Windscreen, rear window and fixed rear quarter windows - removal and refitting
1 With the exception of the cab rear window on P100 models, all fixed glass panels are direct glazed to the body using a special adhesive. Special tools are required to remove the old glass and to fit the new glass, therefore the work is best entrusted to a dealer or replacement glass specialist.
2 The cab rear window on P100 models can be removed as follows, although it is advisable to entrust the work to a specialist.
3 Remove the six Torx bolts and nut/washer assemblies, and withdraw the safety grille from the rear of the cab.
4 Prise out one end of the trim insert from the window rubber, then pull out the remainder of the trim.
5 With the aid of an assistant, carefully push the glass and rubber into the passenger compartment.
6 Remove all traces of old sealer from the glass, rubber and cab aperture.
7 Commence refitting by pushing the window rubber into the aperture, ensuring that the trim panel and body panel engage in their respective grooves in the rubber.
8 Working from outside the cab, enter the bottom edge of the glass into the rubber, and hold the glass against the rubber while an assistant working from inside the passenger compartment pushes the rubber over the glass.
9 The trim insert must now be refitted to the rubber, preferably using a suitable windscreen trim insert tool. If no special tool is available, the trim can be refitted by prising open the rubber lips and pressing the trim into its groove, although this is likely to prove difficult and time consuming.
10 Refit the safety grille to the rear of the cab on completion.
Automatic transmission brake band adjustment (Every 24 000 miles (40 000 km)
or 2 years)
Note: A brake band torque wrench - Ford tool No 17-005, or a conventional torque wrench and a splined socket of suitable size to fit the square section head of the adjuster screw(s) will be requir ...
Starter motor brushes - renewal
1 Starter motor brush renewal is a relatively difficult procedure, requiring skill in the use of a soldering iron. It should also be borne in mind that if the starter motor has been in service lon ...
Coil - testing, removal and refitting
Testing All models except 1.6 and 1.8 litre CVH (R6A type) 1 The coil is located on the left-hand side of the engine compartment and is retained by a metal strap (see illustration). It is of high ...