1

EVERYTHING YOU WANTED TO KNOW

ABOUT THE NEW LOANER TOOL PROGRAM
TABLE OF CONTENTS
INTRODUCTION 3
INSTRUCTIONS / PROCEDURES: LOANER — SALES — RETURNS 4-5
LOANER TOOL KIT - IDENTIFICATION 6
REPLACEMENT PART ORDERS 7
Kit #1 648627 Strut Spring Compressor 8
Kit #3 648626 5-Piece Front End Service Set 10
Kit #6 648615 Valve Spring Compressor Kit 12
Kit #8 648619 Pilot Bearing Puller 14
Kit #10 648635 4-Piece Axle Nut Socket Set 16
Kit #11 648636 5-Piece Spindle Nut Socket Set 18
Kit #13 648644 Power Steering Pump Pulley Puller 20
Kit #14 648645 Heavy Duty Steering Wheel Puller 22
Kit #15 648646 5-Piece Fork Set 24
Kit #20 648605 Power Steering & Alternator Pulley Tool Set 26
Kit #23 648610 9-Piece Double Flaring Tool Set 28
Kit #25
Kit #26
Kit #29 648744 Vacuum Pump Set 30
Kit #34 648746 Fan Clutch Wrench Set 32
Kit #35
Kit #39 648603 Coil Spring Compressor 34
Kit #40 648608 Master Hub Puller Set 36 - 39
Kit #41 648611 Master Axle Puller Set 40 - 43
Kit #42 648612 4-Piece Exhaust Set 44
Kit #43 648613 Combo 2/3 Jaw Reversible Gear Puller 46
Kit #45 648616 Crankshaft Pulley & Harmonic Balancer Puller & Installer Set 48 - 51
Kit #46 648617 23-Piece Master Ball Joint "U" Joint Service Set 52
Kit #48 648622 Master Disc Brake Kit 54
Kit #51 648625 Oxygen Sensor Wrench Set 56
Kit #52 648629 Serpentine Belt Tool Set 58
Kit #68 944050 Needle Torque Wrench 60
Kit #70 940427 22-Piece Cooling System Tester Kit 62 - 65
Kit #72 940579 10-Piece Master Ball Joint Service Kit 66
Kit #76 641321 Honda lower Ball Joint Adapter Set 68
Kit #77 641322 Ford Ball Joint Adapter Set 70
Kit #83 641326 6-Piece Oil Filter Socket Set 72
Kit #85

“I’M READY”
“I’M READY”
“I’M READY”“I’M READY”
 WELCOME
TO THE ADVANCE AUTO PARTS /

INSTALLER KITS TOOL PROGRAM

In our ongoing effort to generate parts sales and outperform our competitors, we are once again
expanding our Installer Kits Tool Program.

Our strategy is straightforward: we want to sell more parts and give the best Customer Service to
every customer who comes through our doors. We must battle all competitors in all classes of
trade who sell parts, and provide better customer service than anybody in the industry.

Let’s review some points you will find in your Loaner Tool catalog.

• 29 Loaner Tool kits available to you for Loan or Sale.

• Brand name POWERBUILT® - Serious Tools for Serious Work®.
• Durable blow-molded carry cases.
• Detailed bilingual usage instructions and photos of each kit.
• 100% Lifetime warranty.
• Professional quality tools designed for the do-it-yourself customer.
• Fast and free customer service for replacement parts.

This is just the beginning for this exciting program.

3
 INSTRUCTIONS AND PROCEDURES
LOANER, SALES, RETURNS

APPLICATION
STEP#1: Use the APAL electronic catalog to determine the “Best Part” for your customer.

STEP#2: Determine the Installer Kit needed to complete the job. Refer to the Installer kits
identification page in this catalog.

LOAN TO THE CUSTOMER

This will be rung through the register as a regular sale. Explain the following to the customer:

1. Keep the receipt; this will be needed when returning the item.
2. Open up the kit and check to see all the parts are there and presentable.
3. Point out and, if needed, explain the instructions to the customer.
4. Ask the customer if he/she needs any other assistance.

RETURNED INSTALLER KIT FROM THE CUSTOMER

This will be returned as an item coming back to the store. Use the information from the receipt to
record the item. If the customer does not have a receipt, use the history in the APAL to accept
the return. Please do the following upon a returned item:

1. Ask the customer how the project went.

2. Open up the kit and check for all the parts and cleanliness.
3. Ask if they had any problem with the kit.
4. Return to the customer the amount that is due them.

ONCE THE CUSTOMER IS GONE, PLEASE DO THE FOLLOWING:

1. Inspect the kit and make sure everything is in working order.
2. Clean the inside and the outside of the kit.
3. If an item needs to be replaced, go the Order/Replacement parts section.
4. Now you are ready to satisfy another customer.

4
SELL TO THE CUSTOMER
Run through the register using the current stock number and retail for the item being sold.

BROKEN/MISSING PARTS – HOW TO HANDLE

If the customer points out, or you notice, that a part in the kit is broken or missing, please go to
the Order/Replacement parts section. Order the item that is needed. Discard the old item once the
new one is received.

Alltrade Tools is celebrating our 30th anniversary as America’s Global Tool Company. Our
formula is the same today as it was in 1979: offer products that provide convenience, innovation
and quality at a fair price.

Alltrade’s product-line encompasses a full-range of hand tools, power tool accessories,

mechanics tools, specialty automotive tools, lubrication equipment, shop service equipment, and
lift equipment.

We are committed to the best quality and customer service;

• Alltrade Tools: manufacturing and assembly plants are all ISO 9001Certified Quality
System.

• Powerbuilt Tools: are tested and designed to meet ANSI standards.ANSI is the American
National Standards Institute.

• Fast, Free Customer Service: Toll free number provided on the product with qualified
service technicians to service/assist and answer any questions.

5
 INSTALLER KITS - IDENTIFICATION
ADVANCE MANUFACTURER Kit DESCRIPTION APPLICATION UPC CODE PIECE
STOCK NUMBER NUMBER Number 028907 COUNT

Safe and easy removal and installation of 103952 2

9150007 648627 #1 STRUT SPRING COMPRESSOR coil springs from McPherson struts.
#3 FRONT END SERVICE SET Automotive front-end work including changing tie rods,
9150006 648626 ball joints, steering linkage and steering boxes. 103945 6

9150012 648615 #6 VALVE SPRING COMPRESSOR Compressing valve springs with the cylinder head
removed from engine. 103839 2

9150015 648619 #8 PILOT BEARING Removing pilot bearings and bushings from flywheel
103877 1
PULLER KIT during clutch replacement.
9150016 648635 #10 AXLE NUT SOCKET Removing front wheel drive axle nuts. Impact rated,
30mm, 32mm, 34mm, 36mm sockets. 104836 4

9150017 648636 #11 SPINDLE NUTSOCKET KIT Removing and installing internal storage rings. 104843 5
9150018 648644 #13 POWER STEERING PULLEY Removing most power steering pump pulleys.
109268 3
PULLER KIT
9150019 648645 #14 HEAVY DUTY STEERING WHEEL Pulling steering wheels with tapped holes. Fits most 109275 13
PULLER KIT domestic and imported vehicles, with or without
telescopic or tilt steering columns.
9150020 648646 #15 FRONT-END FORK KIT Separating tie rod, ball joints and pitman arms. Includes 109282 5
striking handle for use with conventional hammers, also
an adapter handle for use with air hammers.
PULLEY REMOVER Pulling and installing power steering pump and 103730 14
9150040 648605 #20 & INSTALLER KIT alternator pulleys.

9 PIECE FLARING TOOL For flaring automotive tubing. Preciseely flares copper, 103785 9
9150055 648610 #23 aluminum and mild steel tubing up to .040" wall
thickness

648744 #29 VACUUM PUMP KIT Unique "push-pull" vacuum pump can be used for 155104 22
9150047
bleeding brakes, air conditioning and heater servicing,
and engine diagnostics.
9150044 648746 #34 FAN CLUTCH WRENCH SET Removing and installing of threaded-on type fan 155128 4
clutches.
9150042 648603 #39 COIL SPRING COMPRESSOR Removing and installing automotive coil springs. Works 230283 5
on straight or curved coil springs up to 3/4" diameter
9150001 648608 #40 MASTER HUB Pulling automotive wheel hubs including front wheel 230290 9
PULLER SET KIT drive and rear hubs on rear wheel drive, independent
rear suspension vehicles.
9150011 648611 #41 MASTER PULLER SET KIT Pulling bearings, front wheel drive axle shafts, 230306 21
as well as dent removal.
9150002 648612 #42 EXHAUST SET KIT Expanding and cutting exhaust 230313 4
pipe and dent removal.
9150008 648613 #43 COMBO 2/3 JAW REV GEAR Pulling gears and pulleys. 6" reach, 6-1/4" spread, 231709 4
PULLER KIT 5-ton capacity.
9150003 648616 #45 HARMONIC BALANCER Removing and Installing harmonic balancers. 230337 33
PULLER& INSTALLER
9150043 648617 #46 23 PIECE MASTER BALL JOINT Removing and replacing all sizes of press-fit ball joints 230368 23
"U" JOINT SERVICE SET found on domestic and import rear wheel drive vehicles.
9150045 648622 #48 MASTER DISC BRAKE KIT Complete brake job in one kit. 230344 30
9150046 648625 #51 Removing and installing oxygen sensor 234731 3
OXYGEN SENSOR WRENCH SET and vacuum switches.
9150000 648629 #52 SERPENTINE BELT KIT Removing and installing serpentine belts on vehicles 234748 13
with spring-loaded automatic belt tensioners.
9150050 944050 #68 NEEDLE TORQUE WRENCH Allows the torque applied to a fastener to be measured 278582 1
accurately, thus avoid damaging components or
fasteners.
9150049 940427 #70 22-PIECE COOLING TESTER KIT Includes an assortment of radiator cap adapters and 314808 22
coolant bottle adapters for testing cooling systems and
most standard radiator caps.
9150054 940579 #72 10 PIECE MASTER BALL JOINT This tool set is designed for use on all cars and light 325095 10
SERVICE KIT trucks that have press-fit type ball joints.
9150052 641321 #76 HONDA LOWER BALL JOINT For 1980 - 2000 model Honda; Accord, Civic, Delsol, 344898 4
ADAPTER SET CRX, and Prelude.
9150051 641322 #77 FORD BALL JOINT For 1996 - 2004 Ford Taurus & Mercury Sable. 344904 3
ADAPTER SET
9150053 641326 #83 6 PIECE OIL FILTER 6 Sizes specialty oil filter sockets for cars listed in 345666 6
SOCKET SET desrciption.

6
 REPLACEMENT PART ORDERS

INSTALLER TOOL KITS

YOU CAN ORDER THE FOLLOWING ITEMS DIRECT FROM ALLTRADE TOOLS:

• Missing or Broken Tools/Parts

• Replacement Cases
• Instruction Sheets

ORDERING PROCEDURE:
Call Alltrade’s Tech Line at 1-866-737-7976.
Hours of operation are 8:00am to 5:00pm PST.

NOTE Alltrade is on Pacific Standard Time.

Please have the following information available upon contacting an Alltrade Customer Service
Representative:

• Store Number
• Contact Name
• Shipping Address
• Contact Phone Number
• Item being ordered – This information can be found in the Tool Kit Parts Diagram.
• Identify the Item by selecting the Kit and then the item needed.

EXAMPLE Kit part number 648627 kit #1 has an item broken. The item is the Safety Pin.
Locate the Safety Pin from the picture, Part # 3. You would order a quantity of 1.

The item will be shipped to your store, for you to replace the broken part. Once the new item is
received, discard the old item.

7
 Kit #1 - Strut Spring Compressor
(648627)

648627-0
Storage Case

648627-1
Ring (4)

648627-2
Hook (4)

648627-3
Safety Pins (4)

648627-4
648627-5 Bolts (2)
Washer (4)

8
 STRUT SPRING COMPRESSOR

WARNING Spring is under compression load when installed. Attempting to remove spring without properly restraining the load with a spring
compressor may result in personal injury. DO NOT remove nut at top of strut rod unless spring is restrained by a spring compressor.

• Remove McPherson strut assembly as described in vehicle servicing information. Make index marks between strut and knuckle to aid in
installation. Also index mark the strut position at the inner fender inside engine compartment.
• Lubricate threads on spring compressor with engine oil.
• Retract the locking safety pins on spring compressor by pulling on the loops. See figure (a).
• Install the hook assembly to the coils closest to the ends of the spring, with the spring compressors positioned so that they are on the
outside of the coil spring. See figures (a) and (c).

NOTE If there is not enough space to install hook between coils, pry coils apart with a pry bar enough to allow hook to enter.

• Press pins in to lock the hook onto the spring. See figure (b).
• Make sure compressor assemblies are straight across from each other on the spring coil (180 degrees apart). See figure (d).
• Hand tighten bolts until there is slight tension on the spring. See figure (c).
• Tighten compressor a small amount with a 15/16’ socket and ratchet, then switch to the other side. See figure (d). Tighten alternately and
evenly until spring clears the seats of the McPherson strut. About 3 inches (76 mm) is normally the most compression that is required.
• Carefully remove the nut from the top of the rod. See figure (e). If equipped, remove top strut mount, upper bearing dust cap, upper spring
seat and upper bearing plate as outlined in vehicle service information. It may be necessary to hold strut rod from turning while removing
nut from top of rod.
• Remove the coil spring and set aside with compressors installed. See figure (f). Proceed with strut disassembly and component overhaul as
described in vehicle service information.
• To reassemble and install, reverse removal procedures and refer to vehicle service information. If installing an aftermarket replacement strut
cartridge, it may be necessary to add a small amount of hydraulic oil to the strut housing. Refer to cartridge manufacturer’s installation
instructions. Note that gas charged units are sold with the rod in a locked down position. Follow the manufacturer’s instructions to release
the rod. Reassemble all necessary original parts. Align index marks during installation. Remove spring compressors only after the nut at the
top of the rod is securely tightened.

Figure (a) Figure (b)

Figure (c) Figure (d) Figure (e) Figure (f)

9
 Kit #3 - 5-Piece Front End
Service Set (648626)

648626-0
Storage Case

648626-6
Pitman Arm
Puller (Large)

648626-1
648626-5
Tie Rod
Pitman Arm
End Puller
Puller (Small)

648626-4
Tie Rod
Lifter Screw

648626-3
Ball Joint 648626-2
Remover Tie Rod
End Lifter

10
 FRONT END SERVICE SET

5pc Front End Service Set

The tools in the front end tool set all work on similar principles but are different sizes and configurations for a wide range of applications. The
various pullers in this set are useful in cases where the parts are to be reused, as opposed to “pickle-fork” type tools that usually damage the
parts. Damaged parts must be replaced.

NOTE Many front-end components use self-locking nuts, which must be replaced when removed. Check the specific vehicle
manufacturer’s service information for applications.

Removal:
1. For tie-rod and ball joint applications, remove the cotter pin. See figure (a).
2. Remove the retaining nut from the tie rod or ball joint stud or the steering box output shaft at the pitman arm. See figures (b) and (c).
3. Position the puller tool so that the center screw presses on the end of the tie rod or ball joint stud or the steering box output shaft. See
figures (d), (e), and (f). The jaws of the puller should be forced between the boot on the tie rod or ball joint and the steering knuckle, or
between the pitman arm and the steering box body. Tighten the puller center screw with a wrench until the parts have been separated.
It may be helpful to tap the head of the center screw with a hammer to break parts loose.

Figure (a) Figure (b) Figure (c) Figure (d)

Figure (e) Figure (f) Figure (g)

11
Kit #6 - Valve Spring Compressor
Kit (648615)

648615-0
Storage Case

648615-6 648615-1
Straight Jaw Compressor
Assembly Body

648615-8
Hardware Kit 648615-5
for Offset Jaw Spring
Assembly

648615-2
Plunger Bar

648615-7 648615-4
2pc. Offset Jaw Assembly “T” Handle Screw

648615-3
Washer

12
 VALVE SPRING COMPRESSOR KIT

Valve Spring Compressor

1. Valve spring compressor is equipped with 2 sets of jaws, an offset jaw and a straight jaw. Determine which jaw best fits the cylinder head being
serviced.
2. Attach jaw to valve compressor tool with the screw and nut provided.
3. Place jaw on valve retainer. Adjust the screw on the jaw so that the jaw fits snugly on the retainer. See figure (a).
4. Slide back the “L” shaped release handle on the inside of the tool body and open the outside handle to its fully open position.
5. Loosen the plunger bar adjuster “T” handle. See figure (e).
6. Position the tool as shown in figure (b). The jaw should engage the valve retainer and the plunger bar should line up with the head of the valve. See
figure (c).
7. Press the plunger bar inward with a fingertip until it rests against the center of the head of the valve. See figure (d).
8. Tighten the ‘T’ handle. See figure (e).
9. Close the handle to compress valve spring as shown in figure (f). Be careful to position valve spring compressor so that the jaw does not damage
the valve cover gasket surface.
10. With the valve spring compressor locked in the compressed position, carefully remove valve keepers from valve retainer using a small screwdriver or
magnetic tool. See figure (g). It may be helpful to tap the valve retainer lightly with a small hammer to free the keepers.
11. Remove valve, valve spring, spring seat and valve retainer from cylinder head. See figure (h) and (i).
12. Service and reinstall valves, valve seals and guides as desired according to manufacturer’s servicing information.
13. Install valves into valve guides. Assemble valve seat, spring and retainer and place in position.
14. Compress the valve spring as outlined in the removal procedures above. Slip the valve keepers into place and release the valve spring compressor. It
may be helpful to place a small amount of grease on the keepers to help keep them in position while the compressor is being released. Make sure
the keepers are seated completely in the valve stem groove.

Figure (a) Figure (b) Figure (c) Figure (d) Figure (e)

Figure (f) Figure (g) Figure (h) Figure (i)

13
 Kit #8 - Pilot Bearing Puller
(648619)

648619-0
Storage
Case

648619-1
Puller Assembly

648619-2
Finger 648619-3
Center Bolt

648619-4
Finger Nut
and Bolt

14
 PILOT BEARING PULLER

1. Remove clutch cover and disc as described in vehicle service information. See figure (a).
2. Make sure that nothing is retaining the pilot bearing. In some cases washers under the flywheel bolts may overlap the edge of the pilot
bearing. If so, remove them as necessary.
3. Turn the “T” handle out (counterclockwise) so that the 2 puller fingers can be placed flat against each other. See figure (b).
4. Pinch the 2 fingers together and insert them into the pilot bearing, with the tips completely behind the back surface of the bearing. If the tips
are not completely behind the back surface of the bearing, the puller will slip and the bearing will not be removed. See figure (c).
5. Position the puller’s “U” shaped body securely against the flywheel. Turn the crosspiece so it is against the right leg of the puller body. See
figure (c).
6. Turn the “T” handle in (clockwise) until the tip of the puller center bolt begins to force the fingers apart.
7. Turn the nut on the puller center bolt down against the puller body. The crosspiece should be turned to rest against the right leg of the puller
body. See figure (d).
8. Continue to turn the “T” handle in until the fingers are as far apart as possible. The notch in the fingers should engage the inner diameter of
the bearing and the lip of the finger’s tips should pull firmly against the back surface of the bearing.
9. Hold the “T” handle firmly while turning the nut on the puller center bolt clockwise with a wrench. See figure (d).
10. Continue turning until the bearing is removed. See figure (e).

Figure (a) Figure (b) Figure (c) Figure (d) Figure (e)

15
 Kit #10 - 4-Piece Axle
Nut Socket Set (648635)

648635-0
Storage Case

648635-4 648635-1
30mm 32mm
Socket Socket

648635-3 648635-2
36mm 34mm
Socket Socket

16
 AXLE NUT SOCKET SET

Removal:
• Determine whether manufacturer recommends loosening axle shaft nut with vehicle on ground and brakes applied, or with wheel
removed from vehicle. Refer to manufacturer’s servicing information for axle shafts.
• If procedure recommended is to remove wheel, loosen lug nuts. Raise and support vehicle. Remove lug nuts and wheel and set
aside.
• For both axle nut removal procedures (on ground or wheel off), remove hub cap (if equipped). Remove cotter pin (if equipped).
• Using recommended socket, loosen axle shaft nut. It may be necessary to use an air impact wrench.
• Remove axle shaft nut.

17
 Kit #11 - 5-Piece Spindle
Nut Socket Set (648636)

648636-0
Storage Case

648636-5 648636-1
Spindle Nut Spindle Nut
Socket Socket

648636-4 648636-2
Spindle Nut Spindle Nut
Socket Socket

648636-3
Spindle Nut Socket

18
 SPINDLE NUT SOCKET SET

1. Refer to manufacturer’s servicing information for drive axles to determine procedure for gaining access to spindle nut.
2. Follow manufacturer’s service procedure for the drive axle and remove wheel and tire, brake disc or drum, locking hubs,
grease cap and grease seals, cotter pins or snap rings, as recommended.
3. Engage spindle nut socket with spindle nut. Remove spindle nut by turning with wrench.
4. Manufacturer may recommend replacement of nut when installing. Refer to manufacturer’s servicing information.

19
 Kit #13 - Power Steering
Pump Pulley Puller (648644)

648644-0
Storage Case

648644-1
Handle

648644-4 648644-2
Nose Piece Puller

648644-3
Jaw Locking
Bolts (2)
5mm x 64mm

20
 POWER STEERING PUMP PULLEY PULLER

1. Grease center bolt.

2. Fit jaws over flange on pulley.
3. Tighten thumb screws to lock jaws into position.
4. Turn the center screw with a ratchet or end wrench.
5. Remove pulley from pump.

21
 Kit #14 - Heavy Duty Steering
Wheel Puller (648645)

648645-8
M8 - 1.25" x 80mm
NF Bolts (2)

648645-0
Storage Case

648645-7
5/16" - 24" x 3-1/2" 648645-1
NF Bolts (2) 3/8" - 16" x 4"
NC Bolts (2)

648645-2
5/16" - 18" x 4-1/2"
NC Bolts (2)

648645-3
648645-6 Yoke
1/4" - 28" x 3"
NF Bolts (2)

648645-5
Center Screw Pad
648645-4
Center Screw

22
 HEAVY DUTY STEERING WHEEL PULLER

1. Remove horn button or center pad from steering wheel.

2. Remove center nut from steering shaft.
3. To ensure proper realignment, index mark steering wheel to steering shaft.
4. Match bolts from kit to holes in steering wheel.
5. Thread bolts with washers through slots in puller body and into steering wheel.
6. Grease large center bolt. Thread center bolt through center hole in puller body.
7. Place tip assembly onto end of center bolt and thread center bolt against steering shaft.
8. Using end wrench or ratchet, tighten center bolt until steering wheel is pulled off of steering shaft.

23
 Kit #15 - 5-Piece Fork Set
(648646)

648646-0
Storage Case

648646-1
1-1/8"
Pitman
Arm Fork

648646-5
Air Hammer
648646-2
Adapter
15/16"
Ball Joint
Fork

648646-3
11/16"
Tie Rod
Fork

648646-4
Striking Handle

24
 FORK SET

1. Assemble desired handle to fork.

2. Remove cotter pin (if equipped) and nut from tie rod, ball joint or pitman arm stud.
3. Insert tines of separator between parts.
4. Strike end of separator with hammer or attach air hammer and apply air pressure to separate.

25
 Kit #20 - Power Steering & Alternator
Pulley Tool Set (648605)

648605-0
Storage Case

648605-1
GM Quad 4
Puller Pin

648605-14
Jaws (2)

648605-2
GM 3.1L V6
Puller Pin
648605-13
Sleeve
648605-3
Center Screw

648605-4
GM Quad 4
648605-12
Threaded Adapter
Thrust Bearing
648605-5
GM 3.1L V6
Threaded Adapter
648605-11
Thrust Washer
648605-6
Universal
Threaded Adapter

648605-7
Ford 4.6L
Threaded Adapter

648605-10 648605-9
Puller Body GM Power Steering 648605-8
Disconnect Center Screw Button

26
 POWER STEERING & ALTERNATOR PULLEY TOOL SET

Standard Power Steering Pump Pulley Removal & Installation

Removal
• Apply a light coat of lubricant to threads on center screw.
• Assemble center screw and button (or puller pin) by inserting the small end of the button into the threaded hole in the center
screw and twisting until they are firmly mated. See figure (a).
• Assemble the puller body to the center screw. The flanged end should face the adapter. See figure (b).
• Position the assembly into the hole in the end of the power steering pump pulley and finger tighten the puller body against the
pulley. Place the jaw halves so that they hold the flanges on the power steering pump pulley and the flange part of the puller
body together. See figure (c).
• Slide sleeve over the 2 jaw halves so that they are caged and tighten puller body and center screw assembly so that it pulls
lightly on the pulley. See figure (d).
• Hold center screw with a wrench and turn the flange nut with another wrench until pulley is removed from pump pulley shaft.
See figures (e) and (f).

Installation
• Select a threaded adapter that fits the threads in the pump pulley shaft.
• Thread center screw and adapter together by hand.
• Tighten center screw and adapter together with wrenches. See figure (g).
• Thread puller body onto center screw and fit thrust bearing over center screw shaft and against flange. See figure (h).
• Place washer against bearing and install assembled tool to pump shaft. Screw end of adapter into pump pulley shaft. See
figures (i) and (j).
• Using two wrenches, hold center screw stationary and turn puller body to force pulley onto shaft. Continue tightening tool
assembly until pulley is completely drawn onto shaft. See figure (k).

(a) (b) (c) (d)

(e) (f) (g) (h)

(i) (j) (k)

27
 Kit #23 - 9 Piece Double Flaring
Tool Kit (648610)

648610-0
Storage Case

648610-1
3/16" Flaring Adapter

648610-2
3/8" Flaring
Adapter

648610-9
Yoke 648610-3
1/4" Flaring
Adapter

648610-4
7/16" Flaring
Adapter
648610-5
5/16" Flaring
Adapter

648610-6
1/2" Flaring
Adapter

648610-7
5/8" Flaring
Adapter

648610-8
9/16" Flaring Bar

28
 DOUBLE FLARING TOOL SET
Instructions:

NOTE: It is extremely important to prepare the tubing before flaring as described

in step 1. Failure to do so will ensure unsatisfactory results.
1. Ensure end of tubing is cut off squarely. Use a reamer, round file or pocket knife blade to deburr inside diameter of tubing.
Round off (chamfer) edge of outside diameter of tubing using small file. See figures 648610a and 648610b.
2. If a flare nut is required and can’t be installed from the other end of the tubing at a later time, slip the required flare nut over
prepared endof the tubing and position it out of the way.
3. Insert tubing through hole in clamping bar matching outside diameter of tubing. Place corresponding size double flaring adapter
with flat surface down on clamping bar next to the end of tubing. Adjust tubing position so that the amount protruding from the
surface of the bar matches the height of the first step of the flaring adapter. See figure 648610c.
4. Tighten the nuts on the flaring bar securely so that tubing will not slip down. Recheck height of exposed tubing against the
flaring adapter and adjust if necessary.
5. Reverse flaring adapter and insert the nipple into the end of the exposed tubing. See figure 648610d. Install the flaring yoke over
flaring bar with tip inserted into the depression in the flaring adapter. See figure 648610e. Tighten hex screw on the yoke until
flaring adapter is pressed firmly against clamping bar. See figure 648610f.
6. Loosen flaring yoke and remove flaring adapter. Check the partially flared tube end and make sure there is no distortion of the
tube. Place tip of the flaring yoke directly into partial flare and slowly tighten center screw until the flare edge is completely
compressed between the yoke and flaring bar. See figure 648610g.
7. Remove flaring yoke and examine double flare for cracks, distortion or other faults. See figure 648610h. If faults are found, cut
off tubing end and repeat flaring process.

Figure A Figure B Figure C Figure D

Figure E Figure F Figure G Figure H

29
 Kit #25 - Upper Control Arm
Bushing Service Set (648604)

648604-0
Storage Case

648604-1
C-Frame Adapter

648604-12 648604-2
“C” Adapter #1 Insert “A”

648604-3
648604-11 Insert “B”
“C” Adapter #2

648604-4
Insert “C”
648604-10
“C” Adapter #3
648604-5
O-Ring

648604-6
648604-9 Receiving
Forcing Cap Adapter

648604-7
Forcing Screw
648604-8
Cap
30
 UPPER CONTROL ARM BUSHING SERVICE SET
Instructions:

• For use on Ford Motor Co., Chrysler Motors and General Motors vehicles
• For use with press-in type bushings
• Allows replacement of bushings without removing the control arm from the vehicle

BUSHING REMOVAL
1. Remove the nuts from the 2 bolts that that attach the upper control arm shaft to the frame. See figure a. Remove the large nut
and washer from the upper control arm shaft so that the threaded end of the shaft can be seen sticking out of the bushing. See
figure b.
2. If necessary, drive the upper control arm to shaft bolt closest to the bushing back into the shaft slightly to allow clearance for
the "C" adapter. Select a "C" adapter that has the closest outer diameter to the size of the bushing and insert it into space
between the bushing and the cross shaft bolt. See figure b.
3. Assemble the "B" cap (with "O" ring) to the receiving adapter as shown in figure c. Center the receiving adapter over the end of
the control arm shaft as shown in figure d.
4. Install the "C" frame so that the forcing screw engages the "B" cap and the "C" adapter is securely engaged by the jaws of the "C"
frame. See figure e. Turn the forcing screw in slowly with the "C" adapter pressing against the end of the bushing.
5. A liberal application of penetrating oil between the inner diameter of the control arm and the outer diameter of the bushing may
be helpful to reduce friction between the bushing and the control arm. After making sure all parts are aligned correctly, turn the
forcing screw with a ratchet until the bushing is removed. See figure f.

BUSHING INSTALLATION
1. Assemble "B" cap (with "O" ring) to the forcing cup as shown in figure g. If necessary, select an insert (inserts "F", "G" and "H")
where the diameter of the insert matches the diameter of the bushing. In the example shown, an insert is not used because the
forcing cup diameter matches that of the bushing.
2. Place the insert inside the forcing cup (if needed). Place a new bushing in position on the control arm shaft as shown in figure
h. Assemble the "C" frame and forcing cup assembly over the control arm shaft as shown in figure h.
3. In a similar manner to that used for bushing removal, turn the forcing screw with a ratchet until bushing is installed. A liberal
application of penetrating oil between the inner diameter of the control arm and the outer diameter of the bushing may be
helpful to reduce friction between the bushing and the control arm. To complete installation, reverse removal procedure.

Figure a Figure b Figure c Figure d

Figure e Figure f Figure g Figure h

31
Kit #26 - 4 Piece Inner Tie-Rod
Remover Set (648607)

648607-0
Storage Case 648607-1
Tie Rod Extension
Bar Tool

648607-4 648607-3 648607-2

1-5/16" 1-3/16" 1-7/16"
Socket Adapter Socket Adapter Socket Adapter

32
 INNER TIE ROD REMOVER SET
Instructions:

Usage instructions:
1. Loosen front wheel lug nuts. Raise and support front of vehicle using jack stands. Remove wheel and tire assembly.
2. Disconnect outer tie rod ends from steering knuckle pickle fork or tie rod end puller. Use a tie rod end puller if outer tie rod is
to be reused.
3. Loosen outer tie rod end locknut using a large adjustable wrench to hold the tie rod end body while turning locknut with an
end wrench. See figure A.
4. Remove clamp from outer end of protective boot or bellows that covers outer tie rod end and seats on steering rack. See
figure B. Loosen screw clamp from inner end of the with a screwdriver. See figure C.
5. Reach through the hole in the fenderwell and remove boot from the steering rack. See figure D. Select proper size socket to fit
hex on inner tie rod end. Reach through the fenderwell and place the socket onto tie rod end. See figure E.
6. Slide tie rod end tool over threaded end of the tie rod end and engage with socket. See figure F. Using a 1/2" ratchet or
breaker bar, turn socket and tool and loosen tie rod end.
See figure G. Reach through hole in fenderwell and remove tie rod end. See figure H. Installation is the reverse of removal
instructions.

Figure a Figure b Figure c Figure d

Figure e Figure f Figure g Figure h

33
 Kit #29 - Vacuum Pump Set
(648744)

648744-0
Storage Case

648744-2
Fluid Reservoir
with Vacuum
Nipples

648744-1
Vacuum Pump
with Gauge
648744-2
Fluid Reservoir
with Sealed Cap

648744-5
Vacuum Nipples
Accessories Kit

648744-4
Vacuum Line

34
 VACUUM PUMP SET

• Checks vacuum-operated automotive components.

• Can be used to bleed hydraulic systems or siphon fluids.
• Includes integrated vacuum/pressure gauge.
• Special vacuum/pressure release mechanism.
• Includes assorted adapters and hydraulic fluid reservoir.

GENERAL USAGE INSTRUCTIONS:

The Powerbuilt vacuum pump is most often used as a vacuum pump or test instrument. The pump may be connected to a
component with the
provided vacuum line, connected directly to the component itself, or connected to an existing vacuum line directly or with the
provided tee
connector.

To create vacuum:
Move the collar to the forward position (away from the handles). With the pump connected to the appropriate component
or vacuum line, simply squeeze the moveable handle of the pump with your hand. Continue the squeezing motion until the
gauge shows the desired level of vacuum.
To check vacuum:
With the pump connected to the appropriate component or vacuum line, read the measured amount of vacuum at the
gauge (engine running). DO NOT pump the handle, as this will cause an incorrect reading.

Bleeding hydraulic components:

The pump may be used to draw hydraulic fluid through hydraulic lines such as brake and clutch lines. (See figure:
Bleeding Brakes.) Attach a short piece of clear plastic line to the pump. Using the fluid reservoir with vacuum nipples,
attach the other end of the clear plastic line to one side of the reservoir’s cap. Attach a long piece of clear plastic line to
the other side of the cap and to the desired hydraulic fitting for bleeding. With the vacuum pump set to vacuum position,
open the hydraulic system’s bleeder valve and slowly draw fluid into the reservoir. Take care not to draw fluid past the
reservoir and into the pump.

RELEASING VACUUM
To release vacuum, slide the collar rearward to the release. This allows air to enter the system, relieving the vacuum.

Figure: Bleeding Brakes

35
Kit #34 - Fan Clutch Wrench Set
(648746)

648746-1 648746-2 648746-3 648746-4

36mm x 1-9/16" 58mm Wrench 1-7/8" Wrench 3-1/4" Wrench
Double End Wrench

36
 FAN CLUTCH WRENCH SET

Fan Clutch Wrench Set

1. Note the hex area where the fan clutch mates to the water pump output shaft. See figure (a).
2. Engage the hex of the fan clutch nut with the appropriate sized wrench. See figure (b).
3. Select the wrench that best fits the 4 bolts on the water pump output shaft. Position the wrench so that it engages the 4 bolts and can be used
to hold the water pump shaft stationary. See figure (c).
4. Turn the two wrenches so that the clutch can be screwed off of the water pump output shaft threads and removed from the vehicle. See figure
(d). Note that some clutches may have reverse threads..
5. Installation is the reverse of removal procedures.

Figure (a) Figure (b)

Figure (c) Figure (d)

37
 Kit #35 - A/C Clutch Service Set
(648747)

648747-0
Storage Case

648747-3
648747-1 648747-9 648747-10
Clutch Plate Clutch Plate
Clutch Plate Clutch Plate
Remover Remover with
Remover Remover
Washer

648747-2
Clutch Plate
Remover 648747-4
Clutch Plate
648747-11
Installer
Clutch Plate
Remover/Installer

648747-13
648747-12 Clutch Plate
Clutch Plate Installer
Installer with
Bearing

648747-8
Disc

648747-5
648747-7
Bolt & Washer Set Universal Orifice
Tube Service
648747-6
Clutch Plate
38 Removal Arbor
 A/C CLUTCH REMOVAL SET
A/C Clutch Removal Set & Installation

Sanden
1. Remove clutch retaining nut. See Figure 648747a. Position disc above clutch end plate and insert the 3 bolts through disc. Thread bolts into
mating holes in clutch end plate.See Figure 648747b.
2. Thread pushrod through disc. See Figure 648747c.
3. Tighten the bolts alternately and evenly until snug. Turn the hex on the arbor (pushrod) until clutch end plate is pulled off of clutch assembly.
See Figures 648747d and 648747e.
4. Remove A/C clutch assembly snap rings and lift clutch assembly off of compressor. To install, reverse removal procedures. Be sure to install
clutch shaft key when installing clutch end plate. See figure 648747f.
5. Press clutch end plate down on output shaft until clutch retaining nut can be installed. See figure 648747g. Tighten nut to pull clutch end plate
into position. See figure 648747a.

Figure A Figure B Figure C Figure D

Figure E Figure F Figure G Figure H

Figure I Figure J Figure K Figure L

39
Figure M Figure N Figure O Figure P

Figure Q Figure R Figure S Figure T

Figure U Figure V Figure W Figure X

Figure Y Figure Z

40
Delphi/Harrison
Procedures for Delphi/Harrison compressors are similar to those for other manufacturers, and can generally be followed for
Mitsubishi, Zexel, and York/Tecumseh, etc.
1. Remove clutch retaining nut. See Figure 648747h. Install remover tool to the clutch end plate by threading the outer body of
the tool into hole in center of clutch end plate. See Figure 648747i.
2. Thread inner arbor through body of tool. See Figure 648747j. Turn hex on pushrod while holding outer body stationary. See
Figure 648747k until clutch end plate is pulled off of clutch assembly. See Figure 648747l.
3. Remove A/C clutch assembly snap rings and lift clutch assembly off of compressor. To install, insert clutch shaft key. See
figure 648747m. Press clutch end plate down on output shaft. See figure 648747n.
4. Assemble clutch installer and install with threads on inner diameter of arbor engaged with threads on outer diameter of clutch
output shaft. The bearing should be against clutch end plate. See figure 648747o.
5. Hold body of tool stationary with wrench and turn inner arbor with ratchet. This will draw the clutch end plate onto the output
shaft. See figure 648747p. Install and tighten clutch retaining nut to complete assembly procedure. See figure 648747q.

Fixed Orifice Tube Removal

1. Discharge A/C system using approved refrigerant recycling equipment. Disconnect condenser-to-evaporator discharge line.
Remove "O" rings (if equipped).
2. Determine best fit of available orifice tube removal tool adapters. Ensure adapter will engage end of the orifice tube. If
discharge line includes a nut at the fitting, go to step 7.
3. If the discharge line does not use a nut, assemble the tool without the adjusting nut on the body. Install adapter. See Figure
648474r. Insert adapter end into the discharge line. See Figure 648474s.
4. Engage adapter with end of the orifice tube. It may be necessary to turn the handle a few degrees to engage tangs on the
orifice tube. See Figure 648474t. Pull back on tool and remove orifice tube from evaporator discharge line. See Figures
648474u and 648747v.
5. Orifice tubes may break during removal. See Figure 648474w. If orifice tube breaks assemble tool body with broken orifice
tube extractor adapter. See Figure 648474x.
6. Insert adapter end into discharge line. See Figure 648474y. Thread broken orifice tube extractor into orifice tube until it is
seated firmly into orifice tube body. Pull back on tool and remove broken orifice tube from evaporator discharge line. See
Figure 648474z.
7. If discharge line uses a nut at the fitting, assemble tool with adjuster nut with internal threads facing the adapter end. Install
adapter. Insert the adapter end into discharge line.
8. Engage adapter with end of the orifice tube. It may be necessary to turn handle a few degrees to engage the on the orifice
tube. Thread adjuster nut onto fitting.
9. While holding the handle of tool stationary, tighten adjuster nut to slowly remove orifice tube. When orifice tube is free from
the line, turn adjuster nut off and pull tool and orifice tube from evaporator discharge line.
10. Orifice tubes sometimes break during removal. See Figure 648474w. If orifice tube breaks off or is broken off in discharge line,
assemble tool body with broken orifice tube extractor. Follow the procedure outlined in step 9 to remove broken orifice tube.

41
 Kit #39 - Coil Spring Compressor
Set (648603)

648603-0
Storage Case

648603-9
Long “Double D”
Socket

648603-8 648603-1
Short “Double D” Shock Absorber
Socket Tool

648603-2
9/16" Hex
648603-7
Socket
Hook (4)

648603-3
Plate (2)
648603-6
Center Screw
648603-4
Black Washer (2)

648603-5
Silver Washer (1)

42
 COIL SPRING COMPRESSOR

Procedure for removing “Double D” type shock absorber nuts:

1. Place the provided 9/16" hex socket over the hex nut on the shock.
2. Fit the proper size oval (“Double D”) socket over the end of shock stem.
3. Insert the square drive wrench (Red handle) into oval socket and hold to keep shock stem from turning.
4. Turn the 9/16" hex socket with a 3/4" end wrench to remove shock nuts. See figure (a).

Procedure for Removing Straight Springs:

1. Lubricate threads on spring compressor with engine oil.
2. Remove the wheel and tire following the manufacturer’s servicing information.
3. If the vehicle has a shock absorber that is located inside the coil spring, remove the shock from the vehicle following the manufacturer’s
servicing information.
4. If the shock is located outside of the coil spring, remove the upper or lower attaching bolt to disengage the shock. See figure (b).
5. Clean any grease or oil from the coil spring. Do NOT attempt to compress an oily spring.
6. Remove the nut and spring retainer located inside and at the bottom of the coil spring. See figures (c), (d) and (e).
7. Insert the spring compressor through the hole at the top of the shock tower or spring seat.
8. Install the hook assemblies to the coils closest to the ends of the spring where the hooks will fit easily. Note that there should be a short and
long hook on each side of the spring. The distance between the ends of the hooks should be equal on each side. Spring compressor should
NOT have both short hooks on one side and both long hooks on the other side. See figure (f).
9. Hand tighten the nut at the end of the shaft until there is slight tension on the spring. Make sure the spring compressor is positioned
straight up and down and that the center bolt is parallel to the spring. The hooks should line up with each other. See figure (f).
10. Place an end wrench or ratchet on the center shaft’s fixed nut. Carefully turn the nut while making sure that the hooks stay properly
positioned on the spring coils. See figure (g).
11. Compress the spring only enough to clear spring seat and remove from the vehicle. In most cases, about 3-4" will be enough. Do not
compress more than necessary. See figure (h).
12. Carefully remove spring from vehicle.

Procedure for Removing Curved Springs:

The procedure for curved springs is the same as that for straight springs, but for curved springs the hook assemblies must be installed so
that both short hooks are on one side of the spring and both long hooks are on the other side.

Figure (a) Figure (b) Figure (c) Figure (d)

Figure (e) Figure (f) Figure (g) Figure (h)

43
 Kit #40 - Master Hub Puller Set
(648608)

648608-0
Storage Case

648608-1
648608-9 FWD Hub Puller
RWD Hub Puller 3.75/4.5"
4.5/5.5"

648608-2
M20 x 1.5 Puller /
Installer
648608-8
5/8" x 5-1/2" NF 648608-3
Center Screw M22 x 1.5 Puller /
Installer

648608-4
5/8" Nut
648608-7 648608-5
648608-6
1-1/2" Tube 3/4" Nut
1-1/8" Washer

44
 MASTER HUB PULLER SET

NOTE In some cases, it may be necessary to loosen hub nut with vehicle on ground and brakes applied. In other cases, hub
nut may be loosened with wheel removed from vehicle. Refer to manufacturer’s servicing information.

Removal (Most Front Wheel Drive Vehicle Hubs)

Note that this kit also contains tools for specific Ford Motor Company applications that require model-specific tools. Instructions for use of
these tools directly follows these instructions.

NOTE Use the tall hub removal tool as necessary for front hubs on most FWD cars. In the tool case this tool is labeled “FWD
3.75/4.5”. Refer to manufacturer’s servicing information to determine the correct tool set applications.

1. Remove wheel, disc brake caliper, disc brake rotor and axle shaft nut and washer following vehicle manufacturer’s servicing information. See
figure (a).
2. Mark hub and bearing assembly in relation to steering knuckle for installation reference.
3. Remove bolts securing hub and bearing assembly to steering knuckle. In the example illustrated, an access hole is provided in the hub to
reach Torx bolts. See figures (b) and (c). Remove splash shield (if equipped). See figure (d).
4. Install front hub remover tool to vehicle’s wheel studs and tighten lug nuts. In the tool case this tool is labeled “FWD 3.75/4.5”. See figure
(e). Tighten front hub remover tool’s center bolt to press axle shaft toward engine and disengage hub. In the tool case this tool is labeled
“5/8" x 1/2" NF CENTER SCREW’. See figure (f).
5. Remove hub and bearing assembly. See figure (g).

Removal (Select Front Wheel Drive Ford Motor Company Vehicles)

These tools and instructions are for removing the hub and axle on Ford Taurus, Tempo and Escort vehicles, and Mercury Topaz, Tempo and Lynx
vehicles. The axle shaft to hub engagement is a press fit and it is necessary to push the end of the axle shaft out of the hub before disengaging
the axle shaft to remove the hub or axle. The axle shaft must be pulled back into the hub when being reinstalled, using the special installer tool.

1. Raise and support vehicle. Remove wheel. Remove brake caliper. See figures (h) and (i).
2. Remove brake rotor. See figure (j). Remove axle shaft nut andwasher. See figure (k) on page 14.

Figure (a) Figure (b) Figure (c) Figure (d) Figure (e)

Figure (f) Figure (g) Figure (h) Figure (i) Figure (j)

45
 Kit #40 - Master Hub Puller Set
(648608)

648608-0
Storage Case

648608-1
648608-9 FWD Hub Puller
RWD Hub Puller 3.75/4.5"
4.5/5.5"

648608-2
M20 x 1.5 Puller /
Installer
648608-8
5/8" x 5-1/2" NF 648608-3
Center Screw M22 x 1.5 Puller /
Installer

648608-4
5/8" Nut
648608-7 648608-5
648608-6
1-1/2" Tube 3/4" Nut
1-1/8" Washer

46
 MASTER HUB PULLER SET

3. Install the tall hub remover tool to vehicle’s wheel studs using lug nuts. In the tool case this tool is labeled ‘FWD 3.75/4.5’ See figure (l) on
page 14. Tighten front hub remover tool’s center bolt to press axle shaft toward engine and disengage hub. In the tool case this tool is
labeled “5/8" x 1/2" NF CENTER SCREW”. See figure (m) on page 14.
4. Bottom out axle shaft in the hub. Although the end of the axle shaft will still be visible inside the hub, the splines will be completely
disengaged when the procedure is completed. See figure (n) on page 14. With the other end of axle shaft disengaged from the transaxle,
axle shaft can be removed.

Installation
1. Install hub loosely on the end of the axle shaft while aligning splines. Turn the threaded socket end of the front hub installer tool firmly onto
end of axle shaft. In the tool case the front hub installer tools are labeled “M20x1.5 and M22x1.5”. Select the one that fits your application.
Slide collar down the shaft of front hub installer tool and seat against the hub. In the tool case the collar is labeled “1 1/2’ tube”.
2. Hand tighten large nut against the collar. See figure (o). Using two wrenches, turn large nut clockwise while holding the shaft. See figure (p).
When tool bottoms out, loosen large nut by turning counterclockwise slightly.
3. Turn shaft of front hub installer tool counterclockwise until tool has been removed from the axle shaft. Check to make sure hub is installed
completely. See figure (q). The threaded shaft on end of axle should protrude from hub. To complete installation, reverse removal
procedures.

Removal (Rear Wheel Drive Rear Hub)

Use the short hub removal tool as necessary for rear hubs on rear wheel drive cars with independent rear suspension.
NOTE
Refer to manufacturer’s servicing information to determine application.

1. Remove wheel, disc brake caliper or brake drum following vehicle manufacturer’s servicing information. Ensure any bolts, nuts or clips that
may retain hub to other suspension parts have been removed following vehicle manufacturer’s servicing information.
2. Position hub removal tool on hub and install lug bolts or lug nuts. In the tool case the tool is labeled “RWD 4.5/5.5”. Tighten rear hub
remover tool’s center bolt to press against axle shaft and remove hub. See figure (r).

NOTE It may be necessary to loosen hub nut with vehicle on ground and brakes applied. Refer to manufacturer’s servicing
instructions.

Figure (k) Figure (l) Figure (m) Figure (n)

Figure (o) Figure (p) Figure (q) Figure (r)

47
 Kit #41 - Master Puller Set
(648611)

648611-3
1-3/8" - 2-7/8"
Bearing Adapter
648611-0
Storage Case
648611-2
5lb. Slide
Hammer Weight 648611-4
1-5/16" - 2-3/8"
Bearing Adapter

648611-5
648611-1
1" - 1-7/8"
Tapping Screw Bearing Adapter

648611-18
Threaded
Adapter
648611-13
Cone

648611-17
Bearing Hook
648611-12
3-Jaw
648611-16 Yoke
Hook

648611-6
648611-15
FWD Axle Puller
Shoulder Bolts
Adapter

648611-7
Axle Yoke

648611-11
648611-14 648611-8
2-Jaw Yoke
Jaws Slide Hammer
648611-10 648611-9 Screw
Adapter Locknut

48
 MASTER AXLE PULLER SET

Axle Pulling - Rear Wheel Drive Vehicles

Slide hammer may be used for pulling axles on rear wheel drive vehicles using the yoke and slide hammer tools. In the tool case these tools
are labeled “Slide Hammer”, “Slide Screw”, “Locknut” and “Yoke”.

1. Remove rear wheel and brake drum. See figure (a). Install yoke to wheel studs. See figure (b). Install and tighten lug nuts. See figure (c).
2. See manufacturer’s servicing instructions and follow procedures for release of the axle shaft from inside of the axle carrier. This usually
involves removing the rear cover from the axle and removing a retaining fastener.
3. Screw the end of the slide screw into the mating threads on yoke, and tighten locknut securely. See figure (d).
4. Position the slide hammer weight against the yoke. See figure (e). Rapidly slide the weight toward the handle end until it hits the ballshaped
stop. See figure (f). Repeat this procedure until axle shaft can be removed. See figure (g).

Seal and Bearing Pulling Using Bearing Adapter - Rear Wheel Drive Vehicles
Slide hammer may be used for seals and bearings on rear wheel drive vehicles using the bearing adapters and bearing hook. In the tool case
the bearing adapters are labeled 1’ - 1 7/8’, 1 5/16’- 2 3/8’ and 1 3/8’-2 7/8’. In the tool case the bearing hook is labeled “hook”.

1. Install bearing hook to slide hammer and place behind bearing seal. Position the weight against the yoke. Rapidly slide the weight toward the
handle end until it hits the ball-shaped stop and the seal is removed. See figures (h) and (i).
2. Determine the correct fitting bearing adapter and install to slide hammer. Place the bearing adapter behind bearing and operate the slide
hammer as outlined above until bearing is removed. See figure (j).

Seals and Bearing Pulling Using Puller Jaws & Yoke - Front & Rear Wheel Drive Vehicles
Slide hammer may be used for pulling bearings and seals, etc. by using the puller jaws and yoke. Use either the 2-jaw yoke or the 3-jaw yoke as
appropriate. Other pieces required are jaws and bolt and nut combinations and cone. In the tool case these tools are labeled “2-jaw yoke”, “3-jaw
yoke”, “jaws”, “cone” and “shoulder bolts”.

1. Attach jaws to the yoke with the provided shoulder bolts and nuts. For inside pulls, the jaws should be installed to the yoke facing outward,
and the cone should be installed to the slide hammer with the concave surface facing outward.
2. Install the yoke and jaw assembly to the slide hammer. Insert the jaws into the opening. See figure (k) on page 19. Adjust the cone by
threading it down so the concave surface engages the tail end of the puller jaws and begins to spread jaws apart.

Figure (a) Figure (b) Figure (c) Figure (d) Figure (e)

Figure (f) Figure (g) Figure (h) Figure (i) Figure (j)

49
 Kit #41 - Master Puller Set
(648611)

648611-3
1-3/8" - 2-7/8"
Bearing Adapter
648611-0
Storage Case 648611-2
5lb. Slide
Hammer Weight 648611-4
1-5/16" - 2-3/8"
Bearing Adapter

648611-5
648611-1
1" - 1-7/8"
Tapping Screw Bearing Adapter

648611-18
Threaded
Adapter
648611-13
Cone

648611-17
Bearing Hook
648611-12
3-Jaw
648611-16 Yoke
Hook

648611-6
648611-15
FWD Axle Puller
Shoulder Bolts
Adapter

648611-7
Axle Yoke

648611-11
648611-14 648611-8
2-Jaw Yoke
Jaws Slide Hammer
648611-10 648611-9 Screw
Adapter Locknut

50
 MASTER AXLE PULLER SET

3. See figure (l). Tighten cone until the jaws are locked securely behind the bearing or seal, etc. Position the weight on the slide hammer body
until it is against the cone. See figure (m). Move the weight rapidly to the rear sharply to remove the bearing, seal or gear.
4. Outside pulls are similar, except the position of the puller jaws should be reversed and the cone should be installed with the convex surface
facing the puller jaws.

Axle Pulling - Front Wheel Drive Vehicles

1. Axle shafts may be pulled from the transaxle of front wheel drive vehicles using the box-like axle shaft puller attachment. In the tool case
this tool is labeled “FWD Axle Puller Adapter”. To use, drain transaxle.
2. Remove front hub and disconnect axle shaft using hub puller as outlined in manufacturer’s vehicle servicing information. See figure (k).
Retain the axle nut for later use.
3. Make sure any snap rings or bolts that may hold axle shaft into transaxle have been removed. Install the axle shaft attachment by guiding
the end of the axle shaft through the provided hole in the axle shaft attachment.
4. Thread the axle nut removed earlier onto the end of the axle shaft. See figure (o). Thread the slide hammer into nut welded to the axle shaft
attachment. See figure (p).
5. Move the weight on the slide hammer body to the rear sharply to pull axle shaft from transaxle. Note that transaxle may leak fluid once axle
shaft is removed and have a suitable container ready to catch fluid if necessary.

Other Uses - The Master Axle Puller Set Kit contains a large slide hammer and a bearing hook, tapping screw, threaded adapter and tapping
screw adapter that make it useful for general use as a slide hammer as well as an axle puller. In the tool case these tools are labeled “Hook”,
“Threaded Adapter”, “Tapping Screw”, and “Adapter”.

Bodywork: Slide hammer may be used for pulling dents from fenders, etc. Drill a small hole through the metal inside the damaged area. Install
the tapping screw into the adapter and thread the adapter onto the slide hammer. Thread the screw firmly into the hole. It may be necessary to
turn the entire slide hammer assembly to do this. See figure (q) and (r). Move the weight on the slide hammer body to the rear sharply to pull
dent outward. Drill additional holes and repeat process until desired result is achieved. Another body work option is the provided bearing hook
style puller, which can be hooked over the edge of damaged body parts and pulled with the slide hammer. See figure (s).

Gear Pulling Using Puller Arms & Yoke - Front & Rear Wheel Drive Vehicles
Slide hammer may be used for pulling gears by using the puller jaws and yoke. Generally follow the procedures listed for pulling seals and
bearings, but where the instructions require attaching the puller jaws to a bearing or seal, instead place the jaws around or behind the gear.

Figure (k) Figure (l) Figure (m) Figure (n) Figure (o)

Figure (p) Figure (q) Figure (r) Figure (s)

51
 Kit #42 - 4-Piece Exhaust Set
(648612)

648612-0
Storage Case

648612-4
2-1/8" - 3-1/2"
648612-1
Expander (Large)
Nut Splitter

648612-3
1-1/2" - 2-1/2"
Expander (Small)

648612-2
Chain Cutter

52
 4-PIECE EXHAUST SET

The 4-piece exhaust pipe tool set includes 4 tools for working on exhaust systems. They include 2 sizes of pipe expanders, a chain cutter and a
nut splitter.

Cutting Exhaust Pipe With Exhaust Pipe Cutter

1. Make a loop of chain around the pipe. Hook the cutting roller’s link pin into the slot in the pipe cutter jaw. See figure (a).
2. Compress the handles of the pipe cutter until the cutting rollers apply pressure to the pipe. Rotate the cutting tool back and forth around
the pipe in a circular motion until the pipe is lightly scribed.
3. Increase pressure on the handles. Continue rotating the tool until the pipe is cut through completely and the pipe halves separate. It may
be necessary to tighten the chain by one link during this process. See figure (b).

Pipe Expander
The pipe expander is designed to slightly expand the diameter of the pipe. This allows slip fitting pipes together when clamping or welding them
together. Expander can also be used to remove clamp dents.

Expanding Diameter With Pipe Expander

1. Adjust the diameter of the expander tool to approximately the same size as the inside diameter of the pipe by compressing the barrel and
turning the nut. Adjust the snap ring to fit flush to the nut using snap ring pliers or simply by turning it down on the threads. See figures
(c) and (d).
2. Insert the tool into the pipe. Turn the hex shaft on the tool with a ratchet. See figure (e). Continue turning until the desired amount of
expansion is obtained and pipes can be fitted together. See figure (f).
3. Tool may be partially withdrawn from the end of the pipe when making tapered expansion joints prior to welding.

Removing Dents With Pipe Expander

1. To repair clamp dents, insert tool into pipe so that the tool body is at the point of the dent.
2. Turn center hex shaft of tool with ratchet to push the dent out. See figure (f). Be careful not to expand pipe.

Splitting or Removing Rusted Nuts With Nut Splitter

The nut splitter can be used to split rusted or corroded nuts up to 5/8".
1. Adjust nut splitter driver to fit the nut to be split and position securely in place.
2. Turn driver with a 3/4" (19mm) wrench until nut is split. See figure (g).

Figure (a) Figure (b) Figure (c) Figure (d)

Figure (e) Figure (f) Figure (g)

53
 Kit #43 - Combo 2/3 Jaw Reversible
Gear Puller 4" & 6" (648613)

648613-0
Storage Case

648613-1
Elbow Plates (6)

648613-6
Shoulder
Bolts (6)

648613-2
Center Bolt

648613-3
2/3 Combo Yoke

648613-5
6" Reversible
Jaws (3)
648613-4
4" Reversible Jaws (3)

54
 REVERSIBLE GEAR PULLER

2/3 JAW REVERSIBLE GEAR PULLER SET

The Combination 2/3 Jaw Reversible Gear Puller Set Kit #43 contains tools for pulling gears and pulleys. It can be used with either 2 or 3 jaws.
Jaws reverse for inside and outside pulls. This set contains jaws in 4" and 6" lengths.

Gear & Pulley Pulling

1. Remove pulley or gear center bolt. See figures (a) and (b).
2. Determine how best to assemble the puller for your application. Choices to be made include whether the pull necessary will work best
with 2 or 3 jaws attached to the 2/3 combo yoke, and whether the jaws should be installed to the yoke for an outside pull or an inside
pull. For an outside pull the jaw tips should face inward. For an inside pull the jaw tips should face outward.
3. Assemble the elbow plates to the 2/3 combo yoke using shoulder bolts and nuts. For a 2-jaw pull attach elbow plates to the yoke pieces
that directly oppose each other. For a 3-jaw pull attach elbow plates to the yoke pieces that form a “Y” pattern.
4. Attach jaws to elbow plates using shoulder bolts and nuts. Hook the jaw ends into or over the desired engagement points on the gear or
pulley. Lightly grease the center bolt and thread it into the yoke by hand until it passes through the hole in the center of the gear or pulley
and engages the area where the pulley or gear mounts. Tighten the center bolt with a wrench, taking care not to damage the threads in
the pulley or gear mounting hole. See figure (c). Continue tightening until gear or pulley is removed. See figure (d).

Figure (a) Figure (b) Figure (c) Figure (d)

55
 Kit #45 - Crankshaft Pulley &
Harmonic Balancer Puller
& Installer Set (648616)
648427-6 thru 648427-13
From Left to Right
648427-6
3/4" x 16 Installer
648427-7
7/16" x 20 Installer
648427-8
1/2" x 20 Installer 648616-0
Storage Case
648427-9
9/16" x 18 Installer
648427-10
5/8" x 18 Installer
648427-11
M12 x 1.5 Installer
648427-12
M14 x 1.5 Installer
648616-13
M16 x 2.0 Installer 648616-21
Pulley Puller

648616-2
Short Pushrod
648616-24
2/3 Combination Yoke
648616-3
Long Pushrod

648616-4
648616-23 Pulley Puller
Center Point Center Bolt

648616-5
648616-22
Installer Center Screw
Puller Center Screw
(7/8" x 4-1/4" NF)
5/8" x 5-7/8" - 18 NF
6 7 8 9 10 11 12 13
648616-21 648616-6 thru 940427-13
3/8" - 24 x 2" NF See Chart Above
Bolts (3)

648616-14
Jam Nut

648616-20
5/16" - 18 x 2" NC
648616-15
Bolts (3)
Nut 7/8" NF
648616-19 648616-16
3/8" - 16 x 4" NF 648616-17 Thrust
Bolts (2) 648616-18 10 - 1.5 x 50mm Bearing
80 - 1.25 x 80mm Bolts (3)
Bolts (3)
56
 CRANKSHAFT PULLEY & HARMONIC
BALANCER PULLER & INSTALLER SET

CRANKSHAFT PULLEY & HARMONIC BALANCER PULLER & INSTALLER SET

This tool kit includes tools for pulling and installing harmonic balancers with threaded holes. This type of balancer is found on many domestic
V8 and V6 engines. The kit also includes a special shallow puller used for removing the crankshaft pulley on many 1990 and newer Chrysler
Corporation engines. See the applications listed below.

Removing Threaded Harmonic Balancers

1. Match slots on the puller body or yoke to holes in balancer to determine the number of bolts needed. In the tool case the puller body is
labeled “2/3 Combination Yoke”.
2. Find a set of bolts that fit the threaded holes in the balancer. There are 5 different sizes (sets) of bolts to choose from in the tool case.
3. Thread bolts with washers through slots in puller body and into holes in harmonic balancer. See figure (a).
4. Grease long black screw. Thread center screw through the hole in the center of the puller body. In the tool case this part is labeled “Puller
Center Screw”.
5. Place center point or tip assembly onto end of center bolt and thread center bolt against crankshaft surface. In the tool case this part is
labeled “Center Point”.
6. Using end wrench or ratchet, tighten center bolt until balancer is pulled off of crankshaft. See figures (a) and (b), noting how the balancer
fits onto the keyway.

Installing Threaded Harmonic Balancers

1. Fit the harmonic balancer to the end of the crankshaft by hand, making sure to line up the keyway. See (b).
2. Select the installer adapter that correctly fits the threaded hole in the end of the crankshaft. Install the jam nut onto the adapter.
See figure (c). In the tool case these parts are labeled “Installer” (in 8 different sizes) and “Jam Nut”.
3. Attach the large forcing nut to installer center screw and slide silver thrust bearing against the nut. In the tool case these parts are labeled
“Installer Center Screw”, “7/8" NF Nut” and “Thrust Bearing”.
4. Thread the installer adapter assembled in step 2 into the opening in the installer center screw. See figure (d).
5. Tighten the jam nut against the installer center screw (using pliers if necessary), so that the installer adapter and the installer center
screw are locked together securely. See figure (e).

Figure (a) Figure (b) Figure (c) Figure (d) Figure (e)

Figure (f) Figure (g) Figure (h) Figure (i)

57
 Kit #45 - Crankshaft Pulley &
Harmonic Balancer Puller
& Installer Set (648616)
648427-6 thru 648427-13
From Left to Right
648427-6
3/4" x 16 Installer
648427-7
7/16" x 20 Installer
648427-8
1/2" x 20 Installer 648616-0
Storage Case
648427-9
9/16" x 18 Installer
648427-10
5/8" x 18 Installer
648427-11
M12 x 1.5 Installer
648427-12
M14 x 1.5 Installer
648616-13
M16 x 2.0 Installer 648616-21
Pulley Puller

648616-2
Short Pushrod
648616-24
2/3 Combination Yoke
648616-3
Long Pushrod

648616-4
648616-23 Pulley Puller
Center Point Center Bolt

648616-5
648616-22
Installer Center Screw
Puller Center Screw
(7/8" x 4-1/4" NF)
5/8" x 5-7/8" - 18 NF
6 7 8 9 10 11 12 13
648616-21 648616-6 thru 940427-13
3/8" - 24 x 2" NF See Chart Above
Bolts (3)

648616-14
Jam Nut

648616-20
5/16" - 18 x 2" NC
648616-15
Bolts (3)
Nut 7/8" NF
648616-19 648616-16
3/8" - 16 x 4" NF 648616-17 Thrust
Bolts (2) 648616-18 10 - 1.5 x 50mm Bearing
80 - 1.25 x 80mm Bolts (3)
Bolts (3)
58
 CRANKSHAFT PULLEY & HARMONIC
BALANCER PULLER & INSTALLER SET

6. Guide the installer portion of the assembled tool into the threaded hole in the crankshaft and hand tighten. See figure (f) on page 27.
7. Using a wrench on the flats provided on the end of the center screw, tighten the tool so that it is threaded firmly into the crankshaft. See
figure (g) on page 27.
8. Adjust the forcing nut by hand so that the thrust bearing is drawn up snugly against the harmonic balancer.
9. Using 2 wrenches, tighten the forcing nut while holding the tool to prevent it from turning. See figure (h) on page 27.
10. Continue tightening the forcing nut until the balancer attains the desired position on the crankshaft.
11. Install and tighten harmonic balancer retaining bolt. See figure (i) on page 27.

Removing Chrysler Corporation Crankshaft Pulleys

Applications include:
Chrysler 1990 and later vans with 3.3L V6 engine
Chrysler 1993-1997 automobiles with 3.3L and 3.5L V6 engines
Chrysler 1994 and later vans with 3.8L V6 engine
Chrysler 1994 and later pickups with 8.0L V10 engine
Chrysler 1995 and later automobiles with 2.0L 4-cylinder, 2.4L 4-cylinder and 2.5L V6 engines
Chrysler 1998 & later automobiles with 2.7L DOHC V6, 3.2L SOHC V6 and 3.5L SOHC V6 engines
Mitsubishi Eclipse 1995-1999 with 2.0L DOHC 4-cylinder naturally aspirated engine

Pulley Removal
1. With drive belts removed from the pulley, use a ratchet and socket to remove the pulley center bolt. See figures (j) and (k).
2. Select a pushrod from the kit that will bottom out in the hole in the end of the crankshaft and in the center bolt of the puller. In the tool
case these parts are labeled “Pushrod” and “Pulley Puller”.
3. Note that the jaws of the puller must be able to lock behind the pulley. See figure (l). The pushrod must be the correct length for the
puller jaws to engage with the pulley.
4. Position the puller/pushrod assembly onto the pulley. Make sure the jaws of the puller are firmly engaged with the backside of the pulley.
See figure (m).
5. Place the jaws of an end wrench across the hex on the puller body and hold to keep from turning. Slowly turn the puller center bolt with a
3/8" ratchet inserted into the square drive on the puller center bolt. See figure (n).
6. Keep turning the puller center bolt until the pulley is free of the end of the crankshaft. See figure (o).

Figure (j) Figure (k) Figure (l)

Figure (m) Figure (n) Figure (o)

59
 Kit #46 - 23 Piece Master Ball Joint
“U” Joint Service Set
(648617)

648617-0
Storage Case

648617-1
Receiving Cup
2-1/4" OD x 7/16" L

648617-18
648617-19 648617-20 648617-21
Receiving Tube Receiving Tube Receiving Cup Receiving Cup
2-7/8" OD x 2-7/8" L 3" OD x 2-1/4" L 2-1/2" OD x 3/4" L 2-1/8" OD x 1/2" L

648617-2
648617-17
Remover
Receiving Tube
1-7/16" OD x 1" L
2-7/16" OD x 3-3/16" L

648617-4
648617-15
Installing Cup
Installing Adapter
2" OD x 2-5/16" L
2" OD x 3" L
648617-16
Short Pin

648617-14 648617-3 648617-5

Receiving Tube Forcing Installing Cup
2-3/4" OD x 2-1/4" L Screw 2-1/2" OD x 2-3/4" L

648617-13 648617-6
Receiving Tube Receiving Tube
2-1/4" OD x 2" L 3" OD x 2-3/16" L

648617-7
648617-12 Receiving Tube
Receiving Tube 2-1/2" OD x
2-1/2" OD x 1-1/2" L 1-11/16" L

648617-8
Receiving Tube
2" OD x 1-11/16" L
648617-23
648617-11 648617-10 648617-9
2-9/64" Socket
Installing/Removing Adapter Installing Adapter C-Frame
3-1/16" OD x 1-1/8" L 3" OD x 1-1/8" L 648617-22
1-59/64" Socket

60
 23 PIECE MASTER BALL JOINT
“U” JOINT SERVICE SET

The 648617 23 Piece Master Ball Joint & U Joint Service Set Kit #46 contains tools for removing and installing the pressed-in type ball joints
found on most vehicles, as well as the special threaded upper ball joints on many Chrysler vehicles. This kit allows changing ball joint without
removing control arm from the vehicle, and the tools contained also can be used to remove and install "U" joints.

Removal of Pressed-in Ball Joints (most vehicles)

NOTE Some vehicles have ball joints that have a small spot-weld attaching them to the control arm. This weld must be
ground off before removing ball joint.

1. Raise and support vehicle and remove all suspension parts necessary to access ball joint. See manufacturer's servicing information for
proper procedures.
2. Place the installing adapter over the ball joint spindle. Select a receiving tube with an inner diameter larger than the outer diameter of ball
joint but small enough to fit snugly in the control arm.
3. Install the removing adapter to the receiving tube. Assemble the "C" frame over the control arm. The hole in the "C" frame should be
placed over the end of the ball joint spindle and against the installing adapter. Line up the forcing screw with the removing adapter.
4. Make sure all parts are correctly aligned. Tighten the forcing screw with a ratchet. Continue tightening until ball joint is forced completely
out of the control arm. Remove "C" frame and disengage ball joint from receiving tube.

Installation of Pressed-in Ball Joints (most vehicles)

1. Make sure the control arm is thoroughly cleaned. Lubricate the outer diameter of new ball joint and inner diameter of control arm
Insertthe ball joint into the hole in control arm until it stays in position.
2. Select a receiving tube with an inner diameter larger than the outer diameter of hole in the control arm but that fits securely on the
control arm. Fit the installing adapter on receiving tube.
3. Assemble the "C" frame over the control arm. The hole in the "C" frame should be placed over the installing adapter. Line up the forcing
screw with the removing adapter.
4. Check the alignment of all parts. Turn the forcing screw slowly and force the ball joint into the control arm. Additional lubrication may
benecessary. Stop when the ball joint is fully seated in the control arm.

61
 Kit #48 - Master Disc Brake Kit
(648622) 648622-1 thru
648622-12
From Left to Right
648622-1
T-60 Socket
648622-2
T-55 Socket
648622-3
T-50 Socket
648622-4
648622-0 T-47 Socket
Storage Case 648622-5
T-45 Socket
648622-6
T-40 Socket
648622-7
1/4" Hex Bit
648622-8
1 2 3 4 5 6 7 8 9 10 11 12 5/16" Hex Bit
648622-9
3/8" Hex Bit
648622-10
7mm Hex Bit
648622-11
8mm Hex Bit
648622-13
648622-12
3/8" x 5/16" Brake
648622-30 Bleeder Wrench 10mm Hex Bit
3/8" Disc Brake
Caliper Wrench

648622-29 648622-14
Compact Tubing 1/4" x 3/8" Brake
Cutter Bleeder Wrench

648622-28
1-1/4" Adapter 648622-15
8mm x 10mm Brake
648622-27
Bleeder Wrench
Long 2-Prong x
648622-16
1-21/32" Adapter
Disc Brake Pad
Spreader
648622-26
Plate

648622-25
Disc 648622-17
Deluxe Tubing
Bender
648622-18
648622-24 T-Handle
1-13/32"
648622-19
Adapter 648622-23
2-1/2" Adapter
Short 2-Prong 648622-21
x 1-21/32" 1-7/8"
Adapter 648622-22 Adapter 648622-20
2" Adapter 2-5/32" Adapter

62
 MASTER DISC BRAKE KIT

The brake kit is designed to perform several basic functions on disk brake cars and trucks.

Function #1 - Adjust the piston position by screwing it into or out of the cylinder bore. This is most commonly necessary on the rear brakes
of vehicles with self-adjusting parking brakes. Some manufacturers also use screw-out pistons on the front brake calipers. See factory servicing
information to determine your type.

Function #2 - Press the piston straight back in the cylinder bore. This is commonly necessary when new brake pads are being installed.

Function #3 - Open and close brake bleeder screws. The included bleeder wrenches are of 6-point design for maximum torque and best fit.

Function #4 - Remove and install specialty type (Torx and Hex) brake caliper attaching bolts. The included socket drivers and hex wrench are
for loosening and tightening female hex sockets and Torx sockets commonly found on automotive brake calipers.

Function #5 - Tubing bending.

Function #6 - Tubing cutting.

63
 Kit #51 - Oxygen Sensor Wrench Kit
(648625)

648625-0
Storage Case

648625-1
Deep Oxygen
Sensor Socket,
Straight (3/8"
Square Drive)

648625-3
Shallow Oxygen Sensor Socket,
Offset (3/8" Square Drive)
648625-2
Deep Oxygen Sensor Socket,
Offset (1/2" Square Drive)

64
 OXYGEN SENSOR WRENCH SET

• For removing and installing oxygen sensors and vacuum switches.

• Each socket equipped with a slot to accommodate wiring pigtail or vacuum nipples.
• Offset sockets for used with square drive ratchets or breakover handles.
• Deep socket can be used with square drive ratchet or 1" end wrench.

Contents include:
• Oxygen sensor socket - The slotted 7/8" deep socket can be used with a 3/8" square drive tool or a 1" end wrench.
• Low Profile Offset Oxygen Sensor Socket - This 22mm offset socket can be used with a 3/8" square drive tool
• Heated Oxygen Sensor Socket - This 22mm deep offset socket has two 1/2" square drive holes for more possible angles.

The 3 sockets included in this set solve access problems common to most oxygen sensor locations, allowing easy removal and installation of
the sensor. Many common vacuum switches may also be removed using the deep socket included in this set.

NOTE DO NOT use any compounds on or around oxygen sensors or oxygen sensor threads unless they have a label that
designates them as safe for use around oxygen sensors. Products containing silicone will damage the sensor and are to be avoided.

NOTE DO NOT allow sensor wiring to contact hot exhaust manifold or pipes.

NOTE DO NOT allow oxygen sensors to be contaminated by common automotive chemicals, including windshield washer
fluid, oil, grease or solvents.

CAUTION Make sure vehicle is well supported and stable when removing oxygen sensor. Take care not to knock vehicle off of
jack stands.

Removal and Installation:

1. Spray threads of old sensor with penetrating oil to ease removal. See notes above.
2. Disconnect old oxygen sensor connector from vehicle wiring harness.
3. Fit oxygen sensor socket onto the sensor, making sure that the wire protrudes through the slot
4. Using a breaker bar or ratchet inserted into the square drive on the socket, turn the sensor counterclockwise to remove it from the
manifold or exhaust pipe.
5. If the sensor is very tight or if the threads are rusted, it may be necessary to tap the breaker bar lightly with a dead blow hammer to
break the sensor loose. Once loosened, it should be possible to remove the sensor with a ratchet.
6. To install, apply a light coating of anti-seize compound to oxygen sensor threads. See notes above. Tighten oxygen sensor to factory
torque specifications or finger tight, plus one turn (when appropriate). Connect oxygen sensor connector to the vehicle wiring harness.

65
 Kit #52 - Serpentine Belt
Tool Set (648629)

648629-0
Storage Case

648629-2 648629-3
Extension Bar Handle

648629-1
1/2" (F) x 3/4" (M)
Square Drive Adapter

648629-13
19mm Socket

648629-12
18mm Socket

648629-11
17mm Socket

648629-10
16mm Socket

648629-9
15mm Socket

648629-8
14mm Socket

648629-7
13mm Socket

648629-4
13mm Crowsfoot

648629-5
14mm Crowsfoot

648629-6
15mm Crowsfoot

66
 SERPENTINE TOOL KIT

1. For removing or installing serpentine belts where it is not possible to access tensioner with standard tools.
2. For vehicles with spring-loaded automatic belt tensioners only.
3. Low profile chrome vanadium sockets and 5 point crowfoot wrenches for strength and durability.
4. Socket rail included for easy organizing.
• Determine whether center bolt of the tensioner can be reached with tool handle
• Select correct size socket and assemble extension to handle if needed
• Install socket to tool
• Snap socket over center bolt with tool handle attached
• Rotate tool handle to release tension on belt
• Disengage belt from pulleys and remove belt
• To install, reverse removal procedure, making sure routing is correct, and that belt is properly aligned in pulley grooves

Includes:
3/8’ Square Drive Bar (Handle): Ford 1.9/2.3L, GM 3.1L
1/2’ Square Drive Bar Extension Bar: Ford 4.6L, Chrysler 2.5/3.0L
13mm wrench: GM Quad 4
14mm wrench: Saturn
15mm wrench: Ford Windstar w/3.8L
13mm socket: GM Quad 4
14mm socket: Saturn
15mm socket: Ford 3.0/3.8L, GM 2.2/2.8/3.8/7.5L, Chrysler 3.0/3.3/3.8L
16mm socket: Ford 3.8/4.0L
18mm socket: GM 3800
19mm socket: GM 3800 engine, Saab 9000, Volkswagen/Audi
1/2’ F x 3/4’ M adapter: Volvo

67
 Kit #68 - Needle Torque Wrench
(944050)

944050-0
Storage Case

944050-1
Needle Torque
Wrench

944050-0
Blow Mold Case

68
 NEEDLE TORQUE WRENCH
944050 Needle Torque Wrench - Allows the torque applied to a fastener to be measured accurately, thus avoid damaging components or
fasteners. Unlike micrometer torque wrenches (sometimes known as click-type), which fatigue and sometimes wear, beam torque wrenches do
not require periodic calibration and adjustment. This wrench's compact head accepts 1/2" sockets or extensions. The palm-fit handle pivots on the
beam to maintain a constant distance from drive point to load point for precise measurement of torque values up to 150 ft. lbs. (203 N.m).

WARNING!
• DO NOT STRIKE THE TORQUE WRENCH OR USE IT AS A HAMMER OR PRY BAR.
• DO NOT STORE THE TORQUE WRENCH IN A PLACE WHERE THE POINTER COULD BE DAMAGED.
• DO NOT DROP THE TORQUE WRENCH. DAMAGE CAN OCCUR TO THE POINTER OR BEAM.

OPERATING INSTRUCTIONS:
1. Before using, make sure the pointer lines up with the "0" (zero) on the indicator scale as shown in Figure 1. If the pointer is bent, it should be
bent back to the center ("0").
2. Install the proper socket into the square drive. Place the socket over the nut or bolt to be tightened.
3. Grasp the pivoting plastic handle and apply force to the center of the plastic handle. Pull the wrench by this handle ONLY. Make sure that the
plastic handle remains centered on the pivot. DO NOT let the handle tilt and contact the beam at either end of the handle.
4. The force applied will cause the beam to bend. The pointer will remain straight while the indicator scale moves under and in relation to the
end of the pointer.
5. When the pointer lines up directly with the desired torque specification, release the applied force and remove the socket from the bolt or nut.
6. Do not continue to apply force once the desired specification is reached. To do so will result in an over-tightened fastener. Over-tightening a
fastener may cause it to break or the threads to strip.
7. The final torque reading should be made while the fastener is still being turned.

NOTE: If you hear squealing or cracking noises from the fastener, it may be seizing. Remove the bolt or nut and check the threads. Clean if
necessary. Fasteners should be free of all dirt and rust. DO NOT lubricate threads as this will lead to incorrect torque measurements.

MAINTENANCE:
1. If the pointer is bent, it should be bent back to the center ("0"). This will not damage the pointer and the wrench will retain its accuracy. If the
beam is bent, the wrench should be removed from service.
2. When the wrench is in use, the pointer should not touch or scrape on the indicator scale or the metal cage that surrounds the pointer needle.
If the pointer does scrape, bend the plastic tip up or down slightly so that the pointer remains centered inside the metal cage.

CONVERSION TABLE
Foot Newton Meter
Pounds Meters Kilograms
(Ft/Lbs.) (Nm) (M Kg)
5 6.78 0.69
10 13.56 1.38
Figure 1 15 20.34 2.07
Indicator Scale 20 27.12 2.76
25 33.90 3.46
Handle 30 40.68 4.15
35 47.46 4.84
Pointer Arm 40 54.24 5.53
45 61.02 6.22
50 67.80 6.91
55 74.58 7.60
60 81.36 8.29
65 88.14 8.98
70 94.92 9.76
75 101.70 10.37
Pivot Point Pointer Bending Beam 80 108.48 11.06
85 115.26 11.75
90 122.04 12.44
95 128.82 13.13
100 135.60 13.82
105 142.38 14.51
110 149.16 15.20
115 155.94 15.89
120 162.72 16.58
125 169.50 17.28
130 176.28 17.97
135 183.06 18.66
140 189.84 19.35
145 196.62 20.04
150 203.40 20.73

69
 Kit #70 - 22-Piece Cooling System
Tester Kit (940427)
940427-12 940427-13 940427-14
Black Orange Red
Nippon Hino Renault, Audi, VW Volvo, Citroen, Renault, Fiat, Peugeot

940427-11 940427-15
Orange Yellow
Mitsubishi, Ford, GM, VW, Ford
Nissan, Mazda
940427-16
Green
940427-10 Volvo, Renault
Blue
Toyota, Honda
940427-17
Black - BMW
940427-0
Storage
Case
940427-18
Black
940427-6 Mercedes Benz
Black
Volvo, Citron, Renault, 940427-7
Fiat, Peugeot Black - Audi, VW 940427-9
Black
Mitsubishi, Ford,
940427-5
Nissan, Mazda
Orange
BMW
940427-8
Black - Honda, Toyota
940427-1 940427-3
Black Yellow - VW, Ford
Mercedes Benz

940427-2 940427-4
Blue Red - BMW
New Audi
(A4, A5, A6)

940427-22
Pressure Gauge

940427-19
Expandable Universal
Radiator 17-24 MM
940427-21
Expandable Universal
940427-20 Radiator 37-39.5 MM
Expandable Universal
Radiator 28-31.5 MM

70
940427 Cooling System Tester Kit - Includes an assortment of radiator cap adapters and coolant bottle adapters for testing cooling
systems and most standard radiator caps. This kit will allow testing of both current and older cars, light trucks and vans.

WARNING!
• MAKE SURE YOU ARE FAMILIAR WITH AND COMPLY WITH ALL WARNINGS RELATING TO COOLING SYSTEM TESTING.
• PROTECTIVE GLOVES AND EYEWEAR ARE RECOMMENDED WHEN PERFORMING COOLING SYSTEM TESTING.
• MAKE SURE THE VEHICLE’S ENGINE IS NOT RUNNING WHILE PERFORMING A VISUAL INSPECTION OF THE COOLING SYSTEM OR WHILE CONNECTING
THE COOLING SYSTEM TESTER.
• DO NOT REMOVE THE RADIATOR CAP OR COOLANT BOTTLE CAP WHEN THE ENGINE IS HOT OR AT OPERATING TEMPERATURE. LET THE ENGINE COOL
FIRST! THE TEMPERATURE OF COOLANT IN A PRESSURIZED COOLING SYSTEM IS HIGHER THAN ITS BOILING POINT AT ATMOSPHERIC PRESSURE.
REMOVING THE CAP WHEN THE ENGINE COOLANT IS HOT MAY CAUSE HIGH-PRESSURE STEAM AND BOILING COOLANT TO ERUPT OUT VIOLENTLY,
POSSIBLY SCALDING THE PERSON REMOVING THE CAP AND NEARBY BYSTANDERS.
• WHEN REMOVING A RADIATOR OR COOLANT BOTTLE CAP, CAUTIOUSLY TURN IT TO THE SAFETY POINT. THIS ALLOWS PRESSURE TO BE RELEASED
SLOWLY, PREVENTING THE PRESSURE IN THE SYSTEM FROM ERUPTING. NEXT PUSH DOWN AND TURN THE CAP A BIT MORE TO DISENGAGE IT FROM
THE STOP TABS.
• DO NOT EXCEED THE MAXIMUM PRESSURE RECOMMENDED BY THE VEHICLE’S MANUFACTURER WHEN PRESSURE TESTING A COOLING SYSTEM.

VISUAL INSPECTION PRIOR TO TESTING

WARNING: NOT REMOVE THE RADIATOR CAP OR COOLANT BOTTLE CAP WHEN THE ENGINE IS HOT OR AT OPERATING TEMPERATURE. LET THE ENGINE
COOL FIRST! THE TEMPERATURE OF COOLANT IN A PRESSURIZED COOLING SYSTEM IS HIGHER THAN ITS BOILING POINT AT ATMOSPHERIC
PRESSURE. REMOVING THE CAP WHEN THE ENGINE COOLANT IS HOT MAY CAUSE HIGH-PRESSURE STEAM AND BOILING COOLANT TO ERUPT
OUT VIOLENTLY, POSSIBLY SCALDING THE PERSON REMOVING THE CAP AND NEARBY BYSTANDERS.

CAUTION: Handle the testing pump with care. DO NOT subject the pressure gauge to unnecessary impacts or shocks as this may damage the gauge.

NOTE: The needle of the pressure gauge should rest in the “Zero” range when the pump is not in use. If the needle does not point to “Zero”, the accuracy of the
gauge must be checked.

1. With engine cool, carefully remove the radiator or pressurized coolant bottle cap. Check the level of coolant, and if necessary add coolant so that the coolant is
at the recommended level.
2. Check the radiator, radiator hoses and heater hoses for visible signs of damage or leaks. Clean the surfaces of the coolant bottle or radiator filler neck where the
cap seals. The sealing surfaces must be in good condition.
3. Check radiator filler neck, examining the sloping cam surfaces. If the sloping cam surfaces are bent, the cap will not seal at the correct pressure or it may not
seal at all.
4. Check the overflow tube. If it is dented or blocked, the system will not operate correctly. Make sure the tube is clean so that is can release pressure properly.

STATIC PRESSURE TEST USING DIRECT-FIT ADAPTER ON SYSTEMS WITH A RADIATOR CAP

WARNING: MAKE SURE ADAPTER SEALS FULLY BEFORE THE COOLING SYSTEM IS PRESSURIZED. NEVER PRESSURIZE A COOLING SYSTEM BEYOND ITS
MAXIMUM SPECIFIED PRESSURE.

1. After performing the radiator and cooling system visual inspection, carefully remove the radiator cap. Select an appropriate adapter that fits the radiator fill
neck. See Figure 1. Wet the rubber gasket inside the adapter.
2. Align the locking ears of the adapter with the notches in the radiator filler neck opening. Lightly push down. Turn the adapter clockwise until the locking ears
climb the radiator filler neck sloping cam surfaces. See Figure 2.
3. Position the female quick-disconnect fitting at the end of the pump’s rubber hose over the male quick-disconnect fitting on the adapter and press down. Make
sure the moveable sleeve on the quick-disconnect fitting snaps forward and that the coupling is fully engaged. See Figure 3.
4. Examine the vehicle’s service information and radiator cap to determine the proper system pressure. Pump the handle of the pressure tester until the needle of
the gauge indicates the rated pressure of the system. See Figure 4.
5. With the system still pressurized, inspect the radiator and cooling system. Check the points where cooling system hoses connect to the radiator and other
components for signs of leakage. When complete, check the reading on gauge and compare to the rated pressure of the system.
6. When testing is complete, release the pressure in the system by slowly and lightly pressing the pressure release valve. Take care not to fully depress the
pressure release valve when the system is at full pressure, as a stream of coolant under pressure may exit the system through the valve. It may help to cover
the pressure release valve with a towel or rag.
7. Disconnect the quick-disconnect fitting and separate the pump and adapter. Clean and dry these components and store them in their proper locations. Refill the
radiator to its proper level and replace the radiator cap.

Figure 1 Figure 2 Figure 3 Figure 4

71
STATIC PRESSURE TEST USING DIRECT-FIT ADAPTER ON SYSTEMS WITH A COOLANT BOTTLE

WARNING: MAKE SURE ADAPTER SEALS FULLY BEFORE THE COOLING SYSTEM IS PRESSURIZED. NEVER PRESSURIZE A COOLING SYSTEM BEYOND ITS
MAXIMUM SPECIFIED PRESSURE.

1. Carefully remove the threaded cap from the coolant

bottle. See Figure 5. Select an appropriate adapter that
fits the threads on the coolant bottle. Thread the adapter
into the coolant bottle until fully seated. See Figure 6.

2. Position the female quick-disconnect fitting at the end of

the pump’s rubber hose over the male quickdisconnect
fitting on the adapter and press down. Make sure the
moveable sleeve on the quick-disconnect fitting snaps
forward and that the coupling is fully engaged. Figure 5 Figure 6 Figure 7
3. Examine the vehicle’s service information and coolant bottle cap to determine the proper system pressure. Pump the handle of the pressure tester until the
needle of the gauge indicates the rated pressure of the system. See Figure 7.

4. With the system still pressurized, inspect the radiator and cooling system. Check the points where hoses connect to the radiator and coolant bottle. Inspect
other system components for signs of leakage. When complete, check the reading on gauge and compare to the rated pressure of the system.

5. When testing is complete, release the pressure in the system by slowly and lightly pressing the pressure release valve. Take care not to fully depress the
pressure release valve when the system is at full pressure, as a stream of coolant under pressure may exit the system through the valve. It may help to cover
the pressure release valve with a towel or rag.

6. Disconnect the quick-disconnect fitting and separate the pump and adapter. Clean and dry these components and store them in their proper locations. Refill the
radiator to its proper level and replace the radiator cap.

STATIC PRESSURE TEST USING EXPANDABLE UNIVERAL-FIT ADAPTER

WARNING: UNIVERSAL-FIT ADAPTER MAY POP OUT OF COOLING BOTTLE UNDER PRESSURE IF SEALING SURFACES ARE WET. TAKE CARE TO ENSURE
SEALING SURFACE IS DRY AND THAT THE FIT IS TIGHT. MAKE SURE ADAPTER SEALS FULLY BEFORE THE COOLING SYSTEM IS PRESSURIZED.
NEVER PRESSURIZE A COOLING SYSTEM BEYOND ITS MAXIMUM SPECIFIED PRESSURE.

NOTE: The universal-fit adapter is illustrated testing a radiator. Testing coolant bottles is similar. Use care if using universal-fit adapters in coolant bottles as
overtightening of the adapter may crack the bottle.

1. Carefully remove the radiator cap. Select a universal-fit adapter that most closely fits the size opening of the radiator fill
neck. See Figure 8. Insert the adapter into the radiator fill neck. Ensure universal-fit adapter is at its shortest height, with the
top and bottom hexagonal adjusting knobs at their closest positions and at the bottom of the stair-step cam slope. See
Figure 9.

2. Holding the bottom adjusting knob stationary, turn the top adjusting knob clockwise until the top of the stair-step cam slope
is reached. See Figure 10.

3. Position the female quick-disconnect fitting at the end of the pump’s rubber hose over the male quick-disconnect fitting on
the adapter and press down. Make sure the moveable sleeve on the quick-disconnect fitting snaps forward and that the
coupling is fully engaged. See Figures 11 and 12.
Figure 8
4. Examine the vehicle’s service information and radiator cap to determine the proper system pressure. Pump the handle of the
pressure tester until the needle of the gauge indicates the rated pressure of the system.

5. With the system still pressurized, inspect the radiator and cooling system. Check the points where cooling system hoses
connect to the radiator and other system components for signs of leakage. When complete, check the reading on gauge and
compare to the rated pressure of the system.

6. When testing is complete, release the pressure in the system by slowly and lightly pressing the pressure release valve. Take
care not to fully depress the pressure release valve when the system is at full pressure, as a stream of coolant under
pressure may exit the system through the valve. It may help to cover the pressure release valve with a towel or rag.

7. Disconnect the quick-disconnect fitting and separate the pump and adapter. Clean and dry these components and store
Figure 9
them in their proper locations. Refill the radiator to its proper level and replace the radiator cap.

Figure 10 Figure 11 Figure 12

72
INTERPRETING STATIC PRESSURE TEST RESULTS
Needle On Gauge Holds Steady: If needle on the gauge remains steady for several minutes, there are no serious coolant leaks in the cooling system.

Needle On Gauge Drops Slowly: If the needle on the gauge drops slowly, there is a small leak or seepage. Examine all connections for seepage or small leaks.
Inspect the radiator, cooling system hoses (including heater hoses). A bright light may be helpful. After repairing leaks, test the system again.

Needle On Gauge Drops Quickly: If the needle on the gauge drops quickly, there is a serious leak. Examine the system for signs of a major leak. Repair any major
leaks. If the radiator is leaking, replace it or have it repaired at a radiator repair shop if necessary. If no leaks are visible, the leak may be internal.

TESTING RADIATOR AND COOLANT BOTTLE CAPS

WARNING: NEVER PRESSURIZE A COOLING BOTTLE CAP OR RADIATOR CAP BEYOND ITS MAXIMUM SPECIFIED
PRESSURE.

1. Carefully remove the radiator or coolant bottle cap. Check manufacturer’s service information and the cap to ensure the
pressure cap fitted has the correct pressure rating for the vehicle’s cooling system.

2. Clean the pressure cap gasket and ensure it is in good condition. Determine which cap adapter is correct for the cap to be
tested. On new caps, wet the rubber gasket with water. Install the cap to the adapter. See Figure 13.

NOTE: If you are testing a new cap, it may be necessary to install and remove the cap several times to properly seat the new
gasket. Figure 13

3. Position the female quick-disconnect fitting at the end of the pump’s rubber hose over the male quick-disconnect fitting on the cap adapter and press down.
Make sure the moveable sleeve on the quick-disconnect fitting snaps forward and that the coupling is fully engaged.

4. Hold the tester with the cap and adapter hanging down. Operate the pump and watch the pressure gauge. Compare the reading on the gauge when the cap
releases pressure to the pressure specified in the service information or on the cap.

5. Disconnect the quick-disconnect fitting and separate the pump and adapter. Remove the cap from the adapter. Clean and dry these components and store them
in their proper locations. Refill the radiator to its proper level and replace the radiator cap.

INTERPRETING PRESSURE CAP TEST RESULTS

The cap must hold pressure below the specified limit. It must relieve any pressure that is above the specified limit. The pressure should hold just below the relief
pressure setting. A cap is considered satisfactory if it holds pressure in the test range for one to two minutes. If the needle on the gauge indicates that the cap is
loosing pressure rapidly, replace the cap. If the cap does not release pressure in the proper range, replace the cap.

Pump Handle Pump

Pressure Gauge

Rubber Hose

Pressure
Release Valve

Quick-Disconnect
Coupler

73
 Kit #72 - 10-Piece Master Ball Joint
Service Kit (940579)

940579-0
Storage Case

940579-10
940579-9 Screw
Installing Adapter
3" (O.D.) x 1-1/8" (L)
940579-1
Removal Adapter
3-1/16" (O.D.) x
1-1/8" (L)
940579-8
Receiving Cup 940579-6
2-1/4" (O.D.) C-Frame
1-7/8" (I.D.)
7/16" (L)
940579-2
Installing Cup
2" (O.D.)
940579-7 1-3/4" (I.D.)
Receiving Tube 3" (L)
2-1/4" (O.D.)
2" (I.D.)
2" (L)

940579-5 940579-3 940579-4

Receiving Tube Receiving Tube Receiving Tube
2" (O.D.) x 1-3/4" (L) 3" (O.D.) x 2-1/4" (L) 2-1/2" (O.D.) x 1-3/4" (L)

74
 MASTER BALL JOINT SERVICE KIT

Ball Joint Removal and Installation

This tool set is designed for use on all cars and light trucks that have press-fit type ball joints. It will help the user remove and install ball joints
without the need to remove the control arm from the vehicle.

NOTE: Some cars and light trucks may have the upper ball joint spot-welded to the control arm. The weld must be cut before attempting to
remove the ball joint.

Removal
1. Assemble the ball joint press over the control arm as shown in Figure 3. Select the correct size receiving tube, and position it under the vehicle
ball joint as shown.
2. Tighten the forcing screw until the receiving tube contacts the control arm. Check alignment of all tooling and components, and continue
tightening the forcing screw until the ball joint is removed.

Installation
1. Clean the control arm and coat the I.D. with a suitable lubricant.
2. Insert the replacement ball joint as straight as possible into the vehicle control arm.
3. Assemble the ball joint press components as shown in Figure 4. Position the receiving tube, and tighten the forcing screw. Check the alignment
of all tooling and components, and continue tightening the forcing screw until the ball joint is firmly seated.

Brake Anchor Pin Removal and Installation

1. Remove all lock ring retainers from the brake anchor pins.
2. Position the C-frame press over the brake spider as shown in Figure 1.
3. Tighten the forcing screw until the anchor pin is removed.

”U” Joint Assembly and Disassembly

The basic C-frame press is used to service the ”U” joints on most cars and light trucks. The ”U” joints can be serviced either on or off the vehicle.

Disassembly
1. Remove any external and/or internal lock rings.
2. Position the C-frame press around the drive shaft yoke, and tighten the forcing screw until the first bearing is removed.
3. Reposition the C-frame and remove the second bearing.

Assembly
1. Clean all dirt and oil from the yoke area.
2. Align the replacement bearing and C-frame press as straight as possible over the yoke. Press the replacement bearing into the yoke, and
reassemble the external/internal lock ring.
3. Reposition the C-frame press and second replacement bearing as straight as possible over the yoke, and press the bearing into the yoke.
Reassemble external/internal lock ring.

Installing Adapter

Ball Joint
Control
Arm

Receiving
Tube
Figure 1
Installing Adapter
Removing
Figure 3 Adapter

Receiving
Control Tube
Arm

Ball Joint

Removing
Adapter
Figure 4

Figure 2 75
 Kit #85 - 5-Piece Truck/SUV Inner Tie
Rod Set (641440)

641440-0
Storage Case

641440-1
Tie Rod
Extension Bar

641440-4
Crowfoot Adapter
1-7/16"

641440-4
Crowfoot Adapter
33.6mm

641440-3
Crowfoot Adapter
38mm

641440-2
Crowfoot Adapter
42mm

76
 5PC TRUCK/SUV INNER TIE ROD SET

Instructions:
1. Loosen but do not remove the vehicle's front wheel lug nuts. Raise and securely support the front of vehicle using jack stands. Remove wheel
and tire assemblies and set aside.

2. Disconnect the outer tire rod end from the steering knuckle. Use a special tool for removing the tie rod end without damage (a tie rod end
puller) if the outer tie rod is to be reused. If the outer tie rod is to be replaced, a pickle fork and hammer can be used to separate the tie rod end
from the steering knuckle.

3. Loosen the outer tie rod end locknut using a pair of adjustable wrenches or end wrenches. Use one wrench to hold the tie rod end body while
turning the locknut with the other wrench. See Figure (a). Remove both the outer tie rod end and the locknut from the threaded shaft of the inner
tie rod end. See Figure (b).

4. Loosen and remove the screw or spring clamps from the steering rack boot that covers the inner tie rod end. See Figures (c) and (d). Remove
the boot and set aside. See Figure (e).

5. Test fit and select the "C" shaped adapter that most closely fits the flat spots found on the far side of the inner tie rod end body. See Figure (f).
Hold the adapter in position while sliding the tie rod end tool over the threaded end of the tie rod. Carefully turn the tool until the flat spots on the
inside of the tool end closely line up with the flats of the adapter. See Figure (g).

6. While holding the adapter so that it does not slip off of the tie rod end flats, press the adapter and tool together lightly until the adapter
engages the ball-bearing détente inside the tool and "clicks" into place. See Figure (h). Insert a ratchet or breaker bar into the square drive hole in
the end of the tie rod tool. See Figure (i). Turn the ratchet or breaker bar until the tie rod is removed from the steering rack. See Figure (j).
Installation is the reverse of removal.

Figure (a) Figure (b) Figure (c) Figure (d) Figure (e)

Figure (f) Figure (g) Figure (h) Figure (i) Figure (j)

77
ALLTRADE TOOLS LLC
1431 Via Plata, Long Beach, CA 90810-1462
Toll Free 800/368-6653
In CA 310/522-9008
FAX 310/522-9066
www.alltradetools.com
© Copyright 2011, ALLTRADE TOOLS LLC Rev. 1 Form 774 Printed in Taiwan