear a vapor respirator if the
instructions call for it.

General Information
1‐6
9. Thoroughly clean all oil, grease
and cleaner residue from any part
that must be heated.
10. Use a nylon brush when cleaning
parts. Metal brushes may cause
a spark.
11. When using a parts washer, only
use the solvent recommended by
the manufacturer. Make sure the
parts washer is equipped with a
metal lid that can lower in case of
fire.
Warning Labels
Most manufacturers attach information
and warning labels to the UV. These
labels contain instructions that are
important to safety when operating,
servicing, transporting and storing the
UV. Refer to the owner’s manual for
the description and location of labels.
Order replacement labels from the
manufacturer if they are missing or
damaged.
Serial Numbers
Serial and identification numbers are
stamped on various locations on the
frame, engine, and carburetor body.
Record these numbers in the quick
reference data section in the front of the
manual. Have these numbers available
when ordering parts.
Fasteners
Proper fastener selection and
installation is important to ensure the UV
operates as designed and can be
serviced efficiently. The choice of
original equipment fasteners is not
arrived at by chance. Make sure
replacement fasteners meet all the
same requirements as the originals.
Many screws, bolts and studs are
combined with nuts to secure particular
components. Marking will indicate the
strength or hardness. Manufacturers
specify the internal diameter and thread
pitch. The measurement across two flats
on a nut or bolt indicates the wrench
size.
Warning
Do not install fasteners with a
strength classification lower than
what was originally installed by the
manufacturer. Doing so may cause
equipment failure and or damage.
Torque Specifications
The material used in the manufacturing
of the UV may be subjected to uneven
stresses if the fasteners of the various
subassemblies are not installed and
tightened correctly. Fasteners that are
improperly installed or work loose can
cause extensive damage. It is essential
to use an accurate torque wrench as
described in this chapter.

General Information
1‐7
Self-Locking Fasteners
Several types of bolts, screws and nuts
incorporate a system that creates
interference between the two fasteners.
Interference is achieved in various
ways. The most common types are the
nylon insert nut and a dry adhesive
coating on the threads of a bolt. Self-
locking fasteners offer greater holding
strength than standard fasteners, which
improves their resistance to vibration.
Self-locking fasteners cannot be reused.
The materials used to from the lock
become distorted after the initial
installation and removal. Discard and
replace self-locking fasteners after
removing them. Do not replace self-
locking fasteners with standard
fasteners.
Washers
The two basic types of washers are flat
washers and lock washers. Flat washers
are simple discs with a hole to fit a
screw or bolt. Lock washers are used to
prevent a fastener from working loose.
Washers can be used as spacers and
seals, or can help distribute fastener
load and prevent the fastener from
damaging the component. As with
fasteners, when replacing washers
make sure the replacement washers are
of the same design and quality.
Cotter Pins
A cotter pin is a split metal pin inserted
into a hole or slot to prevent a fastener
from loosening. In certain applications,
such as the rear axle on an UV or
motorcycle, the fastener must be
secured in this way. For these
applications, a cotter pin and castellated
(slotted) nut is used. To use a cotterpin,
first make sure the diameter is correct
for the hole in the fastener. After
correctly tightening the fastener and
aligning the holes, insert the cotter pin
through the hole and bend the ends over
the fastener. Unless instructed to do so,
never loosen a tightened fastener to
align the holes. If the holes do not align,
tighten the fastener enough to achieve
alignment. Cotter pins are available in
various diameters and lengths. Measure
the length from the bottom of the head
to the tip of the shortest pin.
Snap Rings and E-clips
Snap rings (Figure 1) are circular-
shaped metal retaining clips. External
type snap rings are used to retain items
on shafts. Internal type snap rings
secure parts within housing bores. In
some applications, in addition to
securing the component(s), snap rings
of varying thicknesses also determine
endplay. These are usually called
selective snap rings.
The two basic types of snap rings are
machined and stamped snap rings.
Machined snap rings (Figure 2) can be
installed in either direction, because
both faces have sharp edges. Stamped
snap rings (Figure 3) are manufactured
with a sharp and a round edge. When
installing a stamped snap ring in a thrust
application, install the sharp edge facing
away from the part producing the thrust.

General Information
1‐8
Observe the following when installing
snap rings:
1. Remove and install snap rings
with snap rings pliers. Refer to
Basic Tools in this chapter.
2. In some applications, it may be
necessary to replace snap rings
after removing them.
3. Compress or expand snap rings
only enough to install them. If
overly expanded they lose their
retaining ability.
4. After installing a snap ring. Make
sure it seats completely
5. Wear eye protection when
removing and installing snap
rings
E-clips are used when it is not practical
to use a snap ring. Remove E-clips with
a flat blade screwdriver by prying
between the shaft and E-clip. To install
an E-clip, center it over the shaftgroove
and push or tap it into place.
Shop Supplies
Lubricants and Fluids
Periodic lubrication helps ensure a long
service life for any type of equipment.
Using the correct type of lubricant is as
important as performing the lubrication
service. The following section describes
the types of lubricants most often
required. Make sure to follow the
recommendation for lubricant types.

General Information
1‐9
Engine Oils
Engine oil for the UV four stroke engine
is classified by two standards: the
American Petroleum Institute (API)
service classification and The Society of
Automotive Engineers (SAE)viscosity
rating Standard classification. The API
and SAE information is on all oil
container labels. Two letters indicate the
API service classification. The number
or sequence of numbers and letter
(10W-40 for example) is the oil’s
viscosity rating. The API service
classification and the SAE viscosity
index are not indications of oil quality.
The API service classification standards,
the first letter in the classification S
indicates that the oil is for spark ignition
engines. The second letter indicates the
standard the oil satisfies.
Note:
Refer to Engine Oil and Filter in
Chapter Three for further information on
API, SAE classifications.
Always use oil with a classification
recommended by the manufacturer.
Using an oil with a different classification
can cause engine damage. Viscosity is
an indication of the oil’s thickness. Thin
oils have a lower number while thick oil
has a higher number. Engine oils fall into
the 5-to-50 weight range for single- grade
oils. Most manufactures recommend
multi-grade oil. These oils
perform
efficiently across a wide range of
operating conditions. Multi-grade oils
are
identified by a W after the first number,
which indicates the low- temperature
viscosity. Engine oils are
most commonly
mineral (petroleum based), but synthetic
and semi-synthetic
types are used more
frequently. When
selecting engine oil,
follow the
manufacturer’s
recommendation for
type, classification
and viscosity.
Greases
Grease is lubricating oil with thickening
agents added to it. The National
Lubricating Grease Institute (NLGI
grades grease. Grades range from
No.000 to No.6, with No.6 being the
thickest. The most typical multipurpose
grease is NLGI No.2. For specific
applications, manufacturers may
recommend water-resistant type grease
or one with an additive such as
molybdenum disulfide (MoS2).
Brake Fluid
Brake fluid is the hydraulic fluid used to
transmit hydraulic pressure (force) tothe
wheel brakes. Brake fluid is classified by
the Department of Transportation
(DOT). Current designations for brake
fluid are DOT 3, DOT 4 and DOT 5.
This classification appears on the fluid
container. Each type of brake fluid has
its own definite characteristics. Do not
mix different types of brake fluid as this
may cause brake system failure. DOT 5
brake fluid is silicone based. DOT 5 is
not compatible with other brake fluids
and may cause brake system failure if
mixed with non DOT 5 fluids. When
adding brake fluid, only use the fluid
recommended by the manufacturer.
Brake fluid will damage any plastic,
painted or plated surfaces it contacts.
Use extreme care when working with
brake fluid and remove any spills
immediately with soap and water.
Hydraulic brake systems require clean

General Information
1‐10
and moisture free brake fluid. Never
reuse brake fluid. Keep containers and
reservoirs properly sealed.
Warning
Never put mineral based petroleum
oil into the brake system. Mineral oil
causes rubber parts in the system to
break down which could cause
complete brake failure.
Coolant
Coolant is a mixture of water and
antifreeze used to dissipate engine heat.
Ethylene glycol is the most common
form of antifreeze. Check the UV
Manufacturer’s recommendations when
selecting antifreeze. Most require one
specifically designed for aluminum
engines. There are types of antifreeze
have additives that inhibit corrosion.
Only mix antifreeze with distilled water.
Impurities in tap water may damage
internal cooling system passages.
Cleaners, Degreasers
and Solvents
Many chemicals are available to remove
oil, grease and other residue from the
UV. Before using cleaning solvents,
consider how they will be used and
disposed of, particularly if they are not
water-soluble. Local ordinances may
restrict types of cleaning chemicals.
Refer to Safety in this chapter. Use
brake parts cleaner for brake system
components. Brake parts cleaner leaves
no residue. Electrical contact cleaner is
a powerful solvent used to remove fuel
deposits and varnish from fuel system
components. Use this cleaner carefully,
as it may damage finishes. Most
solvents are designed to be used with a
parts washing cabinet for individual
component cleaning. For safety, use
only nonflammable or high flash point
solvents.
Gasket Sealant
Sealant is used in combination with a
gasket or seal. In other applications,
such as between crankcase halves, only
a sealant is used. Follow the
manufacturer’s recommendation when
using a sealant. Use extreme care when
choosing a different sealant based on its
resistance to heat, various fluids and its
sealing capabilities.
Gasket Remover
Aerosol gasket remover can help
remove stubborn gaskets. This product
can speed up the removal process and
prevent damage to the mating surface
that may be caused by using a scraping
tool. Most of these types of products are
very caustic. Follow the gasket remover
manufacturer’s instructions for use.

General Information
1‐11
Thread locking
Compound
A thread locking compound is a fluid
applied to the threads of fasteners. After
tightening the fastener, the fluid dries
and becomes a solid filler between the
threads. This makes it difficult for the
fastener to work loose from vibration or
heat expansion and contraction. Use
thread locking compound sparingly.
Excess fluid can run into adjoining parts.
Caution
Thread locking compounds are
anaerobic and will stress, crack and
damage most plastics. Use caution
when using these products in areas
where there are plastic components.
Thread locking compounds are available
in a wide range of compounds for
various strengths, temperature and
repair applications. Follow the
manufacturer’s recommendations
regarding compound selection.
Basic Tools
Most of the procedures in this manual
can be carried out with basic hand tools
and test equipment familiar to the home
mechanic. Always use the correct tools
for the job. Keep tools organized and
clean. Store them in a tool chest with
related tools organized together.
Quality tools are essential. The best are
constructed of high-strength alloy steel.
These tools are light, easy to use and
resistant to wear. Their working surface
is devoid of sharp edges and carefully
polished. They have an easy-to-clean
finish and are comfortable to use.
Quality tools are a good investment.
Some of the procedures in this manual
specify special tools. In many cases the
tools is illustrated in use. Those with a
large tool kit may be able to perform the
jobs, however, in some cases, the
specialized equipment or expertise may
make it impractical for the home
mechanic to attempt the procedure.
When necessary, such operations are
recommended to have a dealership or
specialist perform the task. It may be
less expensive to have a professional
perform these jobs, especially when
considering the cost of equipment.
When purchasing tools to perform the
procedures covered in this manual,
consider the tool’s potential frequency of
use. If a tool kit is just now being
started, consider purchasing a basic tool
set from a quality tool supplier and they
may offer substantial savings when
complicated, specialized tools need to
be added.
Screwdrivers
Screwdrivers of various lengths and
types are mandatory for the simplest
tool kit. The two basic types are the
slotted tip (flat blade) and the Phillips tip.
These are available in sets that often
include an assortment of tip size and
shaft lengths. As with all tools, use a
screwdriver designed for the job. Make
sure the tool fits the size of thefastener.
Use them only for driving screws. Never
use a screwdriver for prying or chiseling
metal. Repair or replace worn or
damaged screwdrivers. A worn tip may
damage the fastener, making it difficult
to remove.
Phillips-head screws are often damaged
by incorrectly fitting screwdrivers.

General Information
1‐12
Quality Phillips screwdrivers are
manufactured with their cross-head tip
machined to Phillips Screw Company
specifications. Poor quality or damaged
Phillips screwdrivers can back out and
round over the screw head. Weakor
soft screw materials can make removal
more difficult. The best type of
screwdriver to use on a Phillips screw
is the ACR® Phillips II® screwdriver,
patented by the horizontal anti-cam out
ribs found on the driving faces or flutes
of the screwdriver’s tip (Figure 4).
ACR® Phillips II® screwdrivers were
designed as part of a manufacturing
drive system to be used with ACR®
Phillips II® screws, but they work well.
Tool suppliers offer ACR® Phillips II®
screwdrivers in different Tip size and
interchangeable bits to fit screwdriver bit
holders.
Note
Another way to prevent the
screwdriver from rounding out the
head of the screw is to apply valve
grinding compound onto the tip. After
loosening or tightening the screw,
clean the screw recess to prevent
engine oil contamination.
Wrenches
Open-end, box-end and combination
wrenches (Figure 5) are available in a
variety of types and sizes.
The box-end wrench is an excellent tool
because it grips the fastener on all
sides. This reduces the chance of the
tool slipping. The box-end wrench is
designed with either a 6 or 12-point
opening. For stubborn or damaged
fasteners, the 6-point provides superior
holding because it contacts the fastener
across a wider area at all six edges. For
general use, the 12-point works well. It
allows the wrench to be removed and
reinstalled without moving the handle
over such a wide area.
An open-end wrench is fast and works
best in areas with limited access. It
contacts the fastener at only two points
and is subject to slipping if under heavy
force, or if the tool or fastener is worn. A
box-end wrench is preferred in most
instances, especially when breaking
loose and applying the final tightness to
a fastener.
The combination wrench has a box-end
on one end and an open-end on the
other. This combination makes it a
convenient tool.

General Information
1‐13
WARNING
Do not use hand sockets with air or
impact tools because they may
shatter and cause injury. Always
wear eye protection when using air or
impact tools .
Various handles are available for
sockets. Use the speed handle for fast
operation. Flexible ratchet heads in
varying lengths allow the socket to be
turned with varying force and at odd
angles. Extension bars allow the socket
to reach difficult areas. The ratchet is
the most versatile. It allows the user to
install or remove the nut without
removing the socket. Sockets combined
with any number of drivers make them
the most convenient tool for fastener
removal and installation.
Impact Drivers
An impact driver provides extra force for
removing fasteners by converting the
impact of a hammer into a turning
motion. This makes it possible to
remove stubborn fasteners without
damaging them. Impact drivers and
interchangeable bits (Figure 10) are
available from most tool suppliers.
When using a socket with an impact
driver, make sure the socket is designed
for impact use. Refer to Socket
Wrenches, Ratchets and handles in this
section.
WARNING
Do not use hand sockets with air or
impact tool because they may shatter
and cause injury. Always wear eye
protection when using air or impact
tools.