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Chrysler RAM TRUCK 1500 1994, Service Manual, Page: 912 / 1702

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Chrysler RAM TRUCK 1500 1994 Service Manual Download Page 912

Summary of Contents for RAM TRUCK 1500 1994

Page 1: ...1 9 9 4 SERVICE MANUAL RAM TRUCK 1500 3500 C H R Y S L E R C O R P O R A T I O N...

Page 2: ...N A RETRIEVAL SYSTEM OR TRANSMITTED I N ANY FORM OR BY ANY MEANS ELECTRONIC ME CHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corpor...

Page 3: ...sure which Group contains the information you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of t...

Page 4: ...Cooling System 8 Electrical 9 Engines f 1 Exhaust System and Intake Manifold 3 Frame and Bumpers f 4 Fuel System f 0 Propeller Shafts f 0 Steering 2 i Transmissions and Transfer Cases 2 2 w h 6 l s an...

Page 5: ......

Page 6: ...data concerning the vehicle Refer to the VIN decoding chart to determine the identification of a ve hicle Fig 1 Vehicle Identification Number VIN Location The VIN is included on the Body Code Plate E...

Page 7: ...T VEHICLE ORDER NUMBER PAINT PROCEDURE 2 1 XXX XXXX XXXX XXXX XXX XXX X xxxxxxxxxxxxxxxxx ION I ENGINE TRIM TRANSMISSION VIN MARKET 93IN 8 Month and year of vehicle manufacture Gross Vehicle Weight Ra...

Page 8: ...ERY CHARGING CONDITION ENGINE OIL M SEAT BELT CD BRAKE FAILURE PARKING BRAKE FRONT HOOD REAR HOOD TRUNK HORN n i LIGHTER 93IN 9 VEHICLE INTERIOR DIMENSIONS A Head Room 40 2 B Hip Room 65 8 C Shoulder...

Page 9: ...erall Width At Front Wheel Lip 79 4 79 4 79 4 79 5 G Track Front 68 5 68 5 68 6 68 6 G Rear 68 0 68 0 68 0 73 0 H Tailgate Load Height 31 2 35 6 31 5 35 6 31 5 35 6 31 4 35 6 1 Overhang Front 37 9 37...

Page 10: ...4 6 94 6 1 Overhang Front 37 9 37 9 37 9 37 9 37 9 37 9 J Axle To End Of Frame 44 1 44 1 44 1 44 1 44 1 44 1 K Center Of Front Wheel To Back Of Cab 79 0 79 0 79 0 79 0 79 0 79 0 L Frame To Top Of Cab...

Page 11: ...5 75R16 all season TYD LT215 85R16 all season TVV GAWR Front 3 300 3 300 3 300 4 000 4 000 Rear 3 800 3 800 4 670 6 085 7 460 S H O R T B O X 119 W B PAYLOAD MAGNUM 3 9L V6 2 000 2 365 M A G N U M 5 2...

Page 12: ...6 all season TWP LT245 75R16 all season TYD LT215 85R16 all season TVV GAWR Front 3 500 3 500 4 500 4 500 Rear 3 600 4 670 6 085 7 060 S H O R T B O X 119 W B 1 PAYLOAD1 M A G N U M 5 2L V8 1 885 _ M...

Page 13: ...eason TYD LT215 85R16 all season TVV LT245 75R16 all season TYD LT215 85R16 all season TVV GAWR Front 4 000 4 000 4 500 4 500 Rear 6 085 7 500 6 085 7 500 L O N G B O X 135 W B PAYLOAD M A G N U M 8 0...

Page 14: ...LT215 85R16D TVV GAWR Front 4 000 4 500 3 570 Rear 6 085 8 000 7 060 135 W B 56 C A PAYLOAD2 4 360 CURB WEIGHT Front 2 870 _ _ Rear 1 570 Total 4 440 139 W B 60 C A PAYLOAD2 6 400 CURB WEIGHT Front 3...

Page 15: ...085 8 000 8 000 TIRES LT245 75R16E TYD LT215 85R16D TVV LT215 85R16D TVV GAWR Front 4 500 4 500 4 500 Rear 6 085 8 000 8 000 135 W B 56 C A PAYLOAD1 3 800 CURB WEIGHT Front 3 285 _ Rear 1 715 Total 5...

Page 16: ...TIRES LT245 75R16E TYD LT245 75R16E TYD LT215 85R16D TVV LT215 85R16D TVV GAWR Front 4 000 4 000 4 500 4 500 Rear 6 085 6 085 8 000 8 000 135 W B 56 C A PAYLOAD1 3 825 4 115 CURB WEIGHT Front 3 200 3...

Page 17: ...5 75R16E TYD LT245 75R16E TYD LT215 85R16D TVV LT215 85R16D TVV GAWR Front 4 500 4 500 4 500 4 500 Rear 6 085 6 085 8 000 8 000 135 W B 56 C A PAYLOAD 3 385 3 090 CURB WEIGHT Front 3 590 3 880 _ Rear...

Page 18: ...5 3 90 3 55 3 902 6 010 6 400 6 010 6 400 6 010 6 400 3 500 3 700 3 300 7 800 8 000 7 600 5 2L MAGNUM V8 Manual 5 speed O D Automatic 4 speed O D H D 3 21 3 55 3 90 3 21 3 55 3 90 6 400 6 400 6 400 6...

Page 19: ...s Tongue Wt 1 200 5 91 1 6 Cummins Diesel Manual 5 speed O D H D Automatic 4 speed O D H D 3 54 4 10 3 54 4 10 10 500 10 500 10 500 10 500 8 500 12 000 8 500 12 500 14 500 18 000 14 500 18 000 3500 4...

Page 20: ...8 800 8 800 8 800 8 800 8 200 11 700 8 200 11 700 14 500 18 000 14 500 18 000 2500 HD 4 x 4 REGULAR CAB 8 0 BOX Tongue Wt 900 8 0L MAGNUM V10 Manual 5 speed O D H D Automatic 4 speed O D H D 3 54 4 10...

Page 21: ...Manual 5 speed O D M D Automatic 4 speed O D H D 3 54 4 09 3 54 4 09 8 800 8 800 8 800 8 800 2 15 000 15 000 15 000 15 000 5 9L 1 6 CUMMINS Diesel Manual 5 speed O D H D Automatic 4 speed O D H D 3 54...

Page 22: ...d Notation chart GRADE CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8 The higher the grade number the greater the bolt strength Identification is determined by the lin...

Page 23: ...p of the bolt head The most commonly used metric bolt strength classes are 9 8 and 12 9 The metric strength class identification number is imprinted on the head of the bolt Fig 2 The higher the class...

Page 24: ...8465 28 37 9629 48 65 0793 68 92 1956 88 119 3120 8 5 9005 28 20 6517 48 35 4030 68 50 1542 88 64 9545 9 12 2024 29 39 3187 49 66 4351 69 93 5514 89 120 6678 9 6 6381 29 21 3893 49 36 1405 69 50 8918...

Page 25: ......

Page 26: ...stems for fuel recommendations CLASSIFICATION OF LUBRICANTS Lubricating fluids and chassis lubricants are clas sified according to standards recommended by the Society of Automotive Engineers SAE Amer...

Page 27: ...ngs Starter motor bearings Suspension strut bearings Rear spring shackle bolts Throttle control cables Throttle linkage ball joints Water pump bearings FLUID CAPACITIES Fuel Tank 118 inch wheel base 9...

Page 28: ...nd slip splines Lubricate front suspension ball joints See Note 1 Lubricate manual transmission gearshift control Inspect front wheel bearings 4x2 Lubricate parking brake ratio lever pivot Inspect bra...

Page 29: ...ual transmission Drain and refill automatic transmission change filters and adjust bands Drain and refill transfer case Inspect brake hoses Rotate tires 82 500 MILES 133 000 KM OR AT 6 6 MONTHS Flush...

Page 30: ...eaner filter PCV Valve check and replace as necessary See Note 2 Replace ignition cables Replace spark plugs Check engine coolant level hoses and clamps Change engine oil Replace engine oil filter Che...

Page 31: ...Check exhaust system Lubricate steering linkage Lubricate propeller shaft universal joints and slip splines Lubricate front suspension ball joints See Note 1 Lubricate front axle drive joint and pivot...

Page 32: ...Check engine coolant level hoses and clamps Change engine oil Replace engine oil filter Check exhaust system Replace battery Lubricate steering linkage Lubricate propeller shaft universal joints and...

Page 33: ...e propeller shaft universal joints and slip splines Lubricate front suspension ball joints See Note 1 Lubricate front axle drive joint and pivot bearings Inspect brake hoses Inspect front wheel bearin...

Page 34: ...HS Change engine oil and replace filter Check engine coolant level hoses and clamps Lubricate steering linkage Lubricate propeller shaft universal joints and slip splines Inspect brake hoses Rotate ti...

Page 35: ...shaft universal joints and slip splines Inspect brake hoses Rotate tires 72 000 MILES 116 OOO KM OR AT 72 MONTHS Change engine oil and replace filter Replace engine coolant Replace fuel filter Replace...

Page 36: ...filter adjust bands Adjust valve lash clearance Inspect drive belts Inspect fan hub Inspect damper Inspect front wheel bearings Inspect and clean water pump weep hole Lubricate steering linkage Lubric...

Page 37: ...spect engine compartment for Battery cable clamp condition clean if necessary Frozen battery Yellow or bright color test indicator if equipped Low battery fluid level Generator drive belt condition a...

Page 38: ...assis hoist A ramp type drive on hoist When a frame contact type hoist is used ver ify that the lifting pads are positioned properly Fig 4 WARNING THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR...

Page 39: ...vehicle with flat bed towing equipment is used the approach ramp angle should not exceed 15 de grees TWO WHEEL DRIVE VEHICLE TOWING Chrysler Corporation recommends that a vehicle be towed with the rea...

Page 40: ...ING WHEEL SECURED SLING TYPE WHEEL LIFT TOW TRUCK RELEASED NEUTRAL POSITION SLING TYPE WHEEL LIFT TOW TRUCK DO NOT TOW THE VEHICLE AT A SPEED FASTER THAN 45 KM H 30 MPH OR A DISTANCE GREATER THAN 24 K...

Page 41: ...e lu bricant Engine failure can result The factory fill engine oil is a high quality energy conserving crankcase lubricant The Recommended SAE Viscosity Grades chart defines the viscosity grades that...

Page 42: ...se 6 Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec tion 7 Start engine and inspect for leaks 8 Stop engine and inspect oil level ENGINE OIL FILTER...

Page 43: ...on or every 12 months Service is required i f coolant is low con taminated rusty or freeze protection is inadequate To properly test cooling system see Group 7 Cooling System The cooling system factor...

Page 44: ...piston backwash I f a crankcase ventilation system becomes plugged the crankcase pressure will increase and force engine oil past the piston rings creating oil con HOUSING Fig 6 Air Cleaner 8 0 L Eng...

Page 45: ...osition plastic or rubber components away from moving parts in engine compartment or under vehi cle or damage will result Do not allow rubber engine mounts or other com ponents to become oil contamina...

Page 46: ...ttle operation in low gears before engine break in period is complete can damage engine Chrysler Corporation vehicle does not require an extended break in period Driving speeds of not over 80 90 km h...

Page 47: ...cle and fill crankcase with specified type and amount of engine oil described in this sec tion 7 Start engine and inspect for leaks 8 Stop engine and inspect oil level ENGINE OIL FILTER SELECTING OIL...

Page 48: ...very 12 months Service is required if coolant is low con taminated rusty or freeze protection is inadequate To properly test cooling system see Group 7 Cooling System The cooling system factory fill i...

Page 49: ...is performed When evidence of deterioration exists replacement is required To reduce deteriora tion of rubber components Chrysler Corporation rec ommends Mopar Foamy Engine Degreaser or equivalent be...

Page 50: ...ll plug from the transmission The oil level should not be below 4 mm 3 16 in from the bottom of the oil fill opening Refer to Group21 Transmission proper service procedures NV 3100 or NV 4500 MANUAL T...

Page 51: ...vel position the vehicle on a level surface and remove fill plug from the case housing The oil level should be at the bottom edge of oil fill opening The transfer case requires periodic maintenance at...

Page 52: ...is Group Refer to Group 2 Front Suspension and Axles and Group 16 Propeller Shafts for proper service procedures Do not use high pressure to lubricate the front axle universal joints BR 1500 AND 2500...

Page 53: ...RING FLUID LEVEL PERSONAL INJURY CAN RESULT CAUTION Do not over fill power steering reservoir when adding fluid seal damage and leakage can re sult TO INSPECT FLUii LEVEL 1 Position vehicle on a level...

Page 54: ...bearings for vehicles equipped with a Dana 60 70 or 80 axle should be cleaned and re packed whenever the rear brakes are serviced Refer to Group 3 Rear Axles for the service procedure BRAKES The brak...

Page 55: ...to the sliding contact areas 2 Lubricate the control lever pivot areas with en gine oil PARKING BRAKE FUNCTIONAL TEST AND INSPECTION 1 Engage the parking brake pedal and then re lease it 2 Test it for...

Page 56: ...se NLGI GC LB 2 EP 2 Hood Hinges As Required Engine Oil Seat Regulator Track Release Mechanism As Required Multi Purpose Grease NLGI GC LB 2 IP 2 Tailgate Hinge As Required Multi Purpose Grease NLGI G...

Page 57: ......

Page 58: ...h a vacuum disconnect to ac tivate the 4WD Tube axle 2WD is a one piece tube This axle mounts to the same bracketry as the four wheel drive axle The steering knuckles are the same as the Model 60 driv...

Page 59: ...onship to the suspen sion The bar extends across the front underside of the chassis and mounts on the frame rails Links connected the bar to the lower suspension arms Sta bilizer bar mounts are isolat...

Page 60: ...avel a greater distance than the inside wheel in or der to complete a turn This difference must be com pensated for in order to prevent the wheels from scuffing and skidding through the turn To accom...

Page 61: ...lt of the wheel relative to the center of the vehicle Tilting the top of the wheel inward provides negative camber Tilting the top of the wheel outward provides positive camber Incorrect camber will c...

Page 62: ...nment the follow ing inspection and necessary corrections must be completed 1 Tires with the same recommended air pressure size and tread wear Refer to Group 22 Wheels and Tires for diagnosis informat...

Page 63: ...OR EX CESSIVELY WORN TIRE TREAD BROKEN OR WEAK REAR SPRING LOW POWER STEERING FLUID LEVEL BROKEN OR WEAK REAR SPRING WORN UPPER SUSPENSION ARM BUSHINGS WORN TIE ROD END BALL STUDS WORN TIE ROD END BAL...

Page 64: ...12 TOE IN position Position clamp bolts to their original position and tighten to 49 N m 36 ft lbs torque Make sure the toe setting does not change during clamp tight ening Fig 4 Drag Link Adjustment...

Page 65: ...0 0 01 0 000 0 00 4 50 0 01 0 000 0 00 4 25 0 13 0 125 0 05 4 25 0 11 0 125 0 04 4 00 0 25 0 250 0 10 4 00 0 21 0 250 0 09 3 75 0 37 0 375 0 15 3 75 0 31 0 375 0 13 3 50 0 49 0 500 0 21 3 50 0 41 0 50...

Page 66: ...is will change the caster angle sig nificantly and camber angle only slightly To retain the camber while adjusting caster move the rear pivot bar in or out Move the forward pivot very slightly in the...

Page 67: ...E TREAD BROKEN OR WEAK REAR SPRING LOW POWER STEERING FLUID LEVEL BROKEN OR WEAK REAR SPRING WORN UPPER SUSPENSION ARM BUSHINGS WORN TIE ROD END BALL STUDS WORN TIE ROD END BALL STUDS SHOCK ABSORBER N...

Page 68: ...ck bar Fig 1 Fig 1 Track Bar INSTALLATION 1 Install the track bar at axle tube bracket Loosely install the retaining bolt and flag nut page Shock Diagnosis 12 Stabilizer Bar 11 Track Bar 11 Upper Susp...

Page 69: ...sorber from engine com partment INSTALLATION 1 Position the lower retainer and grommet on the upper stud Insert the shock absorber through the spring from engine compartment SHOCK IOLT J9402 47 Fig 4...

Page 70: ...t or scribe alignment marks on the cam ad justers and suspension arm for installation reference Fig 5 3 Remove the lower suspension arm nut cam and cam bolt from the axle 4 Remove the nut and bolt fro...

Page 71: ...pacing on both sides Tighten the bolts to 47 N m 35 ft lbs torque 2 Install links on stabilizer bar and lower suspen sion arm Install grommets retainers and nuts Tighten nuts to 34 N m 25 ft lbs torqu...

Page 72: ...n front of shock mount 7 Remove cotter pin and nut from lower ball stud Separate ball stud with remover C 4150A 8 Remove lower shock bolt from suspension arm 9 Lower jack and suspension arm until spri...

Page 73: ...s far outboard as possible The upper suspension arms must not contact the rebound bumpers 2 Install a dial indicator and clamp assembly to the lower suspension arm 3 Position indicator plunger against...

Page 74: ...ct the floor vehicle weight relieved from the tire 2 Grasp the top of the tire and apply force in and out Look for any movement at the ball joints be tween the upper suspension arm and steering knuckl...

Page 75: ...n the nut to 41 54 N m 30 40 ft lbs torque to preload bearing while rotating the hub ro tor Stop hub rotor and loosen nut to completely re lease bearing preload torque Tighten the nut finger tight and...

Page 76: ...re Mis ad justment will produce noise If a mis adjustment condition is not corrected component failure can re sult Excessive bearing preload may not be noisy This condition will cause high temperature...

Page 77: ...nut Excessive pinion yoke run out Bent axle shaft Check for loose or damaged front end components or engine transmission mounts These components can contribute to what appears to be a rear end vi bra...

Page 78: ...ue g Readjust as necessary h If necessary replace scuffed gears a Replace broken axle shaft after correcting axle shaft tube alignment b Replace broken axle shaft Avoid excessive weight on vehicle c R...

Page 79: ...flange and reseal a Refill differential housing b Drain flush and refill with correct amount of the correct lubricant c Readjust bearings d Inspect gears for excessive wear or scoring Replace as nece...

Page 80: ...shims The shims are located between the differential bearing cones and case Pinion bearing preload is set and maintained by the use of a collapsible spacer PINION GEAR DEPTH MEASUREMENT WITH GAUGE SE...

Page 81: ...load torque after seal installation 7 Remove the pinion yoke nut and washer Use Remover C 452 and Holder C 3281 to remove the pinion yoke Fig 2 8 Mark the positions of the yoke and pinion gear for in...

Page 82: ...nd at tach the propeller shaft to the yoke 9 Add API grade GL 5 hypoid gear lubricant to the differential housing i f necessary 10 Install wheel and tire assemblies 11 Remove support and lower the veh...

Page 83: ...e opposite bearing cap Position the yoke with the sockets in a vise Fig 8 3 Compress the vise jaws to force the bearing cap into the larger socket receiver LARGE DIAMETER SOCKET WRENCH J8902 16 Fig 8...

Page 84: ...XLE VACUUM CONTROL SYSTEM The disconnect axle control system consists of Shift motor Indicator switch Vacuum switch Vacuum harness Fig 9 Refer to Group 21 Transmissions for addi tional information CHE...

Page 85: ...T VACUUM SHOULD BE BETWEEN 10 20 IN HG DICONNECTTHE SHIFT MOTOR VACUUM HOSES TEST FOR VACUUM IN VACUUM HOSE THAT CONNECTS TO INBOARD SHIFT MOTOR PORT VACUUM SHOULD BE BETWEEN 10 20 IN HG DICONNECTTHE...

Page 86: ...L POSITION FRONT AXLE DOES NOT CONNECT REMOVE VACUUM HOSES FROM AXLE SHIFT MOTOR PORTS START ENGINE TEST FOR VACUUM AT HOSE REMOVED FROM OUT BOARD PORT ON SHIFT MOTOR SHOULD BE BETWEEN 10 20 IN HG NO...

Page 87: ...bolts Tighten the bolts to 11 N m 96 in lbs torque 6 Add 148 ml 5 ounces of API grade GL 5 hy poid gear lubricant to the shift motor housing Add lubricant through indicator switch mounting hole 7 Ins...

Page 88: ...installation 8 Insert the axle shaft into the tube Engage the splined end of the shaft with the shift collar Refer to Hub Bearing and Axle Shaft in this section 9 Install the vacuum motor housing Refe...

Page 89: ...20 2 Position tools as shown to install ball stud Fig 21 LOWER BALL STUD REPLACEMENT 60 AXLE 1 Position tools as shown to remove ball stud Fig 22 2 Position tools as shown to install ball stud Fig 23...

Page 90: ...uckle arm Install the ABS sensor wire and bracket to the knuckle refer to Group 5 Brakes for proper set up KNUCKLE INSTALLATION MODEL 60 1 Position the steering knuckle on the ball studs SPECIAL TOOL...

Page 91: ...at this time 5 Connect the track bar to the axle bracket and install the bolt Do not tighten at this time It is important that the springs support the weight of the vehicle when the track bar is con...

Page 92: ...not to damage housing 2 Clean the inside perimeter of the differential housing with fine crocus cloth 3 Apply a light film of oil to the inside lip of the new axle shaft seal J9302 18 Fig 26 Different...

Page 93: ...e case from the vise PINION REMOVAL DISASSEMBLY 1 Remove the pinion yoke nut and washer Use yoke Holder C3281 and yoke Remover C 452 to re move pinion yoke Fig 32 2 Drive out pinion gear from housing...

Page 94: ...5 7 Remove the collapsible preload spacer Fig 36 8 Remove the inner bearing from the pinion with Bearing Splitter 1130 and Bearing Splitter Bridge 938 Fig 37 J9302 23 Fig 35 Rear Bearing Cup Removal F...

Page 95: ...2 Invert the differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignment 3 Install new ring gear bolts and alternately tighten to 95 122 N m 70 90 ft lbs t...

Page 96: ...etched into both pinion gears Add or subtract the thickness of original depth shims to compensate for the difference in depth vari ances Refer to the Depth Variance charts PINION GEAR DEPTH VARIANCE...

Page 97: ...r plunger against the back of the ring gear Fig 43 3 Insert a small pry bar between the bearing cap and left side of differential case Pry the case as far as possible to right side Fig 43 Zero the dia...

Page 98: ...vel distance whether inward or outward indicated by the pointer Take the plunger travel indicated plus or mi nus the variance etched in the gear This will be the required thickness for the depth shims...

Page 99: ...Preload Spacer YOKE INSTALLER YOKE HOLDER DRIVE PINION GEAR J9302 68 Fig 50 Rear Bearing Installation 4 Install a new collapsible preload spacer on pin ion shaft Fig 51 5 Install pinion front bearing...

Page 100: ...Original Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 26 to 4 52 N m 20 to 40 in lbs DIFFERENTIAL SHIM PACK MEASUREMENT AND ADJUSTMENT 1 Place Master Differential Bearing D 345 for 44 axle or D...

Page 101: ...This will provide the required differential bearing preload 11 Install bearing on the hub with Driver Handle C 4171 and Bearing Installer C 3716A for 44 axle Use Bearing Installer C 4190 for 60 axle...

Page 102: ...ined within the specified limits until the correct tooth contact patterns are obtained 2 Apply a thin coat of hydrated ferric oxide to the drive and coast side of the ring gear 3 Rotate the ring gear...

Page 103: ...HE DRIVE SIDE OF TOOTH PATTERN SHOULD BE CENTERED O N THE COAST SIDE OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN A N D TOP OF THE TOOTH RI...

Page 104: ...Lubricant SAE 80W 90 Lube Capacity 3 43 L 116 oz Axle Ratio 3 54 3 92 4 09 4 55 Ring Gear Diameter 215 9 mm 8 50 in Pinion Standard Setting 109 5 mm 4 312 in Pinion Bearing Preload Original Bearing 1...

Page 105: ...lbs Axle Shaft Nut 218 to 272 N m 160 to 200 ft lbs Bearing to Knuckle Bolts 156 to 176 N m 115 to 130 ft lbs Lower Ball Stud N u t 108 N m 80 ft lbs Upper Ball Stud Nut 101 N m 75 ft lbs RWAL ABS Sen...

Page 106: ...degrees 1 00 0 50 4x2 6010 118 7 3 65 0 50 4x2 6400 118 7 3 65 0 50 4x2 6010 134 7 3 80 0 50 4x2 6400 134 7 3 80 0 50 4x2 7500 134 7 3 55 0 50 4x2 8800 134 7 3 45 0 50 4x2 10500 134 7 3 25 0 50 4x4 64...

Page 107: ......

Page 108: ...m the vehicle The axle are equipped with a remote vent fitting A stamped metal axle gear ratio identification tag is attached to the housing cover The rear wheel anti lock RWAL or four wheel an ti loc...

Page 109: ...ng the differential pin ion gears do not rotate on the pinion mate shaft This occurs because input torque applied to the gears is divided and distributed equally between the two side gears As a result...

Page 110: ...ust be replaced To test a shock absorber hold it in an upright position and force the piston into and out of the cylinder four or five times The action through out each stroke should be smooth and eve...

Page 111: ...e spring pad or spacer 3 Align spring front eye with bolt hole in the front bracket Install the eye pivot bolt and nut 4 Align shackle eye with bolt hole in rear bracket Install bolt and nut 5 Tighten...

Page 112: ...adjustment condition is not corrected component failure can result GEAR AND BEARING NOISE GEAR NOISE Axle gear noise can be caused by insufficient lubri cant Incorrect backlash tooth contact or worn d...

Page 113: ...he rear wheels until both reference marks face the front of the vehicle Measure the dis tance between the outside edges of the two pieces of tape Record this measurement as the front of tire FTR measu...

Page 114: ...e g Readjust as necessary h If necessary replace scuffed gears a Replace broken axle shaft after correcting axle shaft tube alignment b Replace broken axle shaft Avoid excessive weight on vehicle c Re...

Page 115: ...nge and reseal a Refill differential housing b Drain flush and refill with correct amount of the correct lubricant c Readjust bearings d Inspect gears for excessive wear or scoring Replace as necessar...

Page 116: ...ion Change 11 Pinion Depth Measurement and Adjustment 17 Pinion Seal Replacement 13 INFORMATION The 9 1 4 axle Fig 1 housing consist of a cast iron center section They also have two steel axle shaft t...

Page 117: ...3 10 REAR SUSPENSION AND AXLE HUB AXLE DIFFERENTIAL SHAFT HOUSING Fig 1 9 1 4 Axle...

Page 118: ...TION Overfilling the differential can result in the lubricant foaming and overheating 7 Refill the differential with the specified quan tity of MOPAR Hypoid Gear Lubricant 8 Install the fill hole plug...

Page 119: ...or seat the bearing in the axle shaft bore 3 Install the new axle shaft seal with Installer C 4826 and Handle C 4171 Fig 7 Fig 7 Axle Shaft Seal Installation 4 When the tool contacts the end of the t...

Page 120: ...g 8 Fig 8 Yoke Removal 8 Remove the pinion shaft seal with Puller C 748 and clean seal contact surface in housing bore Fig 9 C 748 J9403 20 Fig 9 Pinion Seal Removal INSTALLATION 1 Inspect splines on...

Page 121: ...ar wheels and brake drums 4 Disconnect the brake fluid tube fittings from the wheel cylinders Cap the fittings to prevent loss of brake fluid 5 Remove the vent hose from the brake tee nip ple 6 Remove...

Page 122: ...mm a damaged differential case could be the cause The marking on the differential case will be very useful later during the differential case runout 4 Remove RWAL ABS sensor from housing 5 Mark the di...

Page 123: ...mes and observe the dial indicator Mark the area of maxi mum flange runout The differential case flange runout must not exceed 0 003 inch 0 08 mm I f the runout exceeds this amount replace the differe...

Page 124: ...de Gear Clear ance Measurement And Adjustment 3 Position thrust washers on differential pinion gears Mesh the pinion gears with the side gears Ensure that the pinion gears are exactly 180 de grees opp...

Page 125: ...the tool and place a piece of 0 002 inch shim stock at each end of the arbor Position the bearing caps on the arbor tool Install the attaching bolts Tighten the cap bolts to 14 N m 10 ft lbs torque 7...

Page 126: ...s not required 12 Lubricate the pinion gear front and rear bear ings with gear lubricant 13 Install new collapsible spacer on pinion gear shaft Install pinion gear in housing 14 Install the pinion yok...

Page 127: ...he differential bearings bearing cups and threaded ad justers A dab of grease can be used to keep the ad justers in position Carefully position the assembled differential case in the housing 2 Observe...

Page 128: ...e of backlash is 0 006 to 0 008 inch 0 15 to 0 203 mm Continue increasing the torque at the right side threaded adjuster until the specified backlash is ob tained The left side threaded adjuster torqu...

Page 129: ...ed when the C clip lock was installed to thrust washer thickness measured The sum will determine the required thickness of the replacement thrust washer 7 If clearance is 0 012 inch 0 305 mm or greate...

Page 130: ...SIDE O F TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN A N D TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRE...

Page 131: ...g Gear Diam 9 25 in 23 50 cm Lubricant SAE 80W 90 Lube Capacity 76 oz 2 26 L Diff Case Clearance 0 005 in 0 12 mm Ring Gear Backlash 0 005 0 008 in 0 12 0 20 mm Pinion Bearing Preload 10 20 in lbs 1 2...

Page 132: ...out disturbing or re moving the wheel bearings The wheel bearings are opposed tapered roller bearings that are part of the hub assembly page Pinion Measurement and Assembly 37 Pinion Removal Disassemb...

Page 133: ...Fig 1 Model 70 and 80 Rear Axle...

Page 134: ...g the sealant If not installed the sealant must be removed and another bead ap plied 7 Install the cover on the differential Install the identification tag Tighten the cover bolts to 47 N m 35 ft lbs...

Page 135: ...REPLACEMENT MODEL 60 REMOVAL 1 Raise and support the vehicle 2 Remove wheel and tire assemblies TORQUE WRENCH J9402 62 Fig 6 Tightening Pinion Shaft Nut 3 Mark the propeller shaft yoke and pinion yoke...

Page 136: ...on shaft will have to be replaced The bearing preload torque will be re adjusted after ward 4 Install a socket and inch pound torque wrench on the pinion nut 5 Rotate the shaft with the torque wrench...

Page 137: ...ply lubricant to surface area of the hub bore Install the inner wheel bearing in the hub Install a replacement bearing seal with an appropriate seal in stallation tool 4 Inspect the bearing and seal c...

Page 138: ...ated in the locating holes Fig 12 Install the holddown clamps and tighten the tool turnbuckle fin ger tight Fig 12 Differential Housing Spreader 3 Install a pilot stud at the left side of the differ e...

Page 139: ...g 20 3 Remove oil slinger or collapsible spacer front bearing and shims Record the thickness of the shims Fig 21 4 Remove front pinion bearing cup with Model 60 and 70 Remover D 158 and Handle C 4171...

Page 140: ...torted or cracked C 452 J9102 31 Fig 19 Pinion Yoke Remowal SPECIAL TOOL 7794A PINION SEAL J9402 59X Fig 20 Pinion Seal Remowal Cup and bearing must be replaced as a matched sets only All machined sur...

Page 141: ...exciter ring for damage and missing teeth I f not removed ensure the ring is firmly pressed onto the differential case Replace the ring if loose or damaged DIFFERENTIAL ASSEMBLY ASSEMBLY 1 Lubricate...

Page 142: ...ernately tighten to Model 60 and 70 163 190 N m 120 140 ft lbs torque Model 80 272 325 N m 200 240 ft lbs torque J9402 64 Fig 26 Master Bearing Tools On Hubs 9 Install a pilot stud at the right side o...

Page 143: ...erline of the axle shaft ring gear to the shoul der of the rear pinion bearing Model 60 axle the standard depth distance is 127 00 mm 5 000 inches Model 70 axle the standard depth distance is 136 525...

Page 144: ...tersecting figure is O OOl inch 0 025mm Sub tract this amount from original shim Refer to the Pinion Gear Depth Variance Chart If equipped the oil slinger must be measured and the thickness included w...

Page 145: ...K 0 PINION HEIGHT BLOCK J9403 39 Fig 34 Pinion Height Block Arbor Discs have different steps to fit other axle sizes Pick correct size step for axle being serviced ARBOR DISC PINION BLOCK PINION HEIGH...

Page 146: ...ims or collapsible spacer if used onto pinion and install pinion gear in hous ing 12 Install pinion front bearing and oil slinger 13 Apply a light coating of gear lubricant on the lip of pinion seal I...

Page 147: ...preload torque with an inch pound torque wrench Fig 41 The torque necessary to rotate the pinion gear should be Original Bearings 1 3 N m 10 20 in lbs New Bearings 2 5 N m 20 40 in lbs Axles equipped...

Page 148: ...eader W 129B with the tool dowel pins seated in the locating holes Fig 44 Install the holddown clamps and tighten the tool turnbuckle fin ger tight SPECIAL TOOL Fig 44 Differential Housing Separation...

Page 149: ...1 Apply a thin coat of hydrated ferric oxide to the drive and coast side of ring gear teeth 2 Rotate the ring gear one complete revolution in both directions while a load is being applied Insert a pry...

Page 150: ...SIDE OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN A N D TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED...

Page 151: ...e most probable cause is incorrect or contaminated lubri cant Before removing the Trac lok unit for repair drain flush and refill the axle with the specified lu bricant Refer to Lubricant change in th...

Page 152: ...aws with the splined end upward Fig 5 2 Place shop towels on vise to avoid gear damage during removal of the ring gear Position the differ ential case on the axle shaft Fig 6 3 Remove and discard the...

Page 153: ...case 14 Remove top side gear and clutch pack Keep plates in correct order during removal PINION GEAR MATE SHAFT PUNCH LOCKPIN J9003 95 Fig 7 Pinion Gear Mate Shaft Lock Pin Removal SPECIAL TOOL C 448...

Page 154: ...ch disc packs on the side gear hubs 5 Position case on fixture 6 Install clutch pack and side gear in lower bore Fig 14 Be sure clutch pack retaining clips re main in position and are seated in the ca...

Page 155: ...HAUL DISASSEMBLY 1 Mark the ring gear half and cover half for in stallation reference Fig 18 UPPER SIDE GEAR A N D CLUTCH DISC PACK DIFFERENTIAL CASE SPECIAL TOOL C 4487 1 J9203 6 Fig 15 Upper Side Ge...

Page 156: ...alla tion 2 Saturate the clutch plates with Hypoid Gear Lubricant or Additive Assemble clutch packs into the side gear plate in exactly the same position as re moved Fig 21 3 Line up the plate ears an...

Page 157: ...AND AXLE FLANGE HALF CLUTCH PINION MATE RING GEAR PLATE DISHED PLATE DISHED PINION MATE DISC DISC CROSS SHAFT BUTTON HALF J9203 74 Fig 20 Power Lok Components Fig 21 Clutch Pack Assembly Figm 2 2 Clut...

Page 158: ......

Page 159: ...ECIFICATIONS REAR SUSPENSION COMPONENTS Description Torque Jounce Bumper to Frame Shock Lower Nut Shock Upper Nut Spring Clamp Nut 6010 to 10500 GVW Spring Clamp Nut 1100 GVW Cab Chassis Spring Front...

Page 160: ...i metallic Vented disc brake rotors are used for all applications Three different calipers are used They are identi fied by caliper piston size and model application which are calipers on 1500 models...

Page 161: ...mination is suspected check the fluid for dirt discoloration or separation into dis tinct layers Drain and flush the system with new brake fluid if contamination is suspected MODEL IDENTIFICATION Diff...

Page 162: ...f test feature de signed to check bulb and circuit operation page Power Booster Check Valve Test 6 Power Booster Vacuum Test 6 Preliminary Brake Check 3 Road Testing 4 Service Brake Diagnosis Procedur...

Page 163: ...in the antilock system Refer to the appro priate antilock system service section within this ser vice manual group DIAGNOSING SERVICE BRAKE PROBLEMS PEDAL FALLS AWAY A brake pedal that falls away unde...

Page 164: ...auses of pull A damaged front tire bruised ply separation can also cause pull A common and frequently misdiagnosed pull condi tion is where direction of pull changes after a few stops The cause is a c...

Page 165: ...ngine and note pedal action a I f pedjal falls away slightly under light foot pressure then holds firm proceed to step 6 b I f pedal is effort is high or no pedal action is discernible power booster o...

Page 166: ...ow Vacuum Condition in that sec tion 1 Check pump vacuum and booster hoses and connections Make sure hoses are in good condition and securely attached Run engine and check for vac uum leaks Replace le...

Page 167: ...TER CYLINDER SERVICEABILITY The cylinder body piston assemblies reservoir grommets seal and cover are all serviceable parts The take up valve is the only non serviceable compo nent The valve is availa...

Page 168: ...excessive wear if fluid level is very near the MIN level Always clean the master cylinder reservoir and cover before adding fluid If this is not done dirt from the cover or reservoir could enter the...

Page 169: ...nation valve and antilock valve brakeline fit tings Work penetrant between fittings and brake lines to ease removal 2 Remove brakelines connecting master cylinder to combination valve Fig 6 Use flare...

Page 170: ...10 4 Remove reservoir with a rocking motion Use a pry tool to help ease reservoir out of cylinder body and grommets Fig 10 If reservoir is to be re placed note and record reservoir code letters Fig 2...

Page 171: ...stuck or seized The valve is not serviceable It will be necessary to replace the cylinder body if the valve is faulty Inspect condition of the secondary piston Replace the piston if it is scored corro...

Page 172: ...jaws on one of the cylinder mounting ears 2 Install bleed tubes in cylinder outlet ports and direct tube ends into appropriate reservoir chambers Fig 15 3 Fill reservoir chambers about 3 4 full with f...

Page 173: ...nstalling valve attaching bolt Then install and tighten valve bolt to 17 N m 13 ft lbs torque 5 Tighten valve and cylinder brakeline fittings to 16 23 N m 140 200 in lbs torque 6 Install master cylind...

Page 174: ...age Power Brake Booster Identification 15 Power Brake Booster Installation 17 Power Brake Booster Operation 16 Power Brake Booster Removal 16 Power Brake Booster Serviceability 16 panel The pedal shaf...

Page 175: ...rential between normal atmospheric pressure and a vacuum The vacuum needed for booster oper ation is taken directly from the engine intake mani fold The entry point for atmospheric pressure is through...

Page 176: ...onnect front rear brakelines to combination valve and RWAL valve Tighten brakeline fittings to 16 23 N m 140 200 in lbs torque 9 Connect harness wires to RWAL valve and pressure differential switch on...

Page 177: ...orted or open BRAKELIGHT SWITCH ADJUSTMENT AND INSTALLATION 1 Pull switch plunger all the way out to fully ex tended position 2 Connect harness wires to switch 3 Press and hold brake pedal down 4 Inst...

Page 178: ...to pedal shaft and to pedal and bracket bushings 3 Position brake pedal in mounting bracket 4 Slide pedal shaft into bracket and through pedal from passenger side 5 Push pedal shaft out driver side of...

Page 179: ...UMP SERVICEABILITY The vacuum pump is not a serviceable component If diagnosis indicates a pump malfunction the pump must be replaced as an assembly Do not disassemble or attempt to repair the pump Th...

Page 180: ...um I f vacuum is consistently below 8 5 inches problem is with vacuum hoses or pump component If output is within specified limits con tinue testing 3 Check booster operation as described in diagno si...

Page 181: ...attaches pump assem bly to engine block Fig 7 10 Remove pump assembly from vehicle Fig 8 VACUUM PUMP REPLACEMENT 1 Remove nuts attaching vacuum pump to adapter Fig 8 BOTTOM INBOARD ADAPTER BRACKET NUT...

Page 182: ...ig 12 6 Install O ring on adapter Fig 11 7 Position adapter on pump studs 8 Install attaching nuts on outboard stud and on the two upper pump studs Do not install nut on lower inboard stud at this tim...

Page 183: ...en install remaining adapter attaching nut on stud Tighten nut to 24 N m 18 ft lbs torque 6 Connect oil feed line to vacuum pump connec tor Tighten line fitting securely 7 Install oil pressure sender...

Page 184: ...dur ing periods of high wheel slip and deceleration Re tarding lockup is accomplished by modulating fluid pressure to the rear brake units Rear brake fluid apply pressure is modulated ac cording to w...

Page 185: ...normal braking the valves allows free flow of brake fluid to the rear brake units In antilock mode the valve will decrease hold or increase fluid apply pressure as needed Fig 4 Combination Valve And...

Page 186: ...ressure to the rear wheel cylinders as needed Closing the valves prevents further fluid flow to the rear wheel cylinders This action isolates the rear brakes from the master cylinder The net effect is...

Page 187: ...ate through the antilock warning light Temporarily grounding the antilock diagnostic connector will produce the flash code sequence Refer to Fault Code Identification in this section FAULT CODE CAPACI...

Page 188: ...e electronic module rear wheel speed sensor exiter ring and in terconnecting brakelines are not repairable These components are serviced by replacement only The combination valve mounting bracket is n...

Page 189: ...ect harness wires to RWAL valve and to combination valve switch Fig 7 10 Fill and bleed brake system Fig 11 Master Cylinder Brakeline Connections Fig 12 Master Cylinder And Combination Valve Mounting...

Page 190: ...harness wires to module 9 Position module and bracket on instrument panel and install attaching screws Figs 14 and 15 10 Install knee bolster REAR SPEED SENSOR REMOVAL INSTALLATION 1 Raise vehicle on...

Page 191: ...SAE J1703 F and DOT 3 standards to fill and bleed the system Bleeding can be performed either manually or with pressure equipment However if pressure equipment is used it will be necessary to hold the...

Page 192: ...ylinder to run out of fluid during bleed operations An empty cyl inder will allow additional air to be drawn into the system Check the cylinder fluid level frequently and add fluid as needed J8905 18...

Page 193: ...Connect bleeder tank pressure hose to adapter Fig 21 6 Bleed master cylinder and valves Bleed master cylinder first combination valve second and RWAL ABS valves third 7 Bleed rear wheel brake units as...

Page 194: ...to a sin gle assembly Fig 1 The valve is mounted on the driver side inner fender panel Fig 1 The valve and motor assembly are attached to a one piece mounting bracket and a stud plate A molded flexibl...

Page 195: ...e Fig 3 Combination valve operation and testing is fully described in the antilock system diagnosis section Refer to this information when diagnosing system faults ABS Electronic Control Module A sepa...

Page 196: ...kes are controlled individu ally and the rear wheel brakes in tandem Fig 7 The ABS system is designed to retard wheel lockup during periods of high wheel slip when braking Re tarding wheel lockup is a...

Page 197: ...ntrol module antilock program The solenoid valves are not static during antilock braking They are cycled continuously to modulate pressure Solenoid cycle time in antilock mode can be measured in milli...

Page 198: ...e During antilock braking the front rear solenoid valves cycle rapidly in response to antilock electronic control unit inputs The driver may experience a slight pulsing sensa tion in the brake pedal a...

Page 199: ...ation can be checked visually and with the aid of a helper Observe the metering valve stem while a helper applies and releases the brakes I f the valve is operating correctly the stem will extend slig...

Page 200: ...system Refer to procedure in this section RWAL VALVE COMBINATION ALVE REMOVAL 1 Disconnect ground wire and harness wires from combination valve switch and RWAL valve Fig 12 2 Disconnect lines to front...

Page 201: ...nder 7 Loosely install nuts that retain master cylinder and combination valve on booster studs 8 Install and connect all remaining brakelines Figs 16 and 10 Tighten line fittings to 16 23 N m 140 200...

Page 202: ...4 wheel drive models the tone wheel is located on the front driveshaft The tone wheel is not a serviceable component On 2 wheel drive models the complete rotor and hub as sembly will have to be repla...

Page 203: ...icle on hoist 2 Disconnect sensor harness at sensor Then dis engage small harness clip from sensor cover Fig 21 3 Disconnect sensor harness at axle connector 4 Unclip sensor harness from plastic retai...

Page 204: ...on 1 2 ton models have a 75 mm 2 95 in bore calipers on 3 4 ton models have an 80 mm 3 14 in bore calipers on 1 ton models and 3 4 ton 4 x 4 models with Dana 60 front axle have an 86 mm 3 38 in bore...

Page 205: ...ces the caliper to slide inward on the mount ing bolts This action brings the outboard brakeshoe lining into contact with the outer surface of the disc brake rotor Fig 5 In summary fluid pressure acti...

Page 206: ...n By Piston Seal DISC BRAKESHOE REMOVAL 1 Raise vehicle 2 Remove wheel and tire assemblies 3 Press caliper piston back into bore with large flat blade screwdriver Fig 7 Use large C clamp to bottom pis...

Page 207: ...spect the brakeshoe lining for wear Replace riv eted lining if worn to within 1 5 mm 1 16 in of rivet heads Replace bonded lining i f thickness is 3 mm 3 16 in or less If the brakeshoes will be reused...

Page 208: ...ip on shoe is properly aligned and seated in caliper piston Fig 18 and 19 4 Install outboard brakeshoe in caliper Be sure spring ends are seated in dimples in caliper Fig 19 APPLY SILICONE GREASE WHER...

Page 209: ...ly 8 Cover open end of front brake hose fitting to prevent dirt entry DISC BRAKE CALIPER DISASSEMBLY 1 Drain brake fluid from caliper 2 Remove brakeshoes from caliper 3 Pad interior of caliper with mi...

Page 210: ...eplacement The bore can be lightly DUST W O T J94Q5 39 Fig 22 Dust Boot Remowal polished by hand but only with crocus cloth Do NOT use any other type of abrasive material for polishing Check condition...

Page 211: ...1 Be sure caliper assembly area of workbench is clean and dry This is important as dust dirt foreign material oil or solvents can damage seals harm pis ton surfaces and contaminate fluid 2 Lubricate c...

Page 212: ...are correctly seated in caliper dimples DISC BRAKE CALIPER INSTALLATION 1 Clean caliper and steering knuckle slide sur faces with wire brush Fig 16 Then apply coat of Mopar multi mileage grease or Dow...

Page 213: ...he center of the brake shoe contact surface Replace the rotor if it is worn below minimum thickness or if refinishing would re duce thickness below the allowable minimum Rotor minimum thickness is usu...

Page 214: ...machining with cutting tools will be required CAUTION Do not refinish a rotor if machining would cause the rotor to fall below minimum allow able thickness The recommended final finish on a rotor bra...

Page 215: ...cessary with Mo par high temperature bearing grease Apply grease to bearing races as well Then install inner bearing in hub and install new grease seal 2 Apply liberal coat of bearing grease to spindl...

Page 216: ...re Use screwdriver or large C clamp to press piston back to bottom of caliper bore Fig 7 4 Remove caliper mounting bolts Figs 8 and 9 5 Remove caliper from rotor Position caliper on steering knuckle a...

Page 217: ...ear Fig 43 Use chassis grease to hold spacer in place on knuckle Fig 43 Hub Spacer Positioning And Installation 5 Apply 1 2 drops of Mopar Lock W Seal or Loc tite 242 to threads of rotor and hub retai...

Page 218: ...ng WHEEL NUT TIGHTENING The wheel attaching nuts should be properly tight ened to ensure efficient brake operation Overtighten ing the nuts or tightening them in the wrong sequence could cause distort...

Page 219: ...he net result is that each shoe helps the other exert ex tra force against the drum I t is servo action that cre page Drum Brake Adjustment 67 Drum Brake Operation 60 General Service Information 60 Wh...

Page 220: ...heck operation of adjuster screw as semblies Make sure each screw assembly rotates freely Lubricate screw threads with Mopar spray lube Replace either assembly if threads are heavily rusted corroded o...

Page 221: ...ed Fig 5 20 Adjust brakeshoes to drum with brake gauge 21 Install brake drum and wheel and tire assem blies 22 Lower vehicle 23 Tighten wheel lug nuts to 108 150 N m 80 110 ft lbs torque 24 Install wh...

Page 222: ...ndary brake shoe and remove lever Fig 8 11 Inspect wheel cylinder If leakage is evident remove and overhaul cylinder Refer to overhaul pro cedure in this section BRAKESHOE INSTALLATION 13 INCH BRAKE 1...

Page 223: ...ondary brake shoe Use new E clip to secure lever to shoe I f lever is secured with U clip pinch new clip together with channel lock pliers to secure it 5 Attach parking brake cable to parking brake le...

Page 224: ...g to primary brakeshoe Use brake spring pliers and long screwdriver to seat spring in shoe 14 Install shoe guide plate on anchor pin 15 Attach adjuster spring to spring retainer at top of adjuster lev...

Page 225: ...s corroded pitted or scored Check condition of the cylinder brakeline and bleed screw threads Replace the wheel cylinder if the Installation 13 Inch Brake threads are damaged in any way replace the bl...

Page 226: ...and lubricate shoe contact pads with multi mileage or silicone grease Fig 3 Fig 14 Seating Wheel Cylinder Dust Boots 2 Apply thin coat of Mopar silicone sealer to wheel cylinder mounting surface of s...

Page 227: ...shoes Fig 8 Repeat adjustment at opposite brakeshoe as sembly 9 Install brake drums and wheels and lower ve hicle 10 Make final adjustment as follows a Drive vehicle and make one forward stop fol lowe...

Page 228: ...vibration and avoid chatter marks BRAKE DRUM REFINISH LIMITS The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge Fig 19 Generally a drum can be ma ch...

Page 229: ...rm on foot pedal assembly Fig 3 9 Insert new cable through floorpan grommet Fig 3 Then feed cable up to arm on pedal assembly Fig 2 10 Hook cable T connector in arm on pedal as sembly Fig 2 11 Secure...

Page 230: ...replaced or disconnected for service When adjustment is necessary perform adjustment only as de scribed i n the following procedure This is nec essary to avoid faulty parking brake operation 1 Raise v...

Page 231: ...cting for bet ter access to pedal assembly as needed 7 Disconnect brakelight wire from switch on pedal assembly 8 Roll carpet back and loosen front cable grom met seal from floorpan Fig 2 9 Disengage...

Page 232: ...in Drum Brake Size 1 2 Ton Models 11x2 in 279x51 mm 3 4 Ton Models 13x2 5 in 330x63 5 mm 1 Ton Models 13x3 5 in 330x89 mm Drum Brake Type All Dual Shoe With Self Adjusting Mechanism Master Cylinder Bo...

Page 233: ...t I I...

Page 234: ...e clutch cover pressure plate is a diaphragm type with a one piece spring and multiple release fingers The pres sure plate release fingers are preset during manufacture and are not adjustable FACING M...

Page 235: ...y is provided at the end of this section refer to Figure 10 312 5 mm 12 3 in 1DIESEL V101 J9406 11 Fig 5 V6 V8 Gas Engine Clutch Covet COVER 281 mm 11 in PRESSURE PLATE rV67V8l J9406 12 Fig 6 VWDiesel...

Page 236: ...nsmission front bearing retainer slide surface Do not apply grease to any part of the clutch cover disc or release bearing RECOMMENDED LUBRICANTS Use Mopar multi purpose grease for the clutch pedal bu...

Page 237: ...distort the flywheel hub caus ing runout Clutch Cover And Disc Runout Check the clutch disc before installation Axial face runout of a new disc should not exceed 0 5 mm 0 020 in Measure runout about 6...

Page 238: ...and wear Use the recom mended factory quality parts to avoid comebacks INSPECTION AND DIAGNOSIS CHARTS The clutch inspection chart Fig 9 outlines items to be checked before and during clutch installat...

Page 239: ...nly if seized noisy or damaged 11 Check clutch cover diaphragm spring and release fingers Replace cover if spring or fingers are bent warped broken cracked Do not tamper with factory spring setting as...

Page 240: ...nd transmission front bearing retainer if sleeve surface is damaged 4 Flywheel height incorrect Flywheel surface improperly machined Too much stock removed or surface is tapered Replace flywheel 5 Wro...

Page 241: ...n pockets over rivet heads in clutch disc Occurs as clutch cools down after use Drill 1 16 inch diameter hole through rivets and scuff sand disc facing with 180 grit paper 5 Clutch disc too thick Wron...

Page 242: ...rroded a Replace both cylinders as assembly and reservoir 4 No fault found with clutch components a Problem actually related to suspension or driveline component b Engine related problem a Further dia...

Page 243: ...torque Replace any clutch bolts that are damaged 4 Components appear overheated Hub of disc cracked or torsion damper springs are distorted or broken Frequent high load full throttle operation Replac...

Page 244: ...NTER A 2 12PK BK JFEED TO I G N I T I O N SWITCH GREEN BYPASS JUMPER A41 20YL AUTOMATIC T R A N S M I S S I O N GREEN A41 A41 18YL 18YL CLUTCH PEDAL POSITION SWITCH O N CLUTCH CYLINDER PUSH ROD M A N...

Page 245: ...on Clutch Housing With NV4500 4 Support engine with wood block and adjustable jack stand Fig 3 Supporting engine is necessary to avoid undue strain on engine mounts J9106 22 Fig 3 Supporting Engine Wi...

Page 246: ...el Fig 7 CLUTCH COVER A N D DISC CLUTCH DISC ALIGNMENT TOOL FLYWHEEL _ J9106 18 Fig 7 Clutch Disc And Cower Alignment Installation 7 Align and hold clutch cover in position and in stall cover bolts fi...

Page 247: ...g Figs 11 and 12 Be sure housing is properly seated on alignment dowels before tightening housing bolts FORK J9406 18 Fig 10 Release Fork And Bearing Spring Clip Position 13 Install transmission 14 Ch...

Page 248: ...surface on transmission front bearing retainer Replace retainer if slide sur face is scored worn or cracked 5 Inspect release lever and pivot stud Be sure stud is secure and in good condition Be sure...

Page 249: ...separately The linkage cylinders J9106 21 Fig 16 Slave Cylindet Removal installation and connecting lines are sealed units They are prefilled with fluid during manufacture and must not be disassembled...

Page 250: ...lock it in place 5 I f cylinder seal is hard to seat unlock cylinder and reseat seal if necessary Then relock cylinder af terward 6 Position clutch fluid reservoir on dash panel and install reservoir...

Page 251: ...flywheel scoring should be per formed with surface grinding equipment Remove only enough material to reduce scoring approximate ly 0 001 0 003 in Heavy stock removal is not rec ommended Replace thefl...

Page 252: ...y be checked off the vehicle MEASURING CLUTCH HOUSING BORE RUNOUT NV4S00 ONLY 1 Remove the clutch housing and strut 2 Remove the clutch cover and disc 3 Replace one of the flywheel bolts with an ap pr...

Page 253: ...004 SAMPLE READINGS J9Q06 27 Fig 24 Housing Bore Measurement Points And Sample Readings SLOT SHOWS DIRECTION OF OFFSET DOWEL S OFFSET ELECTION TIR VALUE OFFSET DOWEL REQUIRED 0 011 0 021 inch 0 007 in...

Page 254: ...sembly and housing tighten the housing bolts nearest the alignment dow els first Clutch housing preferred bolt torques are 41 N m 30 ft lbs for 3 8 in diameter bolts 68 N m 50 ft lbs for 7 16 in diame...

Page 255: ......

Page 256: ...ight Duty Cycle engines The 5 9L V 8 gas powered engine will be re ferred to as either LDC Light Duty Cycle or HDC page ENGINE BLOCK HEATERS 58 SERVICE PROCEDURES 16 SPECIFICATIONS 5i Heavy Duty Cycle...

Page 257: ...SEL ENGINE Coolant flow circuits for the 5 9L diesel engine are shown in figure 2 The diesel cooling system consists of a cross flow radiator engine driven cooling fan thermal viscous fan drive fan sh...

Page 258: ...COOLING SYSTEM 7 1 Coolant Flow from Cylinder Block Fig 3 Cylinder Block Coolant Routing Diesel Engine...

Page 259: ...s and observing the Malfunction Indicator Lamp This lamp was formerly referred to as the Check Engine Lamp The lamp is located on the instrument panel They can also be displayed through the use of the...

Page 260: ...mal during temporary operation with heavy load towing a trailer high outdoor temperatures and or on a steep loss grade Improper refilling procedures can result in trapped air in the system Subsequent...

Page 261: ...ESULT FROM SCALDING COOLANT Inspect coolant level in the coolant reserve tank and radiator Inspect system for leaks 5 Inspect heater door controls Refer to Group 24 Heating and Air Conditioning G A U...

Page 262: ...correct radiator c If symptom occurs during low speed operation only inspect the thermal viscous fan drive Repair as necessary TEMPERATURE GAUGE READS HOT PRESSURE CAP VENTS RESULTING IN STEAM AND COO...

Page 263: ...accessory drive belt 5 Air leak on the suction side of the water pump allows air to build up in cooling system causing thermostat to open late 1 a The gauge pointer may move up and down within the nor...

Page 264: ...system clean ana flush system before replacing with 50 50 mixture of ethylene glycol a n d water C O O L I N G SYSTEM H O S E S COLLAPSE O N C O O L D O W N 1 Inspect pressure cap vent valve 2 Coolan...

Page 265: ...hoses for kinks or binds Also inspect condition of heat doors in heater Refer to Group 24 Heat and Air Conditioning 2 Is coolant level low 3 Check On Board Diagnostics Is code 17 set in memory 3 Cond...

Page 266: ...nt reserve tank and radiator Inspect system for leaks 5 Inspect heater door controls Refer to Group 24 Heating and Air Conditioning GAUGE READING HIGH NO PRESSURE BLOW OFF FROM RADIATOR PRESSURE CAP O...

Page 267: ...on A C with incorrect radiator c If symptom occurs during low speed operation only inspect the thermal viscous fan drive Repair as necessary TEMPERATURE GAUGE READS HOT PRESSURE CAP VENTS RESULTING IN...

Page 268: ...e accessory drive belt 5 Air leak on the suction side of the water pump allows air to build up in cooling system causing thermostat to open late 1 a The gauge pointer may move up and down within the n...

Page 269: ...seal out of position C O O L I N G S Y S T E M H O S E S C O L L A P S E O N C O O L D O W N t 1 Inspect pressure cap vent valve 2 Coolant reserve tank hose p l u g g e d or kinked 3 Inside of pressu...

Page 270: ...O N 1 Does g a u g e read low 2 Is coolant level low 3 Thermostat stuck in open position 1 If YES replace thermostat If N O inspect the heater hoses for kinks or binds Also inspect condition of heat d...

Page 271: ...ced because of bearing shaft damage or leaking shaft seal the mechanical cooling fan assembly should also be inspected Inspect for fa tigue cracks loose blades or loose rivets that could have resulted...

Page 272: ...t place the thermal viscous fan drive in the hori zontal position I f stored horizontally the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubr...

Page 273: ...pry the water pump at timing chain case cover The machined surfaces may be damaged resulting in leaks Fig 7 Coolant Return Tube 3 9L V 6 or 5 2 5 9L V 8 LDC Gas Engines Fig 8 Coolant Return Tube 5 9L...

Page 274: ...orque Place a bar or screwdriver between water pump pulley bolts Fig 4 to prevent pulley from rotating 10 Relax tension from automatic belt tensioner Figs 5 or 6 Install drive belt CAUTION When instal...

Page 275: ...lso check condi tion of the thermal viscous fan drive Refer to Viscous Fan Drive in this group 1 Disconnect negative battery cable from battery 2 Drain cooling system Refer to Draining Cooling System...

Page 276: ...e thermal viscous fan drive in the hori zontal position I f stored horizontally the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant Do n...

Page 277: ...assembly if it has any of the following conditions The body is cracked or damaged Water leaks from the shaft seal This is evident by traces of coolant below the vent hole Loose or rough turning beari...

Page 278: ...lt routing The correct belt with correct length must be used AUTOMATIC TENSIONER J9307 55 Fig 21 Belt Routing 8 0L V 10 Engine With A C 11 Position fan shroud and fan blade viscous fan drive assembly...

Page 279: ...manifold and water pump on all gas powered engines To test for leaks refer to Test ing Cooling System for Leaks in this group FAN BLADE ASSEMBLY WATER PUMP PULLEY WATER PUMP THREADED NUT THREADED SHAF...

Page 280: ...ypical WARNING THE A C SYSTEM S UNDER PRESSURE EVEN WITH THE ENGINE OFF REFER TO REFRIG ERANT WARNINGS IN GROUP 24 HEATING AND AIR CONDITIONING 1 Disconnect negative battery cable from battery 2 Parti...

Page 281: ...tor mounting bracket 10 Disconnect throttle body control cables Refer to Accelerator Pedal and Throttle Cable in Group 14 Fuel System 11 Remove heater hose coolant return tube mounting bolt Figs 32 or...

Page 282: ...ll coolant return tube and its mounting bolt to engine Figs 32 or 33 7 Connect throttle body control cables 8 Install oil dipstick mounting bolt 9 3 9L V 6 or J2 5 9L V 8 LDC Gas Engines Install idler...

Page 283: ...D GROOVE J9207 14 Fig 38 Thermostat 3 9L 6 or 5 2 5 9L V 8 Gas Powered Engines TEMP COOLANT RUBBER LIP SEAL J9407 16 Fig 39 Thermostat 8 0L V 10 Engine The thermostat of the 5 9L diesel engine is loca...

Page 284: ...t be lit by an open too soon condition But i f the thermostat has failed open a Diagnostic Trouble Code DTC number 17 will be set and stored in the PCM Do not change a thermostat for lack of heat as i...

Page 285: ...UMBER HPC 20 MAY B E USED FOR LARGER CLAMPS AL WAYS WEAR SAFETY G L A S S E S WHEN SERVICING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps Fi...

Page 286: ...not the engine may overheat due to the water pump ro tating in the wrong direction Refer to Belt Schemat ics in the Engine Accessory Drive Belt section of this group for correct engine belt routing T...

Page 287: ...ld gasket INSTALLATION 1 Clean mating areas of intake manifold and thermostat housing 2 Check the condition for tears or cracks of the rubber thermostat seal located in the intake manifold Figs 47 or...

Page 288: ...s threaded into the front of the cylinder head Fig 51 It is connected to the thermostat housing with a rubber hose and screw type clamps Fig 51 THERMOSTAT REMOVAL DIESEL ENGINE WARNING DO NOT LOOSEN T...

Page 289: ...o 43 N m 32 ft lbs torque 5 Install the check valve hose and hose clamp at thermostat housing Fig 52 6 Install accessory drive belt Refer to Belt Re moval Installation in the Engine Accessory Drive Be...

Page 290: ...spections The coolant level can be checked at the coolant reserve overflow tank The coolant reserve overflow system provides a quick visual method for determining the coolant level without removing th...

Page 291: ...the system is being filled Water pressure or flow will hold the valve closed Due to the use of this valve the engine must not be operating when refilling the cool ing system Refer to Thermostat Operat...

Page 292: ...rom the radiator 3 Disconnect the radiator lower hose from the water pump CAUTION Be sure the heater control valve is closed heat off This will prevent coolant flow with scale and other deposits from...

Page 293: ...akage Large radiator leak holes should be repaired by a reputable radiator repair shop INTERNAL LEAKAGE INSPECTION Remove engine oil pan drain plug and drain a small amount of engine oil I f coolant i...

Page 294: ...rovides some reserve coolant to cover minor leaks and evaporation or boiling losses The coolant reserve overflow tank is mounted to the fan shroud on all engines except the 8 0L V 10 Fig 59 On the 8 0...

Page 295: ...tested by removing overflow hose from ra diator filler neck nipple Attach hose of pressure tester tool 7700 or equivalent to nipple It will be necessary to disconnect hose from its adapter for filler...

Page 296: ...tor core and vertical side tanks Aluminum cores with plastic side tanks are used on all 3 9L V 6 and 5 2 5 9L V 8 engines Copper brass cores are used with the 8 0L V 10 and diesel engines The radiator...

Page 297: ...om the fan shroud pull straight up The tank slips into T slots on the fan shroud 7 Disconnect electrical connectors at windshield washer reservoir tank and remove tank Refer to Group 8K Windshield Wip...

Page 298: ...nuts 16 Position heater controls to full heat position 17 Fill cooling system with coolant Refer to Re filling Cooling System in this group 18 Operate engine until it reaches normal tem perature Check...

Page 299: ...n drive at this time 5 Remove four fan shroud to radiator mounting bolts 6 Remove fan shroud and fan blade viscous fan drive assembly as a complete unit from vehicle After removing fan blade viscous f...

Page 300: ...from vehicle 5 Remove fan blade to viscous fan drive mount ing bolts Inspect the fan for cracks loose rivets loose or bent fan blades INSPECTION The fan cannot be repaired I f the fan is damaged it mu...

Page 301: ...lted from excessive vibration Replace fan blade assembly if any of these conditions are found Also inspect wa ter pump bearing and shaft assembly for any re lated damage due to a viscous drive malfunc...

Page 302: ...n this group If the transmission operates properly after repairing the leak drain the transmission and remove the transmission oil pan Inspect for sludge and or rust Inspect for a dirty or plugged inl...

Page 303: ...ap bolts and mounting straps at support bracket Fig 1 13 Remove oil cooler from the A shaped radiator support bracket M O U N T I N G BOLTS ALIGNMENT DOWELS 2 J9407 38 Fig 3 Radiator Mounting Bolts Ty...

Page 304: ...ater to oil cooler and a separate air to oil cooler Both cool ers are supplied as standard equipment on diesel engine powered models when equipped with an auto matic transmission Transmission oil is c...

Page 305: ...m the transmission lines These are located near the power steering gearbox Refer to Group 21 Transmissions for procedures 5 Remove the charge air cooler to oil cooler bolt Fig 5 6 Remove two mounting...

Page 306: ...on I f anything differs between these schematics and the Belt Routing Label use the schematics on Belt Routing Label This label is located in the en gine compartment BELT TENSION ALL ENGINES Correct a...

Page 307: ...sing oil ethylene glycol that has reauced friction Driven component bearing failure Belt glazed and hardened from heat and excessive slippage Belt tension either too high or too low Incorrect belt Pul...

Page 308: ...viewed from front until tension has been relieved from belt 3 Remove belt from idler pulley first 4 Remove belt from vehicle AUTOMATIC TENSIONER J9307 56 Fig 4 Belt Routing S 9L HDC Gas Engine and 8...

Page 309: ...t tensioner will be used on all belt configurations such as with or without power steering or air conditioning For more information refer to Automatic Belt Tensioner proceeding in this group PULLEY BO...

Page 310: ...n Refer to Figs 5 or 6 for correct engine belt routing The correct belt with correct length must be used 1 Position drive belt over all pulleys except wa ter pump pulley 2 Attach a 3 8 inch ratchet to...

Page 311: ...unting bracket two bolts Do not remove coil mounting bracket from cylinder head 4 Remove tensioner assembly from mounting bracket one nut Fig 13 WARNING BECAUSE OF HIGH SPRING PRES SURE DO NOT ATTEMPT...

Page 312: ...cket A dowel pin is located on back of tensioner Fig 14 Align this to dowel hole Fig 15 in tensioner mount ing bracket Tighten bolt to 41 N m 30 ft lbs torque 3 Install drive belt Refer to Belt Remova...

Page 313: ...located on the right side of engine next to the oil filter Fig 1 The 8 0L V 10 engine has the block heater located on the right side of engine next to the engine oil dip stick tube Fig 2 Fig 1 Engine...

Page 314: ...vehicles with air conditioning and or heavy duty cooling systems J9407 21 TORQUE D t c r i p t i o n T o r q w Automatic Belt Tensioner Pulley Bolt 3 9L 5 2L 5 9L LDC G a s Engine 61 N m 45 ft lbs Aut...

Page 315: ......

Page 316: ...RAL INFORMATION The battery starting and charging systems operate with one another and therefore must be thoroughly tested as a complete system In order for the vehicle to start and charge properly it...

Page 317: ...NTED STARTER INTERLOCK SWITCH M A N TRANSMISSION ONLY GROUND CIRCUIT NEUTRAL SAFETY SWITCH AUTO TRANS ONLY THIS CIRCUIT GROUNDED AT ALL TIMES AAAN TRANS ONLY 928A 17 Fig 1 Starting System Components T...

Page 318: ...cator When the electrolyte level is below the top of the plates yellow or bright test indicator the battery must be replaced The battery must be completely charged green test indicator and the top pos...

Page 319: ...n most cases the battery can be charged and returned to service When a vehicle will not be used for 20 days or more stored remove IOD fuse from the fuseblock module to reduce battery discharging T E S...

Page 320: ...s on for 15 seconds then allow up to 5 minutes for voltage to stabilize 2 Remove both battery cables negative first On diesel models with dual batteries each battery must be disconnected and tested se...

Page 321: ...th the battery temperature at a minimum of 70 F 21 C replace the battery LOAD TEST TEMPERATURE Minimum Vbhoge Temperature Minimum Vbhoge P C 9 6 70 and above 21 and above 9 5 60 16 9 4 50 10 9 3 40 4...

Page 322: ...p before completing service see Group 8B Battery Starter Generator Service CHARGING TIME REQUIRED The time required to charge a battery will vary de pending upon the following factors 1 Size o f Batte...

Page 323: ...to 15 9 volts u p to 8 hrs 13 9 volts or less up to 16 hrs J928A 6 measurable during charging time the battery may be good and charging should be completed in the normal manner Fig 11 Voltmeter Accur...

Page 324: ...GROUP LOAD TEST DISCHARGE BATTERY AT 300 AMPERES FOR 15 SECONDS ALLOW BATTERY TO RECOVER FOR 15 SECONDS CONNECT VOLTMETER A N D AMPERE LOAD EQUAL TO 1 2 THE COLD CRANKING AMPERE RATING OF THE BATTERY...

Page 325: ...sition switch if equipped clutch switch if equipped igni page Starter System Diagnostic Inspections 10 Starting System Cold Cranking Test 10 tion switch starter relay and battery including all ground...

Page 326: ...STARTER RELAY FAULTY STARTER ASSEMBLY FAULTY STARTER IMPROPERLY M O U N T E D REFER T O APPROPRIATE G R O U P A N D S E C T I O N O F THIS M A N U A L F O R PROPER S E R V I C E A N D TEST P R O C E...

Page 327: ...Fig 5 4 Rotate and hold the ignition switch in the START position I f voltage reads above 0 2 volt cor STARTER M O T O R VOLTMETER 898A20 Fig 5 Test Positive Battery Cable Resistance Typical rect poo...

Page 328: ...nnected to terminal 30 in the de energized position The solenoid terminal 87 is connected to the bat tery terminal 30 in the energized position which supplies battery voltage to the operated device Th...

Page 329: ...be continuity Fig 11 4 I f there is continuity solenoid is good I f there is no continuity in either test solenoid has an open circuit and is defective Replace the starter motor 5 Install starter as d...

Page 330: ...ness Re place or torque bolt as required refer to Torque Spec ifications Inspect generator drive belt condition and tension Tension or replace belt as required Refer to Belt Ten sion Specifications pa...

Page 331: ...OR OUTPUT TEST Generator output test determines whether genera tor can deliver its rated current output PREPARATION 1 Before starting any tests make sure vehicle has a fully charged battery Test and p...

Page 332: ...nerator output wire resistance is not excessive the generator should be replaced Refer to Group 8B Battery Starter Generator Service for information 2 After current output test is completed reduce eng...

Page 333: ...ROSS FUSIBLE LINK RESISTANCE O K TEST GENERATOR CURRENT OUTPUT CURRENT OUTPUT O K LOOSE OR CORRODED WIRING CONNECTIONS AT BULKHEAD DISCONNECT REFER TO USING ONBOARD DIAGNOSTIC SYSTEM OVER CHARGING NOI...

Page 334: ...amp will dis play a DTC by flashing on and off There is a short pause between flashes and a longer pause between digits All codes displayed are two digit numbers with a four second pause between codes...

Page 335: ...n Free Running Test 11 Amperage Draw 73 Amps Minimum Speed rpm 3601 rpm Solenoid Closing Voltage 7 5 Volts Cranking Amperage Draw Test 125 250 Amps Engine should be up to operating temperature Extreme...

Page 336: ...ge 7 5 Volts Cranking Amperage Draw Test 125 250 A m p s Engine should be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw J948B 26 GENERATOR SPECIFI...

Page 337: ......

Page 338: ...indicator Fig 1 that displays a colored ball to indicate battery state of charge Green Indicator Full charge Black Indicator Discharged Yellow Indicator Battery replacement required Fig 1 Maintenance...

Page 339: ...nspect battery case and cover for cracks or leakage If cracks or leaks are present battery must be replaced 6 Inspect battery tray for damage caused by loss of acid from battery I f acid damage is pre...

Page 340: ...ged hold down ledge 10 Install battery in vehicle making sure that battery is properly positioned on battery tray Figs 2 and 3 11 Install battery holddown clamp making sure that it is properly positio...

Page 341: ...gnition switch should be immediately released to the ON position to prevent starter motor damage WARNING ALWAYS DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE SERVICING THE STARTER STARTER MOTOR REMOVA...

Page 342: ...noid wire Tighten solenoid nut to 6 N m 55 in lbs 3 Attach battery cable to starter motor Tighten cable nut to 10 N m 90 in lbs 4 Connect negative cables to batteries BATTERY STARTER GENERATOR SERVICE...

Page 343: ...matic tensioner Fig 1 3 Rotate tensioner assembly clockwise as viewed from front until tension has been relieved from belt 4 Remove belt from idler pulley first 5 Remove belt from vehicle 6 Remove low...

Page 344: ...7 Cooling Belt Removal Installation REMOVAL 1 Disconnect negative cable from battery 2 Attach a socket or wrench to pulley mounting bolt of automatic tensioner Fig 4 The threads on this bolt are left...

Page 345: ...nsioner counterclock wise Place belt over water pump pulley Let ten sioner rotate back into place Remove socket Be sure belt is properly seated on all pulleys 6 Connect negative cable to battery GENER...

Page 346: ...ppondenso Engine Application 5 9L 5 2L 3 9L Part Number and 53005984 1 4 Kw 12 4 No of Poles 4 4 Reduction Gear Train Free Running Test 11 Amperage Draw 73 Amps Minimum Speed rpm 3601 rpm 7 5 Volts Cr...

Page 347: ...rpm Min Minimum Speed rpm 11 200 Amps Max 3000 rpm Min 8 Volts Cranking Amperage Draw Test 450 700 Amps Engine should be up to operating temperature Extremely heavy oil or tight engine will increase s...

Page 348: ...ar the compass Magnetic bit drivers used on fasteners that hold the overhead console assembly to the roof of the vehicle can also effect operation of the compass Both a magnet on the roof or a magneti...

Page 349: ...should read OC DIAGNOSTIC PROCEDURES Follow the appropriate diagnostic flow chart Chart 1 describes the procedures for compass and display problems Chart 2 describes the procedures for outside tem pe...

Page 350: ...ON VARIANCE PROCEDURE YES NO MODULE IS DEFECTIVE REPLACE PERFORM CALIBRATION VARIANCE PROCEDURE M A G N E T S YES w REMOVE NEARBY 1 MAGNETS Jmo PERFORM DEGAUSSING PROCEDURE DEGAUSSING PROCEDURE DISPLA...

Page 351: ...MAP COURTESY LAMPS I CONFIRM LAMPS FLICKER REPLACE SUSPECTED BAD BULB PERFORM INDICATED REPAIR ELECTRONICS MALFUNCTION YES CHECK VOLTAGES GROUND PERFORM INDICATED REPAIR REPLACE LAMP ASSEMBLY NO YES T...

Page 352: ...OF DISPLAY I TURN IGNITION O N NOTE DO NOT START ENGINE I TOGGLE COMP TEMP SWITCH TO UGHT DISPLAY DONE REPAIR WIRING BETWEEN COMPASS MODULE AND TEMP SENSOR REPLACE TEMPERATURE SENSOR DONE COMPASS MODU...

Page 353: ...GROUND A7 AO h4 BATTERY B2 Zll Zll ENGINE r GROUND FUSE 17 15 AMP FUSE 18 15 AMP Zll Zll TO r LEFT DOOR JAMB SWITCH M l LPARK HEAD HEAD LAMP SWITCH j i l l FUSE 13 5 AMP L_4_J T Zll E2 L OVERHEAD CON...

Page 354: ...down until CAL display appears This takes about 10 seconds and ap pears about 5 seconds after the VAR display appears 3 Release buttons 4 Drive vehicle on a level surface that is away from metal obje...

Page 355: ...roof Unplug the tool 10 Calibrate the compass and set the variance as described SELF DIAGNOSTIC TEST The self diagnostic test is used to confirm that the display and all of its segments are operating...

Page 356: ...front edge of console to indenta tion of headliner install 2 screws 3 Push up on console housing adjacent to each reading courtesy lamp lens until the mounting lips are felt to seat into position COMP...

Page 357: ...Fig 4 Compass Module Removal Installation 4 Slide lens toward center of console to engage lens pivots Pivot lens up into position and snap in Test by pressing lens for proper operation and light ing...

Page 358: ...ice proce dures can be found in the Fuel System section of this repair manual The 3 9L V 6 and 5 2L V 8 engines will be referred to in this Ignition group as Light Duty Cycle LDC engines The 5 9L V 8...

Page 359: ...on the 8 0L V 10 engine only Refer to Ignition Coil Packs 8 0L V 10 Engine in this Ignition System group for addi tional information The ignition system consists of Spark Plugs Ignition Coil multiple...

Page 360: ...n sensor to differentiate between fuel injection and spark events It is also used to synchronize the fuel injectors with their re spective cylinders The sensor generates electrical pulses These pulses...

Page 361: ...hen they pass under the sensor The pulses are the input to the PCM For each engine revolution there are 8 pulses generated on V 8 engines The engine will not operate if the PCM does not re ceive a cra...

Page 362: ...holddown clamp and bolt Al though the distributor can be rotated it will have no effect on ignition timing All distributors contain an internal oil seal that prevents oil from entering the distributo...

Page 363: ...istributor less ignition system Because of the DIS basic ignition timing is not adjustable on any 8 0L V 10 engine Two separate coil packs containing a total of five independent coils are attached to...

Page 364: ...r The throttle position sensor Transmission gear selection For component testing refer to the Diagnostics Ser vice Procedures section of this group For removal and installation of the coil packs refer...

Page 365: ...fuel stream in the manifold varies the sensor resistance will change This will result in a different input voltage to the PCM For more information refer to Group 14 Fuel System On 3 9L V 6 or 5 2 5 9...

Page 366: ...tial base and advance for changing engine operating conditions The PCM adjusts ignition timing based on inputs it receives from The engine coolant temperature sensor The crankshaft position sensor eng...

Page 367: ...The camshaft position sensor Fig 1 is located in the distributor on all 3 9L V 6 or 5 2L 5 9L V 8 en gines To perform a complete test of this sensor and its circuitry refer to the DRB scan tool Also r...

Page 368: ...ystem com ponents refer to the Component Removal Installa tion section of this group For system operation and component identification refer to the Component Identification System Opera tion section o...

Page 369: ...ring harness connector 3 Place an ohmmeter across terminals B and C Fig 3 Ohmmeter should be set to IK to 1 OK scale for this test The meter reading should be open no resistance Replace sensor i f a l...

Page 370: ...rnal ballast resistor 3 9L V 6 or 5 2 5 9L V 8 LDC Gas Engines The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head Fig 9 This bracket is mounted on top of th...

Page 371: ...tions To test the primary resistance of the front coil pack attach an ohmmeter between the B coil termi nal and either the right cylinders 3 2 center cylin ders 7 4 or left coil cylinders 1 6 termina...

Page 372: ...ensor is installed in the thermostat housing Fig 19 TO LIFT COIL TO RIGHT COIL B TERMINAL FRONT OF ENGINE J948D 17 Fig 15 Checking Coil Primary Resistance Rear Coils 8 0L V 10 Engine Primary Resistanc...

Page 373: ...re harness terminal 4 to the sensor connector ter minal Repair the wire harness if an open circuit is indicated TEMPERATURE RESISTANCE OHMS C F MIN MAX 40 40 291 490 381 710 20 4 85 850 108 390 10 14...

Page 374: ...ENGINE To prevent unnecessary diagnostic time and wrong test results the previous Checking For Spark test should be performed prior to this test WARNING S E T PARKING BRAKE OR BLOCK THE DRIVE WHEELS B...

Page 375: ...TIMING Base initial ignition timing is NOT adjust able on any engine On a 3 9L V 6 or a 5 2 5 9L V 8 engine do not attempt to adjust ignition timing by rotating the distributor All ignition timing fu...

Page 376: ...Diagnostics Procedures manual To test the MAP sensor only refer to MAP Sensor in Group 14 Fuel System POWERTRAIN CONTROL MODULE POM The powertrain control module PCM is located in the right rear side...

Page 377: ...oolant in the com bustion chamber Spark plug performance is not af fected by MMT deposits NORMAL DRY BLACK COLD CARBON FOULING J908D 15 Fig 31 Normal Operation and Cold Carbon Fouling COLD FOULING CAR...

Page 378: ...ND J908D 13 Fig 35 Chipped Electrode Insulator PREIGNITION DAMAGE Preignition damage is usually caused by excessive combustion chamber temperature The center elec trode dissolves first and the ground...

Page 379: ...ers should be in good condition Terminals should fit tightly to the ig nition coil distributor cap and spark plugs The spark plug cover boot of the cable should fit tight around the spark plug insulat...

Page 380: ...nal description diagnosis and re moval or installation of the 02S refer to Group 14 Fuel Systems in this manual 0N B0ARD DIAGNOSTICS OBD F O R IGNITION SYSTEM COMPONENTS The powertrain control module...

Page 381: ...nent identification refer to the Component Identification System Opera tion section of this group AUTOMATIC SHUT DOWN ASD RELAY The automatic shut down ASD relay is located in the power distribution c...

Page 382: ...n sensor is located in the tim ing chain case cover on the left front side of the en gine Fig 3 A thin plastic rib is molded into the face of the sen sor Fig 4 to position the depth of sensor to the u...

Page 383: ...sensor is aligned to scribe line 11 Install sensor mounting bolt and tighten to 6 N m 50 in lbs torque 12 Connect engine wiring harness to sensor har ness SENSOR REPLACEMENT NEW SENSOR If a new replac...

Page 384: ...n lbs torque 5 Coat the threads of the oil pressure sending unit with thread sealant Do not allow any of the thread sealant to get into the sending unit opening or the opening at the engine Install se...

Page 385: ...ness and lower the vehicle ENGINE COOLANT TEMPERATURE SENSOR WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SYSTEM MUST B E PARTIALLY DRAINED B E F O R E REMOV ING THE COOLANT TE...

Page 386: ...egative battery cable at battery 2 Remove air cleaner assembly and connecting tubes 3 Remove the spark plug cables and secondary ignition coil cable at distributor cap Mark position of cables before r...

Page 387: ...YL NO 1 alignment mark on the cam shaft position sensor Fig 14 7 Tighten clamp holddown bolt Fig 15 to 22 5 N m 200 in lbs torque 8 Connect camshaft position sensor wiring har ness to main engine harn...

Page 388: ...tached to a common mount ing bracket located above the right engine valve cover Fig 18 The front and rear coil packs can be serviced separately 1 Remove the secondary spark plug cables from the coil p...

Page 389: ...to the inner fender Install two mounting bolts 2 Connect the electrical connector to ICM 3 Position the coolant reserve overflow tank to the inner fender Install and tighten three mounting bolts 4 Con...

Page 390: ...ir as necessary 2 Position PCM and install mounting bolts Tighten bolts to 1 N m 9 in lbs torque 3 Connect 60 way electrical connector to PCM Tighten bolt to 4 N m 35 in lbs torque 4 Connect negative...

Page 391: ...ines 89 mm 035 in 8 0L V 10 Engines 1 14 mm 045 in Also refer to the specifications section at the back of this group for additional spark plug information PLUG INSTALLATION Always tighten spark plugs...

Page 392: ...V 8 engines spark plug ca ble boot heat shields are pressed into the cylinder head to surround each cable boot and spark plug Fig 31 These shields protect the spark plug boots from damage due to engi...

Page 393: ...the column Re lease two connector locks on the 7 terminal wiring connector Remove the connector from the ignition switch Fig 3 6 Release connector lock on the Key In Switch and Halo Light 4 terminal c...

Page 394: ...parallel with the ignition switch terminals Fig 6 Apply a dab of grease to flag and pin Position park lock link and slider to mid travel Position igni tion switch against lock housing face Be sure pi...

Page 395: ...ions found on the Vehicle Emission Control Information VECI label and the following specifications use specifications on V E C I label The VECI label is located in the engine compart ment IGNITION TIM...

Page 396: ...ft lbs 14 mm Thread 3 4 Reach 8 0L V 10 RC9MC4 RC9MC4 All 045 1 14 mm 41 N m 30 ft lbs 14 mm Thread 3 4 Reach J948D 19 SPARK PLUG CABLE RESISTANCE MINIMUM M A X I M U M 250 Ohms Per Inch 1000 Ohms Per...

Page 397: ...Ignition Coil Mount Bolts 8 0L V 10 Engine 10 N m 90 in lbs Intake Manifold A i r Temp Sensor All Engines 13 N m 10 ft lbs M A P Sensor To Throttle Body Mounting Bolts 3 9L 5 2L 5 9L Engine 3 N m 25 i...

Page 398: ...i tion voltage is supplied to the instrument cluster in dicator lamps by fuse 12 Voltage for the illumination lamps is supplied through fuse 13 The voltage supplied to the instrument cluster is suppli...

Page 399: ...magnetic field which changes the pointer position The oil pressure sender is a variable resistor that changes electrical resistance with a change in oil pressure calibration values shown in Specificat...

Page 400: ...DICATOR Indicates that the transfer case is in a four wheel drive mode of operation MALFUNCTION INDICATOR CHECK ENGINE LAMP The malfunction indicator Check Engine lamp il luminates each time the ignit...

Page 401: ...h is closed with unequal brake system hydraulic pressures or The ignition switch is in the START position to test the bulb or The park brake switch is closed with the parking brake applied or The vacu...

Page 402: ...onnected to a sensor that monitors intake air temperature in the intake manifold I f intake air temperature is low and igni tion switch is in ON position the PCM sends current to the intake manifold a...

Page 403: ...unit ground cavity of sending unit connector Fig 1 Gauge should read FULL I f OK see Fuel Tank Sending Unit Test If not OK turn ignition switch OFF and continue to next step 4 Pull instrument cluster...

Page 404: ...a defective sending unit sensor or wiring I f all gauges and warning lamps are inopera tive check battery feed from ignition switch through fuse 12 and wiring to cavity 8 of cluster connector B black...

Page 405: ...WITCH LIGHT SENDING UNIT GAUGE 898E 2 Fig 5 Combination Oil Pressure Sending Unit Terminals 2 Using a jumper wire ground switch cavity of connector Fig 5 to engine The lamp should light I f OK check s...

Page 406: ...t OK re pair short circuit as required STEERING PUMP ENGINE BLOCK J9119 74 Fig 8 Oil Pressure Sending Unit Diesel J948E 55 Fig 9 Oil Pressure Lamp High Line Cluster 6 With ignition switch in ON positi...

Page 407: ...OK repair open circuit as required 5 Check continuity between temperature gauge input terminal Figs 15 or 16 and ground There should be no continuity I f OK go to next step I f not OK repair short ci...

Page 408: ...uster Replacement for removal procedures 2 Disconnect vehicle speed sensor and check for continuity in G7 circuit between vehicle speed sensor connector and speedometer speed sensor input termi nal Fi...

Page 409: ...k the gauge check for a good tach signal from the power train control module PCM Refer to the Powertrain Diagnostic Test Procedures manual for the appropri ate tests 1 Pull instrument cluster from das...

Page 410: ...nnector A cavity 5 to splice joint connector C Refer to Group 8W Wiring Diagrams for more information from splice joint connector C check the suspected faulty switch and its circuit Also see Group 5 B...

Page 411: ...emoval procedures The bulb location is labeled on the cluster printed circuit Refer to Group 8W Wiring Di agrams for terminal information 2 Check for battery voltage between bulb B and ground terminal...

Page 412: ...not OK continue to next step 4 Unplug cluster connector B black With igni tion switch in ON position check for battery voltage at connector cavity 8 I f OK replace cluster printed circuit board I f no...

Page 413: ...inal information 2 Fuel level must be below 1 8 full as indicated on fuel gauge or a 100 ohm resistor must be in stalled between fuel tank sending unit connector in put to gauge cavity and ground Turn...

Page 414: ...S U J CO LU s I A 9 I 1 B7 B5 A3 I to 3 LA4 u UJ X u a 2 6 6 BP IS UP Iff B1 z i 0 f AT U J _ X flD f A l s l Al2l AT4 z a 3 PIN NUMBER IN Z OS J948E 23 INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD HIGH...

Page 415: ...PEEDOMETER SCREWS FUEL GAUGE SCREWS OIL PRESSURE GAUGE SCREWS 1 ILLUMINATION 2 TURN SIGNAL INDICATORS 3 HIGH BEAM INDICATOR 4 ABS 5 MAINTENANCE INDICATOR 6 BRAKE 7 UPSHIFT INDICATOR 8 SEAT BELT WARNIN...

Page 416: ...hms High Normal 3 77 ohms ENGINE FREQUENCY INDICATION V6 V8 100 HZ 3000 RPM 200 Diesel VIO 125 HZ 3000 RPM 200 TEMPERATURE GAUGE CALIBRATION DIESEL ENGINE POINTER POSITION RESISTANCE Low N o r m a l 3...

Page 417: ...g connector from cigar lighter Fig 4 6 Unplug connector from auxiliary power outlet 7 Reverse removal procedures to install bezel 8 Connect negative cable to battery INSTRUMENT CLUSTER REPLACEMENT REM...

Page 418: ...neath cable retainer Fig 9 INDICATOR PRND21 SCREW ADJUSTING J948E 66 Fig 9 PRND21 Indicator Adjustment 5 Install knee blocker 6 Plug connectors onto cigar lighter and auxiliary power outlet attached t...

Page 419: ...CATOR 5 LOW FUEL Fig 10 instrument Cluster Printed Circuit Board High Line Diesel J948E 22 SPEEDOMETER SCREWS FUEL GAUGE SCREWS GAUGE PRESSURE SCREWS 1 ILLUMINATION 2 TURN SIGNAL INDICATORS 3 HIGH BEA...

Page 420: ...ING CIRCUIT 1 Pull instrument cluster from dash Refer to In strument Cluster Replacement 2 Remove connector from cluster Fig 14 FUEL CIRCUIT CONNECTOR J948E 59 Fig 14 Low Fuel Warning Connector 3 Remo...

Page 421: ...emove bulb from socket INSTALLATION 1 Install bulb into socket 2 Install socket assembly into printed circuit board 3 Position cluster into place in panel See cluster installation 4 Connect negative c...

Page 422: ...on red cable connector to release Re move cable end from control unit 7 Remove control INSTALLATION 1 Position control near panel 2 Connect control cables to control see Heater A C Section 3 Connect...

Page 423: ...Typical 3 Disconnect wires to switch and lamp Fig 6 4 Remove bulb from socket 5 Reverse removal procedures to install switch and lamp 6 Tuck any wiring that was exposed by lamp re moval back into rece...

Page 424: ...od latch in engine com partment 2 Remove 2 screws holding handle assembly to instrument panel 3 Remove assembly by pulling cable rearward through dash panel grommet INSTALLATION 1 Feed cable assembly...

Page 425: ...move latch retaining clip 3 Remove latch 4 Reverse removal procedure to install CATCH REMOVAL 1 Open glove box door 2 Remove glove box lamp and switch assembly Refer to Glove Box Lamp Switch in this s...

Page 426: ...rouds from col umn Fig 18 STEERING WHEEL NUT TILT UPPER LEVER SHROUD PANEL BRACKET SPACER CLOCK SPRING LOWER SHROUD NUT J928J 2 Fig 18 Steering Column Shrouds 10 Remove lower fixed column shroud 11 Lo...

Page 427: ...er Screws AIRBAG CONTROL MODULE J948M 2 Fig 24 Airbag Control Module ACM 19 Disconnect wiring at ACM 20 Disconnect left side wiring 21 Remove 2 screws holding brake release to bot tom of instrument pa...

Page 428: ...ghten Only CAUTION Check that all wiring is clear and not pinched 8 Tighten the 2 steering column bracket nuts to 12 N m 110 in lbs torque 9 Tighten 3 toe plate nuts and washers Fig 21 to 23 N m 200 i...

Page 429: ......

Page 430: ...s manual supplied with the vehicle When installing or removing the ignition off draw IOD fuse it is important that the ignition switch be in the OFF position Failure to place the ignition switch in th...

Page 431: ...VARIABLE 6 ACCESSORY SWITCHED B 7 BATTERY MEMORY TURN IGNITION KEY TO ACCESSORY POSITION TUNE RADIO TO KNOWN STRONG STATION SET VOLUME TO LISTENING LEVEL NO YES CHECK FUSE S IGNITION MEMORY FEED NOISE...

Page 432: ...OR AHOOSE CONNECTIONS B BROKEN WIRES Q CORROSION EXCHANGE RADIO REPAIR AS NECESSARY USING AN OHMMETER CHECK SPEAKER WIRES FOR SHORT TO GROUND REFER TO ABOVE DIAGRAM FOR SPEAKER PLUS AND MINUS TERMINAL...

Page 433: ...IS ATTACHED TO GROUND LOG ON REAR OF RADIO r SUBSTITUTE CHOKE RELAY P BODY WITH A KNOWN GOOD ONE REPAIR AS NECESSARY WITH IGNITION ON USING A VOLTMETER CHECK FOR BATTERY VOLTAGE AT TERMINAL 1 AND 2 OF...

Page 434: ...GROUND REFER TO RADIO CONNECTORS DIAGRAM FOR SPEAKER PLUS AND MINUS TERMINALS PLACE ONE LEAD OF THE OHMMETER TO PLUS TERMINAL AND THE OTHER LEAD TO GROUND SWITCH THE LEAD TO THE MINUS TERMINAL DISCONN...

Page 435: ...WITH ALL ELECTRICAL ACCESSORIES OFF START ENGINE WITH ENGINE RUNNING IF THERE IS STATIC NOISE CHECK THE FOLLOWING A ELECTRIC FUEL PUMP B IGNITION SYSTEM FAULTS C CHECK GROUND CONNECTIONS D CHECK ANTEN...

Page 436: ...TY CAPSTAN AND DRIVE SYSTEM POOR PERFORMANCE TRYAKI GOOD MOWN TAPE CLEAN WITH WET HEAD CLEANER YES NO IF NOT OK EXCHANGE UNIT REPAIR AS NECESSARY LOSS OF HIGH FREQUENCY CLEAN WITH WET HEAD CLEANER ADV...

Page 437: ...8F 8 AUDIO SYSTEMS RADIO SCHEMATICS INFINITY RADIO O O 3 O I CO L I o z S o 00 o...

Page 438: ...W O POWER SEATS STANDARD REAR RIGHT SPEAKER 6 x 9 STANDARD STANDARD REAR SPEAKER LEFT SPEAKER J948F 14...

Page 439: ...shell of the connector and radio end pin 3 Continuity should be observed between the ground shell of the connector and the mounting hard ware on the fender TIP OF MAST TEST POINT RY684 Fig 1 Antenna...

Page 440: ...NNECTOR CLIPS J948E 10 Fig 4 Cigar Lighter Removal 6 Unplug connector from auxiliary power outlet 7 Remove 2 mounting screws from front of radio Fig 5 J948FS Fig 5 Radio to Instrument Panel Mounting 8...

Page 441: ...cowl panel to A pillar area 2 Insert antenna body through hole in fender 3 Install adapter making sure tab indexes with opening in fender and antenna body 4 Install cap nut and tighten securely with t...

Page 442: ...to speaker 2 Position speaker into place install mounting screws and tighten securely AUDIO SYSTEMS 8F 13 Fig 14 Power Mirror Switch Retaining Nut 3 Install door trim panel by starting with re tainer...

Page 443: ...tinuity across the relay and choke connectors I f no continuity replace relay choke assembly The relay choke is located behind the instrument panel to the right of the RWAL module i f equipped Fig 17...

Page 444: ...Fig 19 RWAL Module Lower Mounting Screws Fig 20 RWAL Module Upper Mounting Screw...

Page 445: ......

Page 446: ...itch Measure resistance be tween relay cavity 85 and ground Meter should read zero ohms I f not repair open to horn switch ground 4 Measure resistance between relay cavity 30 and ground Meter should r...

Page 447: ...ble 3 Gain access to the horn switch connectors as described in Horn Switch Replacement 4 Disconnect horn wires located in the lower por tion of steering wheel 5 Repeat the previous test and if the te...

Page 448: ...Fig 7 Fig 6 Horn Button Removal HORN CIRCUIT CONNECTORS J94SG S Fig 7 Horn Button Connectors INSTALLATION 1 Connect electrical leads to horn button termi nals 2 Snap horn buttons into place in steerin...

Page 449: ...Fig 8 Horn Removal and Installation 4 To install horn s reverse the removal proce dures Tighten bolt to 20 ft lbs HORN RELAY The horn relay is located in the power distribution center PDC Fig 9 Refer...

Page 450: ...age speed control without erasing memory A sudden increase in engine speed may be experienced if the clutch pedal is depressed while the speed control system is engaged Pushing the OFF button to unlat...

Page 451: ...L WHEN J SET COAST BUTTON IS PRESSED AND RELEASED HUNTING SURGE OR SPEED VARIATIONS AT LOW SPEEDS EXCESSIVE SAG O N HILLS OR IN TRAILER T O W I N G SPIED SETTING AFTER LOCK IN TOO HIGH OR TOO LOW f i...

Page 452: ...LD RESUME PREVIOUSLY MEMORIZED SPEED I VEHICLE RESUMES SPEED I DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE SPEED CONTROL DISENGAGES DEFECTIVE SWITCH I FAULTY ELECTRICAL CIRCUIT N O SYSTEM DISEN...

Page 453: ...ELEASED I HUNTING SURGE OR SPEED VARIATIONS AT LOW SPEEDS FUSE BLOWN I TORQUE CONVERTER CLUTCH ROUGHNESS INSUFFICIENT VACUUM AT SERVO X AMPLIFICATION OF ENGINE SURGE SPEED CONTROL THROTTLE CABLE DISCO...

Page 454: ...HOULD RESUME PREVIOUSLY MEMORIZED SPEED VEHICLE RESUMES SPEED i DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE SPEED CONTROL DISENGAGES DEFECTIVE SWITCH FAULTY ELECTRICAL CIRCUIT N O SYSTEM DISENG...

Page 455: ...OFF ON On third cycle leave switch in ON position b After switch has been cycled observe mal function indicator lamp Check Engine on in page Stop Lamp Switch Test 8 Vacuum Supply Test 8 Vehicle Speed...

Page 456: ...ircuit as necessary Fig 1 Servo And Harness Connector ELECTRICAL TESTS AT POWEKTRAIN CONTROL MODULE 1 Unplug 60 way connector from powertrain con trol module located on the passenger side dash panel i...

Page 457: ...gine PCM re quires a signal from the engine speed sensor to cav ity number 24 To diagnose the engine speed sensor refer to the appropriate Powertrain Diagnostic Proce dures manual VEHICLE SPEED CONTRO...

Page 458: ...control system will be inoperative VEHICLE SPEED CONTROL SYSTEM SCHEMATIC IGNITION SWITCH 1 SPEED 2 CONTROL SERVO 3 4 V 3 6 V35 POWERTRAIN CONTROL MODULE 33 53 29 49 48 50 z r V 3 0 Z l Z l 2 A21 OFF...

Page 459: ...speed sensor signal detected during road load conditions An open or shorted condition detected in the Speed Control vacuum or vent solenoid circuits Speed Control switch input below the minimum accep...

Page 460: ...mp Switch Replacment 16 Vacuum Pump Diesel Engine 16 2 With throttle blocked to full open position align hole in cable sleeve with hole in servo pin and install hairpin clip 3 Insert servo studs throu...

Page 461: ...servo away from mounting bracket INSTALLATION 1 Insert servo studs through holes in servo mounting bracket Fig 6 Speed Control Servo Mounting 2 With throttle blocked to full open position align hole i...

Page 462: ...sure that it is properly positioned on battery Tighten bolt to 4 N m 35 in lbs SERVO THROTTLE CABLE ASSEMBLY R E M O V A L 1 Remove air cleaner except V 10 and diesel 2 Using finger pressure only remo...

Page 463: ...Fig 10 Speed Control Cable Diesel...

Page 464: ...h Removal 3 Pull switches from wheel and unplug connector Fig 12 Fig 12 Speed Control Switches 4 Plug electrical connector into new switches 5 Install new switches with 2 screws SPEED CONTROL VACUUM R...

Page 465: ...lock wise direction 1 8 turn Fig 8 3 Pull switch rearward and remove from bracket INSTALLATION PULL PLUNGER INDEX KEY 948H 6 Fig 17 Stop Lamp Switch 1 Before installing switch ensure adjustable switch...

Page 466: ...n position Observe the turn indi cator arrow on instrument cluster If the arrow re mains lit check for burned out exterior turn signal bulb replace as required Turn indicator should now flash if not g...

Page 467: ...13 Meter should read battery voltage If not repair open cir cuit in wiring to hazard flasher TURN SIGNAL AND HAZARD WARNING FLASHER LOCATION The turn signal and hazard warning flashers are both locate...

Page 468: ...e both upper and lower steering column covers 4 Remove multi function switch tamper proof mounting screws tamper proof torx bit Snap On TTXR20B2 or equivalent required 5 Gently pull switch away from c...

Page 469: ......

Page 470: ...n addition to low and high speed has a delay mode The delay mode has a range of 2 to 15 seconds This is accomplished by a variable resistor in the wiper switch and is con trolled electrically by a con...

Page 471: ...CTION DEFECTIVE MOTOR MOTOR WILL HOT RUN A ANY SPEEDl LOOSENESS OF THE MOTOR CRANK OR OTHER DRIVE PARTS MOTOR WILL NOT RUN CHECK VOLTAGE AT MOTOR T VOLTAGE PRESENT DEFECTIVE MOTOR CHECK GROUND CHECK S...

Page 472: ...r than 3 volts in voltage is observed the problem is a faulty mo tor assembly 5 Disconnect motor wiring connector and replace fuse a If fuse does not blow motor is defective b If fuse blows switch or...

Page 473: ...p wherever it is when column switch is put in O F F position Wipers do not continue running to PARK position PROCEDURE 1 Remove motor wiring connector and clean ter minals Reconnect connector and test...

Page 474: ...to rear of multi function switch 7 Remove switch connector Figs 2 and 3 8 Using an ohmmeter test for continuity no re sistance between the terminals of the switch as shown in the continuity chart 9 Re...

Page 475: ...ly when wash is operated but do not provide an extra wipe when the wash control is released PROCEDURE Replace the control unit CONDITION Wipers start erratically during DELAY mode PROCEDURE 1 Verify t...

Page 476: ...WIPER SWITCH GROUND 5 PARK 6 INTERMITTENT 7 DELAY 1 DELAY INPUT 8 WASHER 2 FEED B 4 WIPER MOTOR 3 5 WASHER A SWITCH TO CLUSTER LOW WASHER FLUID LEVEL SENSOR INTERMITTENT WIPER CONTROL MODULE INTERMITT...

Page 477: ...ly place wiper arm tip on glass surface page Wiper Blade Replacement 8 Wiper Blades 8 Wiper Motor Replacement 9 Wiper Switch Replacement 10 5 For installation reverse above procedures When complete tu...

Page 478: ...si tion remove arms and reposition on pivots BLACK OUT AREA TIP OF BLADE 22MM FROM EDGE OF BLACK OUT J948K 22 Fig 5 Adjusting Wiper Arms WIPER MOTOR REPLACEMENT REMOVAL 1 Disconnect negative cable fro...

Page 479: ...ground connector to ground tab 6 Install motor and linkage 7 Connect washer hoses 8 Install cowl grille 9 Install weatherstrip 10 Install wiper arms refer to Wiper Arm Re placement Be sure to lock wi...

Page 480: ...SHER PUMP REPLACEMENT LOW FLUID LEVEL SENSOR REMOWAL CLAMPS ALWAYS WEAR SAFETY G L A S S E S WHEN SERVICING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant te...

Page 481: ...ce on res ervoir 2 Position pump sensor into place and push in firmly until it locks into grommet 3 Connect electrical lead and hose to pump sen sor 4 Install reservoir onto radiator fan shroud 5 Fill...

Page 482: ...R U N S PUMP NOT PUMPING FLUID N O FLUID IN RESERVOIR NOZZLE JET UNDER COWL PANEL NOZZLE JETS PLUGGED BROKEN OR LOOSE HOSE FAULTY PUMP MOTOR RUNS PUMP PUMPING FLUID T SYSTEM OPERATES INTERMITTENTLY L...

Page 483: ......

Page 484: ...Verify that bulbs are in good condition and test continuity of the circuit ground Refer to Group 8W Wiring Diagrams for component location and circuit information SAFETY PRECAUTIONS WARNING EYE PROTEC...

Page 485: ...of missing fuel Test for high resistance in headlamp circuits Defective headlamp bulb SYMPTOM Headlamps flash randomly ACTION Test for poor circuit ground Test for high resistance in headlamp circuit...

Page 486: ...1 The preferred headlamp alignment is 0 for the up down adjustment a n d 1 down for the left right adjustment The high beam pattern should be correct when the low beams are aligned properly To adjust...

Page 487: ...everse the preceding operation BULB SOCKET BULB RETAINING RING ELECTRICAL CONNECTOR LENS REFLECTOR PLASTIC BASE UNLOCK 918L 34 Fig 1 Headlamp Bulb FRONT SIDE MARKER LAMP BULB REMOVAL 1 Remove park and...

Page 488: ...AIL STOP TURN SIGNAL AND BACK UP LAMP BULB CHASSIS CAB REMOVAL 1 Remove screws holding tail lamp lens to lamp body 2 Separate lens from lamp 3 Remove bulb from socket SCREW RETAINING STUDS J948L 6 Fig...

Page 489: ...iator clo sure panel 6 Disengage wire connector from headlamp bulb 7 Separate headlamp module from vehicle INSTALLATION Reverse the preceding operation ROOF CLEARANCE LAMPS REMOVAL FIG 2J 1 Insert a f...

Page 490: ...er 6 Separate retainer from rear fender INSTALLATION Reverse the preceding operation Fig 4 Side Identification Lamps REAR IDENTIFICATION ID LAMPS The bulbs in the side ID lamps can not be replaced If...

Page 491: ...AL FIG 7 1 Remove nuts holding tail lamp to mounting bracket 2 Disengage tail lamp wire connector from body wire harness 3 Separate tail lamp fromvehicle INSTALLATION Reverse the preceding operation i...

Page 492: ...is running with the headlamp switch OFF The Daytime running lamps will go out when the headlamp switch is pulled out The passing light feature will flash bright high beams while the daytime running la...

Page 493: ...ntact local dealer for location of nearest ASC When illumination goes out in the Electronic Instrument Cluster EIC the complete button module must be replaced The Mechanical Instrument Cluster MIC use...

Page 494: ...OR 2 MINUTES B E F O R E BEGINNING COMPONENT REMOVAL To inspect system use Passive Restraint System Di agnostic Procedures Manual If the airbag module assembly is defective and non deployed refer to C...

Page 495: ...r s side airbag module This assem bly consists of a flat ribbon like electrically conductive tape which winds and unwinds with the steering wheel rotation page Airbag Module Handling Undeployed 2 Airb...

Page 496: ...g system compo nents are replaced as required by the extent of dam age AIRBAG SYSTEM CHECK 1 Disconnect battery negative cable and isolate 2 Connect DRB scan tool to ACM diagnostic 6 way connector cli...

Page 497: ...N RUN 5 START 4 PASSENGER 1 AIR BAG 2 13 3 12 CCD 11 AIR BAG 4 DIAGNOSTIC MODULE R43 R45 Dl D 2 Ml ABS MODULE TO 5 CLUSTER TO 5 MESSAGE CENTER TO J CLUSTER TWISTED PAIR TWISTED PAIR D l l D12 D10 11 1...

Page 498: ...ARGE FOR 2 MINUTES BEFORE BEGINNING COMPONENT REMOVAL REMOVAL When removing a deployed airbag module rubber gloves eye protection and long sleeved shirt should be worn There may be deposits on the sur...

Page 499: ...M FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI B L E PERSONAL INJURY ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES B E F O R E BEGINNING COMPONENT REMOVAL The impact s...

Page 500: ...WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI B L E PERSONAL INJURY ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE BEGINNING COM...

Page 501: ...ectrical connector Fig 12 8 Unplug electrical connector from speed control servo 9 Move battery tray enough to access impact sen sor Fig 12 Speed Control Servo Mounting 10 Remove 3 screws holding sens...

Page 502: ...2 Remove 2 screws and cover from bottom of cen ter console Fig 13 Fig 13 Airbag Control Module Cover Screws 3 Remove 4 screws holding ACM to transmission tunnel Fig 14 4 Disconnect wiring at ACM 1 1...

Page 503: ...the inside of clockspring Pull the horn lead through the wheel The airbag and speed control leads go through the bottom larger hole in the steer ing wheel Make sure not to pinch them between the stee...

Page 504: ...el rotate the rotor 2 full turns and a half in the counterclockwise direction The horn wire should end up at the top and the squib wire at the bottom 6 Install steering wheel Refer to Group 19 Steer i...

Page 505: ...f i...

Page 506: ...EST 1 For switch testing remove the switchfromits mounting location as described in the Service Proce dures section of this group 2 Using an ohmmeter refer to Fig 1 to deter mine if continuity is corr...

Page 507: ...ROUND P34 P33 AO P33 RIGHT DOOR LOCK MOTOR LEFT DOOR LOCK MOTOR J948P 1 Fig 2 Power Door Lock Circuit Schematic LOCK MOTOR STALL TEST exceeds 8 amps at room temperature or i f the motor lb test the lo...

Page 508: ...S 8 Fig 3 Door Switch Connectors 5 Plug connector onto new switch 6 Install a new switch by inserting front of switch into trim panel then pushing down rear of switch LOCK MOTOR AND LATCH ASSEMBLY REP...

Page 509: ...low access to lock motor Fig 6 6 Remove 3 screws holding lock motor and latch assembly to door 7 Disconnect linkage rods 8 Pull motor and latch out far enough to unplug electrical connector and remove...

Page 510: ...s released With the switch in the REAR position the polarity is reversed and causes the motor to run in the oppo site direction and drive the seat backward The front motor works in a similar way when...

Page 511: ...itch from seat far enough to access con nector and unplug 4 To install switch reverse removal procedures POWER SEAT MOTOR REPLACEMENT The seat motors are not serviced separately Re place the power sea...

Page 512: ...Fig 4 Driver s Power Seat Removal Fig 5 Center Seat Section Attachment...

Page 513: ......

Page 514: ...switch in ON voltage supply comes from the 40 amp fuse cavity 2 in the power distri bution center PDC to the 30 amp circuit breaker in cavity 1 of the fuseblock module Power then goes to the driver s...

Page 515: ...en circuit or poor ground I f OK install left door switch 5 Remove passenger door switch as described in the Service Procedures section of this group 6 Measure voltage at lock terminal cavity 3 of rig...

Page 516: ...948S 8 Fig 3 Door Switch Connectors 5 Plug connector onto new switch 6 Install a new switch by inserting front of switch into trim panel then pushing down rear of switch REGULATOR AND MOTOR REPLACEMEN...

Page 517: ...lator from door Fig 9 INSTALLATION 1 Place regulator inside door by sliding 2 loose screws in slots in door J 9 4 8 S 7 Fig 9 Window Regulator Removal 2 Install remaining 4 screws 3 Tighten 4 regulato...

Page 518: ...TOR TEST PROCEDURE 1 Remove power mirror switch from mounting po sition refer to Service Procedures Mirror Switch Replacement 2 Disconnect wiring harness at switch connector 3 Connect 2 jumper wires a...

Page 519: ...B and PK D B W T and PK Mirror Selector Knob in R Position MOVE LEVER CONTINUITY B E T W E E N W T and BK YL and PK YL BK and PK W T and PK DB and BK D B W T and BK WT and PK YL and BK YL BK and BK W...

Page 520: ...O P I BATTERY POWER MIRROR SWITCH Ml W POWER LOCKS FEED G N D Z3 Z3 X W O POWER LOCKS n U I 1 11 MIRROR 5 2 7 d 34 1 RT MIRROR 1 UP LTJ L 4 4 4 RT P75 P7J P73 P70 P72 P74 LEFT SIDE COWL GROUND r 75 I...

Page 521: ...Door Switch Connectors 5 Pull power mirror switch control knob rearward to remove from switch Fig 5 6 Remove switch retaining nut from switch Fig 6 Fig 5 Power Mirror Switch Control Knob Installation...

Page 522: ...switch panel into place 6 Install door pull cup 7 Install door panel attaching screws MIRROR ASSEMBLY REPLACEMENT 1 Remove door trim panel as described in Mirror Switch Replacement POWER MIRRORS 8T S...

Page 523: ...ORWARD FACING SENSOR J948T 9 Fig 1 Automatic Day Night Mirror DIAGNOSIS Light sensor must be covered completely so that no light reaches the sensor Use one finger pressed tightly against the sensor or...

Page 524: ...warning sound KEY4N4GNITION To sound the key in ignition alarm the module needs the ignition key warning switch must be closed the driver s door jamb switch must be closed These conditions ground pin...

Page 525: ...IEW SAME AS REAR SIDE WIRE SIDE CONNECTOR VIEW X DoNotCare SEAT BELT SW SHOWN BUCKLED FUNCTION DESCRIPTION IGN SEAT BELT DRIVER S DOOR KEY HEAD LAMPS Seat Belt Reminder 4 to 8 Second Tone and Lamp Out...

Page 526: ...BUZZER WARNING SYSTEMS 8U 3 K 00 CM 5 0 0 i I q E c...

Page 527: ...STEERING COLUMN IGNITION SWITCH 938D 1 Fig 8 Key In Switch And Halo Lamp Connector Fig 9 Key Cylinder Pin c Rotate key clockwise to OFF position The key cylinder should now be unseated from ignition s...

Page 528: ...cylin der inward toward the ignition switch rotate key clockwise to the ON position 7 Check for proper operation of push to lock halo lamp ACCESSORY LOCK OFF ON START col umn lock and shift lock if ap...

Page 529: ...8U 8 BUZZER WARNING SYSTEMS 5 Pull buzzer module out of fuseblock module 6 Tb install a new buzzer module reverse re moval procedures Fig 15 Fuseblock Module Removal...

Page 530: ...ar vehicle by letter or number designation A chart showing the breakdown of these designations is included in the Introduction Section of this service manual SECONDARY IGNITION WIRING Secondary igniti...

Page 531: ...s not show the second ary codes that may apply to some models LOCATING A SYSTEM OR COMPONENT To locate a system or component in the diagrams refer to the alphabetical index at the front of the di agra...

Page 532: ...Locks Mirrors Q Power Assist System Windows R Airbag System S Air Suspension Automatic Load Leveling T Electronic Automatic Transaxle V Windshield Wipers and Washers Vehicle Speed Control System W Po...

Page 533: ...ing half 10 Connect battery and test affected systems CONNECTOR LOCKING WEDGE CONNECTOR LOCKING FINGER a 928W 144 Fig 9 Connector Locking Finger and Locking Wedge Typical CONNECTOR AND TERMINAL ASSEMB...

Page 534: ...example 3 13 Solder the connection together using rosin core type solder only Do not use acid core solder 14 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint unti...

Page 535: ...BSS DIGITAL READOUT OPEN CONTACT 0 SINGLE FILAMENT LAMP CLOSED CONTACT DUAL FILAMENT LAMP CLOSED SWITCH L E D LIGHT EMITTING DIODE OPEN SWITCH THERMISTOR CLOSED G A N G E D SWITCH GAUGE OPEN G A N G E...

Page 536: ...tion Radio Illumination HEVAC Switch Overhead Console 14 20 ABS Module and Relays Vacuum Sensor Diesel Only 15 10 Transmission Range 16 15 Air Bag Module 17 15 Radio Buzzer Glove Box Dome Lamp Power M...

Page 537: ...ABS FRONT WHEEL SENSOR A C COMPRESSOR a 33 HEADLAMP TURN SIGNAL SIDE MARKER HORNS POWER SEAT SW SEAT SELT SWITCH POWER LOCK SW POWER WINDOW SW POWER MIRROR SW STOP TURN LAMP JUNCTION BLOCK J 9 4 8 W 1...

Page 538: ...LE GROUND H AIRBAG MODULE GROUND I WARNING BUZZER HEADLAMP CARGO GROUND IGNITION SWITCH GROUND P ABS POWER ROOF GROUND OVERHEAD CONSOLE DAY NIGHT MIRROR LEFT COWL GROUND POWER SEAT SEAT BELT SWITCH CE...

Page 539: ...Wiring 9 10 11 12 Engine Wiring 3 9L 16 Engine Wiring 5 2L 5 9L 17 Engine Wiring 8 0L 18 Engine Wiring 5 9L Diesel 19 Caption Fig Four Wheel Drive Wiring 20 Frame Wiring 2 Instrument Panel Wiring 6 7...

Page 540: ...Fig 1 Rear Lamp Wiring...

Page 541: ...CHASSIS WIRING HARNESS REAR WHEEL SPEED SENSOR FRAME ASSEMBLY FUEL TANK X MEMBER TO LEFT TAIL LAMP CHASSIS WIRING HARNESS TO ENGINE COMPARTMENT WIRING 0 o 0 33 s J948W 33 Fig 2 Frame Wiring...

Page 542: ......

Page 543: ...Fig 4 Roof Wiring...

Page 544: ......

Page 545: ...OVE BOX LAMP A N D SWITCH TO DOOR WIRING TO A l t BAG SQUIB TO DOOR WIRING y i c w I N DIRFCTION OF INSTRUMENT PANEL SUPPORT INSTRUMENT PANEL ASSEMBLY INSTRUMENT PANEL TO HEADLAMP AND DASH WIRING CONN...

Page 546: ...EL HARNESS OF ARROW X TO FUSE BLOCK TO BLOWER MOTOR TO IGNITION SWITCH ROOF WIRING CONNECTOR INSTRUMENT PANEL TO PARK BRAKE HARNESS SWITCH GROUND SEE VIEW Z TO STOP LAMP SWITCH GROUND VIEW IN DIRECTIO...

Page 547: ...J948W 39 Fig 8 Steering Column Wiring...

Page 548: ...BRAKE MASTER CYLINDER OF ARROW Y BRAKE GROUND ABS CONTROL UNIT CONNECTOR POWER DISTRIBUTION CENTER OF ARROW 7 ABS FRONT WHEEL SENSOR CONNECTOR BRAKE W A R N I N G LAMP SWITCH CONNECTOR OF ARROW V PRE...

Page 549: ...TOR LEFT FENDER SIDE SHIELD VIEW IN DIRECTION QF ARROW Z VACUUM SENSOR DIESEL ONLY BATTERY HEADLAMP AND DASH WIRING HARNESS VEHICLE SPEED CONTROL SERVO HEADLAMP AND DASH WIRING HARNESS POWER DISTRIBUT...

Page 550: ...ARROW Z VIEW IN DIRECTION OF ARROW Y GROUND PARK A N D TURN SIGNAL LAMP CONNECTOR FRONT BUMPER ASSEMBLY HORNS TO ENGINE COMPARTMENT WIRING TO HEADLAMP VIEW IN DIRECTION OF ARROW Y HEADLAMP A N D DASH...

Page 551: ...Fig 12 Engine Compartment Wiring...

Page 552: ...TION CENTER FEED LINE AIR CLEANER ASSEMBLY TO LEFT BATTERY TO ENGINE STARTER GROUND MOTOR POWER DISTRIBUTION CENTER FEED ENGINE STARTER MOTOR BATTERY BATTERY EE o 2 m TO ENGINE STARTER WIRING BATTERY...

Page 553: ...ION OVERDRIVE SOLENOID TO ENGINE WIRING TRANSMISSION TEMPERATURE SENSOR VEHICLE SPEED SENSOR HEATED OXYGEN SENSOR 5 2L AND 5 9L HEAVY DUTY VEHICLE SPEED SENSOR HEATED OXYGEN SENSOR 1 VEHICLE SPEED SEN...

Page 554: ...9L TO ENGINE WIRING TO HEATED OXYGEN SENSOR BACK UP LAMP SWITCH HEATED OXYGEN SENSOR TO ENGINE WIRING VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR JUMPER HARNESS CONNECTOR VEHICLE SPEED SENSOR BACK UP L...

Page 555: ...J948W 47 Fig 16 Engine Wiring 3 9L...

Page 556: ...FUEL THROTTLE POSITION MAP SENSOR ENGINE OIL Fig 17 Engine Wiring S 2L 5 9L...

Page 557: ...m J948W 49 Fig 18 Engine Wiring 8 0L...

Page 558: ...POSITION SENSOR FUEL HEATER VIEW IN DIRECTION OF ARROW X Til I VIEW IN DIRECTION OF ARROW T WATER IN FUEL SENSOR CONNECTOR ENGINE WIRING HARNESS INTAKE CHARGE AIR TEMPERATURE SENSOR VIEW IN DIRECTION...

Page 559: ...Fig 20 Four Wheel Drive Wiring...

Page 560: ...C7 6 X2 8 F14 6 X13 6 F18 7 X13 1 2 F18 1 Diesel 11 X53 LT Door 4 F18 1 V 6 V 8 9 X54 RT Door 4 F18 1 V 10 10 X55 LT Door 4 F21 6 X56 RT Door 4 F35 5 Z1 7 G7 1 8 Z1 1 7 G9 7 Z1 2 8 G107 8 Z1 3 8 K4 8...

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Page 572: ...Connector 136 Brake Sensor RWAL 56 58 61 Brake Warning Switch 56 57 62 Bulkhead Connector 123 124 125 126 Buss Bar 4 Buzzer 109 110 Wiring Diagram Sheet Name Sheet Number Bypass Jumper 9 Camshaft Pos...

Page 573: ...nsor 18 Vehicle Speed Sensors 20 Fuel Injection Ignition System 5 2L 5 9L Engines 23 32 Automatic Shut Down Relay 25 Charge Air Temperature Sensor 28 Crankshaft Position Sensor 28 Data Link Connector...

Page 574: ...r Lamps 66 Glove Box Lamps 78 Headlamp Left 67 69 Headlamp Right 68 70 Wiring Diagram Sheet Name Sheet Number Identification Lamps 65 Ignition Switch Lamp 108 110 Illumination Lamps 96 97 License Lamp...

Page 575: ...Fuel Pump Relay 90 Fuel Shut Down Relay 47 Heated Intake Air System Relays 43 Horn Relay 52 Time Delay Relay 108 110 Trailer Tow Relay 113 Resistors Blower M o t o r 96 97 Right Door Connector 1 139...

Page 576: ...72 Splice Z1 3 68 70 Splice Z2 95 Splice Z2 1 92 95 Wiring Diagram Sheet Name Sheet Number Splice Z2 2 95 Splice Z3 83 Splice Z3 1 78 Splice Z3 2 99 101 103 Splice Z4 65 Splice Z4 1 81 Splice Z11 82...

Page 577: ...h 11 Trans O D Solenoid 10 Trans O D Switch 10 Transmission Range Switch 12 Transmission Temperature Sensor 10 Turn Signal Hazard Switch 85 Wiring Diagram Sheet Name Sheet Number Turn Signal Flasher 8...

Page 578: ...WIRING DIAGRAMS 8W 4 9...

Page 579: ...RCULATION SOLENOID SH 1 9 2 9 4 1 EVAP PURGE SOLENOID SH 1 9 2 9 4 1 POWERTRAIN CONTROL MODULE SH 1 9 2 9 4 1 4 3 IGNITION MODULE SH 39 FUEL HEATER RELAY SH 47 FUEL SHUT DOWN SOLENOID SH 48 INTAKE AIR...

Page 580: ...ULE SH 83 WIPER MOTOR SH 84 WIPER SWITCH SH 84 F U S E 14 20 AMP YELLOW A20 18RD DB J REAR WHEEL ANTI LOCK MODULE SH 5 5 5 7 VACUUM SENSOR SH 5 7 6 2 ANTI LOCK BRAKE SYSTEM CONTROLLER SH 62 ABS POWER...

Page 581: ...X LAMP AND SWITCH SH 78 RADIO CHOKE SH 94 OVERHEAD MAP LAMP SH 80 OVERHEAD CONSOLE SH 81 TIME DELAY RELAY SH 1 0 8 1 1 0 FUSE 18 15 AMP LIGHT BLUE 1 9 FUSE 1 9 20 AMP YELLOW F33 20PK RD HEADLAMP SWITC...

Page 582: ...GY WT F U S I B L E LINK 3 40 AMP F U S I B L E LINK 4 30 AMP A16 14GY WT A l l 6BK G Y ft BUSS BAR F U S I B L E LINK 120 AMP A l l 6BK GY J FEED TO GENERATOR S E E SH 5 6 A10 12RD D G F U S I B L E...

Page 583: ...H 4 ZO 6BK BATTERY G R O U N D LEFT FRONT OF ENGINE BODY G R O U N D LEFT FENDER SHIELD B L A C K TO HAZARD 1 FLASHER C SEE SH 85 FEED FEED TO P O W E R DISTRIBUTION CENTER SEE SH 4 SH 124 L9 18BK VT...

Page 584: ...GINE BLOCK RIGHT S I D E OF ENGINE BODY GROUND RIGHT S I D E S H I E L D FEED TO POWER DISTRIBUTION CENTER S E E SH 4 TO FEED HAZARD V t t U i A euro FLASHER S E E SH 8 5 SH 124 L9 1 8 B K V T S P L I...

Page 585: ...E SH 98 INST PNL A2 1 2 P K B K A22 1 2 B K 0 R F U S E F2 30 AMP A22 1 2 B K 0 R A41 18YL A21 12DB G9 2 2 G Y B K A2 1 2 P K B K A22 1 2 B K 0 R A31 12BK WT A l 12RD TO BLOWER MOTOR S E E SH 9 G 9 8...

Page 586: ...8 R D D B Y m 1 8 R D D B 1 A20 18RD DB FEED F23 18DB Y L L10 22BR L G TO AIRBAG n r r n SYSTEM C O N T R O L L E D MODULE S E E SH 53 L10 2 2 B R L G L10 2 2 B R L G TO REAR WHEEL ANTI LOCK MODULE S...

Page 587: ...TTERY T40 12BR LEFT FENDER SIDE SHIELD T40 12BR POSITIVE TERMINAL SEE SH 5 6 T0 Z122J SPLICE SEE SH 15 25 42 47 T G N D SPLICE SEE SH 16 26 42 48 G N D BLACK GAS ONLY Z12 20BK TN T41 20BK WT T40 12BR...

Page 588: ...RING COLUMN t J 6 SH 123 JENG A h SH 127 SH 127 3 9L 5 2L 5 9 L O N L Y T6 20OR W T G54 200R B K TRANSMISSION OVERDRIVE SOLENOID MOUNTED ON TRANSMISSION K54 2 0 0 R B K F18 2 0 L G B K i T60 20BR TO w...

Page 589: ...P T O S W I T C H RIGHT SIDE O F P T O G 1 0 7 1 8 B K G Y B L A C K Z l 2 0 B K JGND TO Z l 3 G 1 0 7 2 0 B K GY G 1 0 7 2 0 B K G Y SPLICE SEE S H 68 70 H D L P D A S H I G 1 0 7 2 0 B K GY i i 26...

Page 590: ...JOINT C O N N E C T O R C SEE S H 7 F E E D LIO 2 2 B R LG A 630 M A N U A L T R A N S M I S S I O N LG 5 2L 5 9L O N L Y RIGHT SIDE T R A N S M I S S SH 128 LIO LIO 1 8 B R L G 1 8 B R J SH 124 62 E...

Page 591: ...REAR OF ENGINE IGNITION COIL i i T T K19 A142 16BK 14DG G Y O R K12 18TN K19 16BK GY K13 18YL WT 1 T A142 16DG 0R i n B L A C K K14 1 8 L B B R INJECTOR 4 T T K14 A142 18LB 160G B R O R A142 16DG 0R A...

Page 592: ...S E SH 10 FEED A142 16DG K38 OR 18GY T T TO TRANSMISSION OVERDRIVE TO FUEL SWITCH PUMP RELAY SEE SH 10 S E E SH 90 FEED FEED T6 220R WT K51 22DB Y L SH 123 T6 220R WT TO GENERATOR S E E SH 5 FEED T60...

Page 593: ...G I N E G R O U N D f L E F T FRONT O F E N G I N E l u SPLICE SEE S H 19 T O T R A N S M I S S I O N O V E R D R I V E S O L E N O I D SEE S H 10 F E E D F E E D 37 T R A N S C O N T R O L 54 T R A...

Page 594: ...1 G14 18PK BK TO POWER STRIBUTION CENTER SEE SH 4 F E E D A14 16RD WT TO TRANSMISSION RANGE SWITCH S E E SH 12 T G N D T41 18BK WT S P L I C E S E E SH 7 6 K2 18TN BK BLACK V40 22WT PK r I I H ENG A...

Page 595: ...20TN 20LG R D R D i A K44 20TN Y L TO VEHICLE SPEED SENSOR S E E SH 2 0 K l K6 K4 18DG 18VT 18BK R D WT L B K7 200R K4 2 0 B K L B K4 1 8 B K L B K6 18VT WT K6 K4 20VT 18BK WT L B K7 200R K4 1 8 B K L...

Page 596: ...8 B K L B K6 18VT WT BLACK K22 180R D B K7 200R K4 1 8 B K L B K22 180R DB K4 K7 20BK 200R L B TO ENGINE COOLANT TEMPERATURE SENSOR S E E SH 16 K24 20GY B K 22 TP S RIGHT S I D E COWL 24 B h 4 SIGNAL...

Page 597: ...8 2 0 L G B K W OVERDRIVE SOLENOID S E E SH 1 0 F18 20LG B K EVAP PURGE SOLENOID RIGHT S I D E COWL BLACK G21 20GY L B K59 K40 K60 K39 F 1 8 18VT 18BR 18YL 18GY 20LG B K WT B K R D B K K52 20PK B K K3...

Page 598: ...NSOR S E E SH 2 1 TO MAP SENSOR S E E SH 17 T0 K7 S P L I C E FEED S E E SH 17 K7 180R K4 1 8 B K L B G7 18WT 0R I VEHICLE SPEED SENSOR 67 20WT O R L E F T SIDE OF TRANSMISSION REAR OF TRANSMISSION f...

Page 599: ...NE GROUND L E F T FRONT OF ENGINE TO AIR CONDITIONING AND HEATER SYSTEM SEE SH 9 8 POWERTRAIN CONTROL MODULE INJECTORS 1 3 AND 5 S E E SH 1 3 1 4 FEED A142 14DG QR S P L I C E S E E SH 14 RIGHT S I D...

Page 600: ...COMPRESSOR CLUTCH RELAY SEE SH 98 J G N D C13 22DB OR TO VEHICLE SPEED CONTROL SYSTEM SEE SH 63 FEED FEED FEED V31 22BR RD V32 22YL RD V33 22WT LG 79 80 81 SH 124 SH 124 SH 124 V31 20BR RD V32 20YL RD...

Page 601: ...R R I G H T F R O N T O F E N G I N E V I G N I T I O N COIL IT T K19 A142 16BK 14DG G Y O R T60 20BR A 16 INJ 1 55 TRANS OD K12 K19 K13 18TN 16BK 18YL GY WT K J L A y T T 15 19 14 INJ 2 COIL INJ 3 DR...

Page 602: ...ECTOR 8 T T K17 A142 18DB 16DG T N O R TO GENERATOR S E E SH 5 FEED T T K18 A142 18RD 16DG Y L O R TO TRANSMISSION OVERDRIVE SWITCH SEE SH 10 y p E E D T6 220R WT SH 1 2 3 T6 220R WT ENG A SH 127 TO F...

Page 603: ...AM O T S P L I C E S E E SH 3 2 F E E D A16 14GY WT TO F E E O r POWER t DISTRIBUTION CENTER S E E SH 4 A142 1 4 D G 0 R Z12 2 0 B K T N ENGINE DATA LINK CONNECTOR Z12 14BK TN ENGINE GROUND L E F T S...

Page 604: ...ENG A SH 127 G14 18PK BK Z12 20BK T N T4I 20BK WT SH 123 TO TRANSMISSION RANGE SWITCH S E E SH 12 GND T41 T41 18BK 20BK WT WT S P L I C E S E E SH 7 6 FEED V40 20WT P K H ENG B h SH 128 A14 16RD WT i...

Page 605: ...O VEHICLE SPEED SENSOR S E E SH 3 0 VACUUM VENT RIGHT SIDE COWL K6 18VT WT K l 18DG RD K4 1 8 B K L B MAP SENSOR MOUNTED ON THROTTLE BODY Kl K6 K4 18DG 18VT 18BK R D WT L B K4 2 0 B K L B K4 1 8 B K L...

Page 606: ...HROTTLE BODY BLACK K22 180R D B K22 180R D B 22 T P S RIGHT S I D E COWL RIGHT REAR OF ENGINE BLACK K24 20GY K 4 O K 20BK B K L B TO ENGINE COOLANT TEMPERATURE SENSOR S E E SH 2 6 K24 20GY B K 24 BH 4...

Page 607: ...V E R D R I V E S O L E N O I D SEE S H 10 F18 2 0 L G BK E V A P P U R G E R I G H T SIDE S O L E N O I D C O W L B L A C K G 2 1 G 2 4 K 5 9 K 4 0 K 6 0 K 3 9 F 1 8 2 0 G Y 2 0 G Y 1 8 V T 1 8 B R...

Page 608: ...D T O R I G H T R W N 8 8 8 J 3 1 1 8 B K L B S E N S O R SEE S H 31 K4 18BK LB G 7 18WT 0R VEHICLE S P E E D S E N S O R LEFT SIDE O F T R A N S M I S S I O N T O M A P S E N S O R SEE S H 2 7 67 1...

Page 609: ...C COMPRESSOR CLUTCH RELAY S E E SH 9 8 Z l l 18BK WT TO AIR CONDITIONING AND HEATER SYSTEM S E E SH 9 8 T FEED C20 18BR i l fJNG K41 18BK D G ENGINE GROUND CI 3 20DB O R SH 127 Z12 1 4 B K 27 34 4 1 T...

Page 610: ...3 FEED FEED FEED V32 22YL R D V33 22WT L G 80 81 SH 124 SH 124 V32 20YL R D V33 20WT L G K141 18TN WT 3 ENG 8 ss SH 128 2 4 ENG B ENG B SH 128 SH 128 V31 20BR R D V32 20YL RD V33 20WT L G 23 48 49 50...

Page 611: ...D G OR K l 1 4 A142 20YL 16DG WT O R ENG A142 16DG 0R A142 14DG 0R A142 14DG O R A142 14DG O R Kl 16 18WT DB FEED TO LEFT HEATED OXYGEN SENSOR S E E SH 35 FEED TO RIGHT HEATED OXYGEN SENSOR S E E SH 3...

Page 612: ...WIRING DIAGRAMS 8W 83 INJECTOR 6 INJECTOR 1 A142 1 6 D G 0 R BLACK INJECTOR U 8 16DG 0R i INJECTOR 9 INJECTOR 1 0 J948W 9 FUEL INJECTION IGNITION SYSTEM 8 0L ENGINE BR 3 4...

Page 613: ...NG DIAGRAMS LEFT HEATED OXYGEN SENSOR 2 23 41 0 2 0 2 RIGHT S I D E COWL POWERTRAIN CONTROL MODULE CONNECTOR S E E SH 121 BR 35 F U E L I N J E C T I O N I G N I T I O N S Y S T E M J 3 0 L E N G I N...

Page 614: ...SENSOR S E E SH 10 TO CAMSHAFT POSITION SENSOR SEE SH 3 8 TO THROTTLE POSITION SENSOR S E E SH 3 8 K4 188K L RIGHT S I D E COWL 47 V S S POWERTRAIN CONTROL MODULE CONNECTOR S E E SH 121 J948W 9 FUEL...

Page 615: ...ROTTLE BODY sU n U T T T Kl K6 K4 18DG 18VT 18BK R D WT L B K4 1 8 B K L B K7 200R K7 180R K7 180R K4 1 8 B K L B K6 18VT WT K6 K4 20VT 18BK WT L B K7 200R FEED TO IGNITION K l K6 MODULE 18DG 20VT S E...

Page 616: ...K7 20OR L K 4 2 0 B K L B K4 1 8 B K L B K24 20GY B K TO ENGINE COOLANT TEMPERATURE SENSOR S E E SH 4 2 K4 1 8 B K L B 1 GND K4 1 6 B K L B JL RIGHT FRONT T OF INTAKE CHARGE AIR TEMPERATURE SENSOR K4...

Page 617: ...0 W T OR B K Z12 16BK TN Z12 14BK TN L Z l l SEE S H 41 E N G I N E D A T A LINK C O N N E C T O R D 2 0 2 0 L G 1 G B K W T I E N G I N E G R O U N D LEFT SIDE O F E N G I N E G N D D 2 1 2 0 P K T O...

Page 618: ...C K ON T H R O T T L E B O D Y TO T R A N S M I S S I O N O V E R D R I V E S O L E N O I D S E E S H 10 F E E D 6 2 1 6 2 4 K 1 8 2 0 6 Y 2 0 6 Y 20RD L B P K Y L JL 1 i T T T 4 3 5 6 17 TACH EMR C O...

Page 619: ...SH 128 HENG A h SH 127 A14 16RD WT T6 200R WT FEED K51 22DB Y L 8 ENG A SH 127 F18 2 0 L G B K TO ENGINE DATA LINK CONNECTOR S E E SH 3 9 FEED TO IGNITION MODULE S E E SH 3 9 F18 20LG BK F18 20LG B K...

Page 620: ...T18 22LG O R 8 HENG B h SH 128 HENG A h SH 127 G3 20BK P K T18 20LG OR T41 20BK WT TO TRANSMISSION RANGE SWITCH S E E SH 1 2 TO S P L I C E S E E SH 3 8 GND TO S P L I C E S E E SH 3 5 GND L E F T S...

Page 621: ...G3 20BK P K SH 123 lslBl G3 20BK P K HENG B h SH 128 TO GENERATOR S E E SH 6 S21 20YL B K FEED TO FUEL HEATER RELAY S E E SH 47 TO TRANSMISSION OVERDRIVE SOLENOID S E E SH 10 FEED F18 1 8 L G B K F18...

Page 622: ...FUEL PUMP RELAY S E E SH 90 G86 20TN OR 68 SH 124 G86 18TN O R ENG C E N G A SH 127 D20 20LG 021 20PK K51 22DB A142 14DB FEED ENG A y SH 127 y A142 14DG OR ENG A142J 10 SH 129 TO GENERATOR S E E SH 6...

Page 623: ...HROTTLE POSITION SENSOR TOP OF INJECTION PUMP AUTOMATIC TRANSMISSION ONLY K22 K6 200R 20VT DB WT K4 1 8 B K L B K4 2 0 B K L B K7 200R FRONT OF ENGINE ON TIMING COVER K4 2 0 B K L B BLACK K24 2 0 G Y...

Page 624: ...0WT OR K7 200R VEHICLE SPEED SENSOR K4 18BK L B K7 200R REAR OF TRANSMISSION G7 18WT OR LEFT REAR OF ENGINE ENG C SH 129 G7 20WT OR i TO JBUX MODULE ONLY S E E SH 107 7 47 8V VEHICLE SPEED SUPPLY SENS...

Page 625: ...8 1 HENG A h SH 127 C13 20DB OR S P L I C E S E E SH 43 ENG 8 t A18 FUEL iORD SHUT B K DOWN RELAY A18 16DB MANUAL TRANSMISSION T 4 l ONLY 22BK WT J G N D TO ENGINE STARTER RELAY S E E SH 9 LEFT S I D...

Page 626: ...INE S P L I C E S E E SH 82 GND T Z11 16BK WT f Z l i 16BK WTJI TO A C COMPRESSOR CLUTCH S E E SH 98 T G N D HENG Ah SH 127 T O T R A N S M I S S I O N R A N G E S W I T C H S E E S H 12 T 4 1 2 0 B K...

Page 627: ...OR ENG A h HENG A h SH 127 TO TRANSMISSION TEMPERATURE SENSOR S E E SH 10 FEED FEED FEED T60 20BR SH 127 TG 200R WT T18 20L6 OR K54 200R BK T54 16VT T60 20BR K54 200R BK 110 37 42 55 54 OVERDRIVE SWI...

Page 628: ...2YL RD El8 0 SH 124 V32 20YL RD FEED FEED V31 22BR RD V33 22WT L G 40J79 SH 124 El8 1 SH 124 V31 20BR RD V33 20WT L G ENG B SH 128 E N G J j SH 128 E N G B SH 128 ENG B SH 128 E N G B SH 128 V35 20LG...

Page 629: ...SING D I E S E L ENGINES LEFT SIDE OF ENGINE G6 22GY 18 SH 123 G6 22GY 8 HENG C h SH 129 GS 16GY F E E D BLACK ENGINE O I L PRESSURE SENDING UNIT FEED G60 22GY Y L 19 SH 123 660 226Y Y L HENG C h SH 1...

Page 630: ...2 F31 18VT HORN RELAY X2 18DG RDX IN POWER DISTRIBUTION CENTER SEE SH 142 F31 20VT FEED TO A C COMPRESSOR CLUTCH RELAY SEE SH 98 WITH POWER GROUP SH 123 X2 18DG RD Zl 18BK T0 A7 SPLICE SEE SH 73 HIGH...

Page 631: ...S H 1 2 3 QjJ 3 6 Z6 1 8 B K 0 R A I R B A G S Y S T E M CONTROL MODULE 1 11 C E N T E R REAR OF I P 1 1 1 2 1 7 1 1 3 1 6 1 1 2 1 5 D2 F 1 4 18WT 18LG B K Y L F 2 3 18DB Y L R41 18BK T N R 4 9 1 8 L...

Page 632: ...8 B K T N R47 1 8 D B L B R49 18LB D2 18WT BK Dl 1 8 V T B R 1 F23 1 8 D B Y L F14 1 8 L G Y L R49 18LB R48 18TN 58 oj SH 124 R49 18LB 57 p j j SH 124 R48 18TN 56 GJ SH l24 R47 1 8 D B L B R47 1 8 D...

Page 633: ...FENDER SIDE SHIELD GROUND B Z8 16BK PK TO 4X4 OR PTO SWITCH S E E SH 11 52 SH 124 B i l l 22LB BK 46 SH 124 TO CLUSTER B S E E SH 8 8 FEED 51 SH 124 FEED G107 20BK G Y 26 SH 123 B108 18WT B101 18LG WT...

Page 634: ...SEE SH 7 78 77 ROLLS TEST 8113 22RD V T i i J ASSEMBLY PLANT USE ONLY TWISTED PAIR BLACK TWISTED PAIR B l 14 22WT V T i GROUND I LEFT SIDE REAR OF INSTRUMENT PANEL REAR WHEEL ANTI LOCK SERVICE CONNEC...

Page 635: ...TION SWITCH S E E SH 7 TO CLUSTER B S E E SH 8 8 FEED A20 18RD D B G19 22LG R D L E F T REAR _ FENDER O S I D E SHIELD B i l l 18LB B K B108 18WT 52 SH 124 B i l l 22LB BK B101 18LG WT 46 SH 124 TO 4X...

Page 636: ...AR WHEEL ANTI LOCK SERVICE CONNECTOR BLACK GROUND I L E F T OF STEERING COLUMN REAR OF INSTRUMENT PANEL TO JOINT CONNECTOR B S E E SH 7 5 FEED Bl 12 20BK Z3 16BK OR F32 20PK D B B l 1 4 2 0 W T V T B1...

Page 637: ...B18 2 0 V T L G B248 16DG WT B249 18WT TN B60 1 2 L B B K B249 B248 B18 B245 B243 B5 B60 18WT 16DG 20VT 18WT 16DG 20VT 12LB T N WT L G L G B K R D B K TO Z2 S P L I C E S E E SH 9 5 B120 12BR WT B120...

Page 638: ...E R D I S T R I B U T I O N C E N T E R S E E S H 1 4 2 8 7 A T O F E E D S P L I C E S E E S H 1 1 4 P R E S S U R E L I M I T I N G V A L U E RR a S O L L E F T S I D E C O W L 1 R R IT R E S E T v...

Page 639: ...M O D U L E D 1 2 2 2 0 R D l l 2 2 W T R D R I G H T F R O N T W H E E L S E N S O R L E F T F R O N T W H E E L S E N S O R 012 2 2 0 R L E F T S I D E S H E I L D nmnrs N nmnr T W I S T E D P A I R...

Page 640: ...JOINT S E E SH 114 G9 20GY S P L I C E B K S E E SH 9 5 TO JOINT CONNECTOR C S E E SH 7 FEED G9 22GY B K Z7 18BK GROUND R D B 28 SH 123 BRAKE J 1 WARNING SWITCH L E F T 1 f FRAME R A I L Y G9 16GY B...

Page 641: ...V31 2 0 B R R D V33 2 0 W T L G V36 2 0 T N R D V35 2 0 L G R D E N G B SH 128 V32 2 0 Y L R D 2 ENG B SH 128 Z l 20BK DIRECT CONNECTION TO SERVO ENG B SH 128 JENG B SH 128 80 SH 124 V32 2 2 Y L R D...

Page 642: ...V33 20WT L G TO JOINT CONNECTOR C SEE SH 7 6 7 7 L FEED V40 20WT PK 5FEED V32 2 0 Y L R D V30 2 0 D B R D FEED F32 18PK DB TO JOINT CONNECTOR B SEE SH 7 5 BLACK 7 V32 2 2 Y L R D V T T V32 V33 V31 22...

Page 643: ...BK L7 1 8 B K Y L Z4 18BK L7 1 8 B K Y L Z4 18BK GROUND FORWARD CENTER OF ROOF PANEL BLACK anID LEFT OUTBOARD CLEARANCE LAMP BLACK LEFT OUTBOARD IDENTIFICATION LAMP BLACK a n r x cmID CENTER IDENTIFIC...

Page 644: ...ER LAMP an an RIGHT REAR FENDER LAMP an an I L 7 1 8 B K Y L Z13 18BK 1 L 7 1 8 B K Y L Z13 I8BK L7 1 8 B K Y L J T 0 L 7 T S P L I C E S E E SH 111 Z13 18BK f L E F T TAILGATE LAMP RIGHT ILGATE LAMP...

Page 645: ...S H 7 2 _ J _ LEFT FENDER SIDE S H I E L D L4 16VT WT F E E D TO JOINT L7 18BK YL CONNECTOR A S E E SH 7 4 40 TO GROUND JOINT S E E SH 114 GND SH 124 Z l 18BK L7 2 0 B K Y L L7 2 0 B K Y L F FEED L E...

Page 646: ...BLUE L3 16RD 0RX Zl 18BK Q GROUND D RIGHT FRONT FENDER SIDE S H I E L D BLACK Zl 18BK L7 1 8 B K Y L X L60 18LG TNX L 6 0 L60 HD LP 20TN DASH BKX 70 SH 124 RIGHT HEADLAMP RIGHT PARK AND TURN SIGNAL LA...

Page 647: ...7 2 L E F T FENDER SIDE S H I E L D LEFT PARK AND TURN SIGNAL LAMP BLACK Z l 18BK L7 1 8 B K Y L L61 1 8 L G T N i L61 HD LP DASH L61 20LG BLACK Y L 69 TO TURN SIGNAL SWITCH FEED SEE SH 8 5 L61 1 8 L...

Page 648: ...P DASH Z l 18BK O GROUND D b r RIGHT FRONT FENDER SIDE S H I E L D Z l 18BK L7 1 8 B K Y L BLACK L60 HD LP 20TN DASH B K RIGHT HEADLAMP RIGHT PARK AND TURN SIGNAL LAMP 70 f e u i o 4 I FEED s TO TURN...

Page 649: ...E E SH 6 9 47 SH 124 A3 1 2 R D L G FEED 634 18RD G Y FEED G34 18RD G Y DAYTIME RUNNING LAMPS MODULE BLACK 27 SH 123 LOCATED ON L E F T FENDER S I D E S H I E L D G34 20RD G Y DAYTIME RUNNING LAMPS J...

Page 650: ...111 BRAKE GROUND O RWAL G N D G N D Z13 Z13 16BK 12BK WITH TRAILER T O W TO WINDSHIELD WASHER PUMP M O T O R SEE SH 83 GND f TO GROUND JOINT SEE SH 114 SPLICE SEE SH 107 109 TO LEFT HEADLAMP SEE SH 67...

Page 651: ...S E E SH 83 W O I N F I N I T Y x RADIO HEADLAMP DIMMER SWITCH SH 136 TO CARGO AND DOME LAMP SYSTEM S E E SH 79 48 SH 124 A7 1 2 R D B K A7 1 2 R D B K A7 1 2 R D B K FEED 5 TO A77T S P L I C E S E E...

Page 652: ...M2 22YL M2 22YL LT DOOR 1 SH 137 RT DOOR 1 L E F T KICK PANEL TO MAP LAMP OR OVERHEAD CONSOLE S E E SH 8 0 8 1 M2 22YL L7 1 8 B K Y L J G N D TO FEED S P L I C E S E E SH 6 5 8 1 8 BODY SH 136 M2 22Y...

Page 653: ...4 A3 12RD LG FEED TO A3 H SPLICE SEE SH 7 1 TO REAR WHEEL ANTI LOCK MODULE SEE SH 5 6 5 8 FEED F32 20PK D B LEFT SIDE OF INSTRUMENT PANEL 1 2 JOINT CONNECTOR B 6 CONNECTOR SEE SH 131 7 8 Ml 20PK FEED...

Page 654: ...T r K HD LP DASH V40 20WT PK V40 20WT PK TO BRAKE SWITCH SEE SH 6 4 FEED TO REAR WHEEL ANTI LOCK MODULE S E E SH 5 6 5 8 FEED V40 20WT P K V40 22WT P K 21 20 22 31 32 33 LEFT SIDE OF INSTRUMENT PANEL...

Page 655: ...SWITCH S E E SH 64 80 SH 124 TO CLOCKSPRING S E E SH 64 FEEO FEED E 22 2 OR N S E 22 s s 2 OR E 22 N y 2 V OR 2 2 R s s M v YL 22 D R S i S 32 v YL 20 D R 1 YL D N S 1 2 3 4 5 18 19 17 L E F T S I D...

Page 656: ...R F 3 0 IBRD OR 1 TO TRANSMISSION OVERDRIVE SWITCH SEE SH 10 G N D Z3 20BK 0R Z3 12BK 0R TO GND HEATER SWITCH O R HVAC SWITCH SEE SH 96 97 Z3 12BK 0R G N D TO SPLICE SEE SH 83 Zll 18BK WTX F30 18RD OR...

Page 657: ...Ml 18PK C3 M3 1 8 P K D B BLACK Ml 18PK J CARGO LAMP 2 Ml 18PK H BODY h SH 136 Ml 18PK Ml 18PK TO FEED S P L I C E S E E SH 1 0 7 1 0 9 BODY I SH 136 M3 22PK D B J GND TO HEADLAMP SWITCH S E E SH 7 3...

Page 658: ...O N N E C T O R A S E E S H 7 4 GNo J G 1 6 22BK L B M2 22YL G N D 1 G N D T O o S P L I C E S E E S H 1 0 7 1 0 9 L T D O O R 1 SH 137 G 6 2 0 B K L B M 2 2 2 Y L S P L I C E S E E S H 6 5 G N D R O...

Page 659: ...E LAMPS BLACK Z l l 20BK WTX 10 M2 22YL Z l l 20BK WTX 632 2 2 B K L B G31 22VT LG X G31 2 2 V T L G X 632 2 2 B K L B X 6 BLACK E2 220R F12 22DB WTX L7 18BK YL X L7 2 0 B K Y L X CONNECTOR SEE SH 1 4...

Page 660: ...L7 2 0 B K Y L X i Ml 20PK FEED JOINT CONNECTOR A S E E SH 7 4 TO AIRBAG ABS DATA LINK CONNECTOR SEE SH 6 1 TO CLUSTER B S E E SH 8 8 RIGHT DOOR JAMB SWITCH JOINT CONNECTOR C S E E SH 7 6 S P L I C E...

Page 661: ...USTER B SEE SH 8 8 TO S P L I C E J S E E SH 7 2 Z l 20BK GND Wll WINDSHIELD WASHER P N L PUMP MOTOR IN WASHER RESERVOIR SH 123 IN WASHER LOW WASHER RESERVOIR FLUID LEVEL SENSOR Z3 2 0 B K 0 R Z3 1 2...

Page 662: ...BR WT V9 18WT BK V8 18VT VIO 18BR MULT I FUNC WASHER 1 S W I T C H r K O F F O N JMULTI 1 FUNC V6 16DB B K MULT I FUNC VIO I8BR V6 1 8 D B B K V5 18DG YL V6 1 6 D B B K V6 1 6 D G B K VG 16DG BK SH 12...

Page 663: ...7 L9 18BK VT SH 124 4 d SH 124 L6 20RD GY L19 18PK WT HAZARD FLASHER IN FUSE BLOCK L61 18LG Y L L60 18TN BK 17 11 MULT I FUNC TO CLUSTER A SEE SH 8 7 FEED MULT I FUNC L60 20TN BK 16 MULT I FUNC 5 F E...

Page 664: ...129 TO POWERTRAIN CONTROL MODULE CAVITY 31 SEE SH 16 26 47 CAVITY 36 SEE SH 39 FEED 1 G14 18PK BK ENG A SH 127 F14 18LG YL G86 18TN OR G85 180R BK G14 18PK BK SH 124 68 fpl SH 124 71 GO SH 124 67 rsi...

Page 665: ...LAMP CK FEED GND GND FEED L BUX ONLY 1 613 20DB RD SEE SH 107 SEAT BELT LAMP FEED 14 FEED FEED FEED FEED FEED FEED FEED G7 22WT 0R SEE SH 20 30 36 48 VEHICLE SPEED 67 20UT 0R SEE SH 46 R41 18BK TN SE...

Page 666: ...CE LAMP G21 22GY LB SEE SH 19 29 40 43 TACH FEED GND FEED FEED FEED FEED G19 22LG RD SEE SH 60 ANTI LOCK LAMP G19 22LG RD SEE SH 55 57 FEED G60 22GY YL SEE SH 51 ENGINE OIL PRESSURE E 2 F14 20LG YL SE...

Page 667: ...FT LAMP CHECK I A4 o AS B6 B4 A9 B7 B5 A3 GENERAL fFT o ILLUMINATION L B J SEAT BELT I Al I a HIGH BEAM A13 0 LEFT TURN A12 0 RIGHT TURN A14 0 o l B8 I IGNITION o A6 I GROUND o A U SP PULSE o jT TA PU...

Page 668: ...S P L I C E S E E SH 8 2 G4 22DB TO AUTOMATIC SHUT DOWN RELAY S E E SH 22 2 5 3 6 4 4 K51 22DB Y L A61 16DG BK 3 I E J SH 123 8 ENG A SH 127 r K 5 1 2 0 D B Y L FEED TO POWERTRAIN CONTROL MODULE CAVIT...

Page 669: ...H 7 FUSE 7 10 AMP X12 18RD WT TO JOINT FEED CONNECTOR B Ml 20PK S E E SH 7 5 DOOR 1 S H l 3 X55 2 0 B R R D SH 1 3 6 X58 2 0 D B 0 R BODY I X57 2 0 B R L B X55 20BR RD X 5 8 18DB 0R X 5 7 18BR LB SH 1...

Page 670: ...20DB RD X54 20VT X55 2 0 B R R D X53 20DG X52 18DB WT X58 18DB 0R X51 18BR YL X57 18BR LB RIGHT DOOR SPEAKER LEFT DOOR SPEAKER RIGHT REAR SPEAKER EQUIPPED LEFT REAR SPEAKER 12 18BK LG 12 18BK LG 491_...

Page 671: ...INT f FEED CONNECTOR A L 7 2 0 B K Y L S E E SH 7 4 TO IGNITION SWITCH S E E SH 7 TO JOINT CONNECTOR C S E E SH 7 7 FEED FUSE Ml 10 AMP E2 220R X12 18RD WT Ml 20PK FEED TO JOINT CONNECTOR B S E E SH 7...

Page 672: ...3 9 D Q Q p 1 X54 20VT h2 SH 1 3 7 pQQp i X53 20DG X54 18VT 3 X53 18DG 12 18BK L G G N IL Z2S S P L I C E S E E SH 9 5 r i X57 X51 18BR L B 18BR Y L X13 12 X13 18BK 18BK J I 18BK R D L G X 5 8 X52 R...

Page 673: ...UND SEE SH 9 1 9 3 GND Z2 1 8 B K L G TO LEFT DOOR SPEAKER I N F I N I T Y SEE SH 94 GND Z2 1 8 B K L G iDOOR iHSH 137 Z2 1 8 B K L G Z 2 18BK LG HDOOR iHSH 139 Z2 18BK LG WITH HIGH L I N E CLUSTER Z2...

Page 674: ...K 0R Ci 120G CI I2DG C7 12BK TN INST PNL C7 FUSE F 2 30 AMP F2 C4 C5 C7 i i I S X f s X f s A22 12BK O R M H BLOWER MOTOR RESISTER RIGHT S I D E COWL FEED T 0 A 2 2 S P L I C E S E E SH 7 FEED f TO JO...

Page 675: ...1 2 3 C7 12BK TN BLOWER MOTOR INST C7 PNL C4 C5 16TN 1BLG C6 C7 14LB 12BK T N Y L LO Ml M2 HI BLOWER MOTOR RESISTER Z3 12BK OR GND TO A C HIGH PRESSURE CUT OUT SWITCH S P L I C E S E E SH 7 8 A C LOW...

Page 676: ...CH RELAY I N POWER DISTRIBUTION CENTER S E E SH 142 C13 22DB O R S P L I C E S E E SH 1 9 2 9 4 1 4 3 C C f r n TO IGNITION S A P I 12DB SWITCH H I L L D M SEE SH 7 ENG A h Z i l 2 l fZ L zil 16BK WT...

Page 677: ...CONNECTOR FORWARD m MASTER SWITCH TO LEFT DOOR LOCK SWITCH S E E SH 101 GND GND GND TO POWER i MIRROR SWITCH S E E SH 103 Z3 Z3 Z3 14BK 14BK 18BK O R O R O R Q21 14WT Q21 O i l 14WT 14LB LEFT S I D E...

Page 678: ...P FROM MASTER SWITCH TN FEED RED Q22 14VT Q26 14VT WT X FORWARD I N CAR Q16 14BR WT F21 I4TN Q12 14BR UP RIGHT FRONT WINDOW L I F T SWITCH CONNECTOR TO A22 12BK OR CIRCUIT BREAKER 1 30 AMP I N FUSE BL...

Page 679: ...OCK SH 138 P36 16PK VT LT DOOR 2 D 0 0 R 2 S H P36 16PK VT P36 16PK VT 10 SH 138 IpoQR 2 P35 160R VTX P35 160R VT F35 16RD F35 16RD DOOR 2 h S HH 0 P35 160R VT F35 16RD LT DOOR 2 RT DOOR 2 SH 140 Z3 1...

Page 680: ...ITCH RIGHT DOOR P36 1 6 P K V T f P35 1 6 0 R V T F35 16RD UNLOCK rr L LOCK P34 16PK BK BLACK P34 16PK BK i P33 1 6 0 R B K P33 1 6 0 R B K RIGHT DOOR P 3 3 P34 160R 16PK B K B K 8 RT DOOR 2 SH 140 RT...

Page 681: ...EFT O S I D E COWL GROUND W 0 POWER WINDOWS AND LOCKS P75 20DB WT P71 20YL GRAY P73 P70 20YL 20WT P K D AT MIRROR a P72 20YL B K P74 20DB P72 2 0 Y L B K J O O R lHSH 13 P70 20WT P75 20DB WT P71 2 0 Y...

Page 682: ...OOR 1 SH 1 3 9 LEFT MIRROR RIGHT MIRROR RT B VIEW OF SWITCH INDEXING FROM FRONT OF SWITCH HORIZONTAL LT R RT VERTICAL RIGHT MIRROR MOTORS P70 20WT POWER MIRROR SWITCH FUNCTION LEVER POSITION CIRCUIT M...

Page 683: ...7 14RD LB REAR VERTICAL SEAT MOTOR P13 14RD WT P19 14YL LG FRONT VERTICAL SEAT MOTOR Z3 14BK 0R LEFT BODY O GROUND LEFT REAR OF CAB UNDER SEAT BLACK 1 z 4E OR P21 7 14RD 14RD L G Li I D 14BKL B P19 14...

Page 684: ...2 2 V T B K L I 1 8 V T B K 22 III S H 1 2 3 S P L I C E S E E S H 1 2 r TO SPLICE S E E S H 8 0 8 1 F U S E D B A C K U P GROUND F E E D L P S AUTOMATIC D A Y N I G H T MIRROR B L A C K L I 2 2 V T...

Page 685: ...20WT OR FEED SPLICE SEE SH 4 6 Ml 20PK Ml 20PK Ml Ml Ml 20PK 18PK 20PK FEED TO UNDERHOOD LAMP SEE SH 72 TO SPLICE SEE SH 73 Ml 20PK 0034 SH 123 y FEED A 7 12RD BK G26 20LB 1 5 G7 20WT OR 1 4 cp pjEpCJ...

Page 686: ...C K L E M50 2 2 Y L R D Z 3 2 0 B K 0 R G 2 6 2 0 L B G16 2 2 B K L B G R A Y TIME DELAY RELAY I N F U S E B L O C K S E E SH 1 1 7 1 1 8 M50 2 2 Y L R D Ml 20PK TO CENTER HIGH MOUNTED STOP LAMP AND C...

Page 687: ...75 SPLICE SEE SH 79 SH 136HB0DYh Ml 20PK Ml 20PK Ml Ml Ml 20PK 18PK 20PK FEED TO UNDERHOOD LAMP SEE SH 72 Ml 20PK TO V7 7SPLICE r FEED SEE SH 73 D Q 3 4 SH 123 A7 12RD BK TO POWER MIRROR SWITCH SEE S...

Page 688: ...Y L 5 4 G R A Y M 5 0 2 2 Y L R D 13 2 0 B K 0 R G 2 6 2 2 L B G 1 6 2 2 B K L B 5 3 5 5 Ulf n T I M E D E L A Y R E L A Y IN F U S E B L O C K S E E S H 1 1 7 1 1 8 T O C E N T E R H I G H M O U N T...

Page 689: ...BACK UP LAMP Z13 18BK Z13 16BK L7 18BK YL Z13 18BK 8VT BK L7 18BK YL Ll 18VT BK L63 L63 18DG 18DG RD RD Z13 Z13 16BK 12BK W 0 TRAILER T O W Z L63 L62 LI 18DG 18BR 18VT RD PK BK X j FEED FEED FEED CHAS...

Page 690: ...w u W TOW w TRAILER L I L I L62 L62 18VT 18VT 18BR 18BR BK BK PK PK L63 18DG RD L63 18DG RD L62 18BR PK Z13 18BK L7 18BK YL LEFT FENDER SIDE SHIELD RIGHT BACK UP LAMP FEED TO TRANSMISSION r L i I8VT B...

Page 691: ...IRING DIAGRAMS i SPLICE SEE SH 112 BLACK A6 1 4 R D T N f J f 0 _ L7 2 0 B K Y L f TRAILER TOW CONNECTOR SPLICE SEE SH 6 7 6 9 BR 113 TRAILER T O W S Y S T E M I N POWER DISTRIBUTION CENTER SEE SH 142...

Page 692: ...188K 4 Z l 1 8 B K 4 T O D A Y T I M E R U N N I N G L I G H T M O D U L E S E E S H 7 1 Z l 18BK Z l 12BK Z l 14BK r Z l 18BK O Z l 18BK Z l 12BK Z l 14BK Z l 18BK Z l 18BK BLACK Z l 12BK T O Z l 12...

Page 693: ...TN FEED TO 8 SPLICE SEE SH 64 BLACK CENTER REAR ROOF PANEL Z3 18BK O R L50 18WT TN 0 1 MOUNTED STOP LAMP 1 I Z3 18BK OR L50 18WT TN CENTER HIGH i MOUNTED STOP LAMP 2 Z3 18BK 0R BLACK L50 18WT TN Z3 1...

Page 694: ...Y I N BUZZER CHIME 73 B3 G26 20LB K E Y I N BUZZER CHIME 73 D M3 22PK DBX CARGO LAMP GROUND 73 H L2 16LG HEADLAMP DIMMER SWITCH FEED 73 I E l 2 0 T N 0 R HEADLAMP DIMMER SWITCH 73 P L20 16LG WT HEADLA...

Page 695: ...59 fW63 5 8 m6 2 5 7 1 6 1 5 6 1 M l 60 BUZZER CB1 CB2 49 45 50 46 51 47 52 48 0 41 37 42 38 44 40 33 29 34 30 36 32 25 21 26 22 27 28 17 18 19 15 13 19 20 VIEWED FROM TERMINAL END LOCATED LEFT SIDE...

Page 696: ...9 0 9 8 10 2 GRAY 1 7 6 4 11 10 RED 1 7 7 6 12 15 LIGHT BLUE 1 7 8 6 13 5 TAN 7 3 7 7 14 20 YELLOW 2 8 5 5 5 7 6 2 S 10 RED 2 8 16 15 LIGHT BLUE 2 8 5 3 17 15 LIGHT BLUE 3 1 0 7 1 0 9 18 15 LIGHT BLU...

Page 697: ...ROL VACUUM 1 7 6 3 3 4 C13 20DB 0R A C COMPRESSOR CLUTCH RELAY GROUND 22 1 3 5 K35 20GY YL EXHAUST GAS RECIRCULATION SOLENOID 13 j 3 6 3 7 T 1 8 20LG 0R TRANSMISSION FEED 1 0 1 5 3 8 K38 18GY FUEL I N...

Page 698: ...L VACUUM 2 7 6 3 34 C13 2 0 D B 0 R A C COMPRESSOR CLUTCH RELAY GROUND 31 35 K35 2 0 6 Y Y L X EXHAUST GAS RECIRCULATION SOLENOID 29 36 37 T18 20LG 0R X TRANSMISSION FEED 25 38 K38 18GY FUEL I N J E C...

Page 699: ...X MALFUNCTION INDICATOR LAMP 42 33 V36 2 0 T N R D VEHICLE SPEED CONTROL VACUUM 3 7 6 3 34 C13 20DB 0R X A C COMPRESSOR CLUTCH RELAY GROUND 34 35 K35 2 0 6 Y Y L EXHAUST GAS RECIRCULATION SOLENOID 41...

Page 700: ...ELAY 48 31 G14 18PK BK t TRANSMISSION TEMPERATURE LAMP 47 32 63 20BK PK t MALFUNCTION INDICATOR LAMP 43 33 V36 2 0 T N R D VEHICLE SPEED CONTROL VACUUM 5 0 6 3 34 C13 20DB 0R A C COMPRESSOR CLUTCH REL...

Page 701: ...PRESSURE SWITCH LOW 51 19 660 2 2 G Y Y L ENGINE OIL PRESSURE SENDING UNIT 51 20 G7 22WT 0R VEHICLE SPEED SENSOR 2 0 3 0 3 6 20 67 20WT 0R VEHICLE SPEED SENSOR 46 21 22 L I 2 2 V T B K BACK UP LAMPS...

Page 702: ...RIGHT IMPACT SENSOR 54 56 R47 18DB LB X FRONT LEFT IMPACT SENSOR 54 57 R48 18TN FRONT RIGHT IMPACT SENSOR 54 58 R49 18LB FRONT LEFT IMPACT SENSOR 54 59 631 2 2 V T L 6 X INTAKE AIR TEMPERATURE SENSOR...

Page 703: ...VEHICLE SPEED SENSOR 2 0 3 0 3 6 4 6 21 22 L I 1 8 V T B K BACK UP LAMPS 12 106 23 A41 18YL ENGINE STARTER RELAY 7 9 24 25 26 6107 2 0 B K 6 Y 4WD LOCK LAMP 1 1 5 5 5 7 26 G107 2 0 B K 6 Y 4WD LOCK L...

Page 704: ...SOR 54 56 R47 18DB LB X FRONT LEFT IMPACT SENSOR 54 57 R48 18TN FRONT RIGHT IMPACT SENSOR 54 58 R49 18LB FRONT LEFT IMPACT SENSOR 54 59 631 1 8 V T L 6 X INTAKE AIR TEMPERATURE SENSOR 82 60 632 1 8 B...

Page 705: ...RESSOR CLUTCH RELAY GROUND 2 2 3 1 3 4 4 7 9 8 3 9 L 5 2 L 5 9 L ONLY D I E S E L ONLY 8 K51 2 0 D B Y L X AUTOMATIC SHUT DOWN RELAY 1 4 2 4 4 1 4 4 9 0 3 9 L 5 2 L 5 9 L ONLY D I E S E L ONLY 9 V40 2...

Page 706: ...ED 8 1 2 10 LIO 18BR LG X BACK UP LAMP SWITCH FEED 12 10 LIO 18BR LG X BACK UP LAMP SWITCH FEED 12 ENG B LEFT SIDE COWL 5 2 L 5 9 L ONLY 5 2 L 5 9 L ONLY VIEWED FROM TERMINAL END 10 6 CAV CIRCUIT FUNC...

Page 707: ...ICLE SPEED SENSOR 2 0 3 0 3 6 4 6 10 G86 1 8 T N 0 R SENSOR GROUND 4 4 8 6 VIEWED FROM TERMINAL END O o o o O O o o o O n BLACK 10 D I E S E L ONLY 5 2 L 5 9 L 8 0 L ONLY D I E S E L ONLY CAV CIRCUIT...

Page 708: ...L L I C E N S E S I D E MARKER LAMPS 74 5 L7 2 0 B K Y L T A I L L I C E N S E S I D E MARKER LAMPS 74 6 M2 22YL DOOR SWITCH GROUNDS 74 7 M2 22YL DOOR SWITCH GROUNDS 74 8 M2 22YL DOOR SWITCH GROUNDS 7...

Page 709: ...AMP 75 2 Ml 20PK DOME AND COURTESY LAMP 75 3 4 F32 1 8 P K D B STOP LAMP SWITCH FEED 75 5 F32 1 8 P K D B STOP LAMP SWITCH FEED 75 6 Ml 18PK DOME AND COURTESY LAMP 75 7 Ml 20PK DOME AND COURTESY LAMP...

Page 710: ...ITION RUN START 76 16 17 V32 20YL RD VEHICLE SPEED CONTROL IGNITION 77 18 V32 22YL RD VEHICLE SPEED CONTROL IGNITION 77 19 V32 22YL RD VEHICLE SPEED CONTROL IGNITION 77 20 G16 22BK LB BUZZER CHI ME PA...

Page 711: ...W T B K PARK BRAKE SWITCH 5 6 5 8 6 G9 22GY BKX BRAKE WARNING LAMP SWITCH 5 6 5 8 7 V40 22WT PK t STOP LAMP SWITCH 5 6 5 8 8 8108 18WT RWAL DUMP SOLENOID 5 5 5 7 9 F32 20PK DB STOP LAMP SWITCH FEED 5...

Page 712: ...Y COIL 60 14 B l 1 4 20WT VTX REAR WHEEL SENSOR LOW 61 l b B6 20WT DBX RIGHT WHEEL SENSOR 61 IB B8 2 0 R D 6 Y X L E F T WHEEL SENSOR 61 17 A20 18RD DBX IGNITION RUN 62 18 B18 2 0 V T L 6 X PUMP VALVE...

Page 713: ...NT 84 9 V3 18BR WT WINDSHIELD WIPER LOW SPEED 84 9 V3 18BR WT WINDSHIELD WIPER LOW SPEED 84 10 11 L60 20TN BKX RIGHT FRONT TURN SI6NAL 85 11 L60 18TN BK RI6HT FRONT TURN SIGNAL 85 12 L62 18BR PK RIGHT...

Page 714: ...TCH 6 4 1 1 5 11 X13 1 8 B K R D NAME BRAND SPEAKER AMPLIFIER B 94 12 X52 20DB WT RIGHT REAR SPEAKER B 9 2 9 4 TO INSTRUMENT PANEL 12 OH O D D D D L D D O D BLACK VIEWED FROM TERMINAL END CAV CIRCUIT...

Page 715: ...PEAKER B 94 8 X55 20BR RD LEFT FRONT D O O R SPEAKER B 91 9 P72 20YL BK POWER MIRROR M O T O R RIGHT 103 10 P74 20DB POWER MIRROR M O T O R RIGHT 104 TO LEFT DOOR BLACK 10 5 O O O O j VIEWED FROM TERM...

Page 716: ...R LOCK SWITCH UNLOCK 101 TO INSTRUMENT PANEL BLACK q i Q 5 v v VIEWED FROM TERMINAL END L E F T S I D E COWL CAV CIRCUIT FUNCTION SHEET 1 F35 16RD POWER DOOR LOCK SWITCH FEED 101 2 F21 14TN POWER WIND...

Page 717: ...R SPEAKER B 94 6 X56 2 0 D B R D RIGHT FRONT DOOR SPEAKER B 91 7 M2 18YL DOOR SWITCH GROUND 7 4 8 0 8 2 8 P74 20DB POWER MIRROR MOTOR RIGHT 104 TO RIGHT DOOR BLACK VIEWED FROM TERMINAL END CAV CIRCUIT...

Page 718: ...POWER DOOR LOCK SWITCH LOCK 101 TO INSTRUMENT PANEL BLACK VIEWED FROM TERMINAL END RIGHT SIDE COWL CAV CIRCUIT FUNCTION SHEET 1 2 3 F21 14TN POWER WINDOW SWITCH 100 4 016 14BR WTX POWER WINDOW MASTER...

Page 719: ...81 2 L7 1 8 B K Y L T A I L L I C E N S E S I D E MARKER LAMPS 81 3 4 G32 2 2 B K L B AIR TEMP SENSOR RETURN 81 5 G31 2 2 V T L G AIR TEMPERATURE SENSOR 81 6 M2 22YL DOOR SWITCH GROUND 81 7 F12 22DB...

Page 720: ...ES A B C TRAILER 1 85 1 7 AJ si 7 1 30 7 AJ si 7 7 AJ si 7 1 8G HORN 8 5 l 30 7 A 861 ABS YELLOW LP A C CLUTCH 1 85 1 7 A 7j 1 30 7 A 7j 7 A 7j 1 86 30 ASD E l 1 861 FUSELINK ALT 1 2 0 AMP TYPE C FUSE...

Page 721: ...R RIGHT 103 3 P70 20WT POWER MIRROR MOTOR RIGHT 103 4 Ml 20PK DOME AND COURTESY LAMP 103 5 P75 20DB WT POWER MIRROR MOTOR LEFT 103 6 P71 20YL POWER MIRROR MOTOR LEFT 103 7 P73 20YL PK POWER MIRROR MO...

Page 722: ...Always inspect the package for the ex piration date before use MOPAR GASKET MAKER Mopar Gasket Maker normally red in color is available in 6 cc tubes This anaerobic type gasket material cures in the...

Page 723: ...than 172 kPa 25 psi from cylinder to cylinder j I f cylinder s have abnormally low compres sion pressures repeat steps 3a through 3h k I f the same cylinder s repeat an abnormally low reading it could...

Page 724: ...shaft Place a minimum of 0 254 mm 0 010 inch shim between the bearing shell and the adjacent bearing cap Tighten the bolts to 18 N m 13 ft lbs torque CHECK N O l BEARING Shim No 2 main bear ing CHECK...

Page 725: ...tially this repair consists of Drilling out worn or damaged threads Tapping the hole with a special Heli Coil Tap or equivalent Installing an insert into the tapped hole This brings the hole back to...

Page 726: ...tery specific gravity Charge or replace as necessary 2 Clean and tighten battery connections Apply a coat of light mineral grease to the terminals 3 Refer to Group 8A Battery Starter Charging System D...

Page 727: ...11 Install new parts as necessary 12 Replace any cracked or shorted cables 13 Test and replace as necessary refer to Group 8D Ignition System 14 Replace sensor ENGINE MISSES O N ACCELERATION 1 Dirty...

Page 728: ...Group 0 Lubrication and Maintenance 2 Check engine oil level Inspect oil pump relief valve and spring 3 Change oil to correct viscosity 4 Measure bearings for correct clearance Repair as necessary 5 C...

Page 729: ...e wires and verify that the fuel shutdown solenoid is functioning Remove the obstruction Drain fuel water separator and replace fuel filter Check fuel inlet restriction Correct cause Check fuel flow b...

Page 730: ...aust system restricted Air in the fuel system or the fuel supply is inadequate Fuel w a x i n g due to extremely cold w e a t h e r Contaminated fuel Adjust the idle speed Visually check for exhaust r...

Page 731: ...n pump delivery valves Repair or replace injection pump Camshaft out of time Check correct gear train timing alignment Damaged camshaft or tappets Inspect camshaft valve lift Replace camshaft and tapp...

Page 732: ...d around mounting capscrews or through holes in the manifold cover Exhaust leak at the manifold or turbocharger Check correct leaks in the manifold or turbocharger gaskets If manifold is cracked repla...

Page 733: ...must b e d i r e c t e d at this location f o r e m e r g e n c y shutdown conditions Repair or replace fuel pump COOLANT TEMPERA TURE ABOVE NORMAL Low coolant level a Check coolant level A d d coolan...

Page 734: ...d fill w i t h clean coolant Verify that the engine load rating is not being exceeded COOLANT TEMPERA TURE BELOW NORMAL Too much air flow across the radiator Incorrect thermostat b r o k e n thermosta...

Page 735: ...replace v a l v e Plugged oil filter Change oil filter O i l filter change interval may need to be revised If cooler was replaced shipping plugs left in cooler C h e c k r e m o v e shipping plugs If...

Page 736: ...ook for reduced viscosity from dilution w i t h fuel c Review reduce the oil change intervals Oil cooler leak Check and replace the oil cooler High blow by forcing oil out the breather Check the breat...

Page 737: ...or abnormally high loading Check the tensioner and inspect the d r i v e belt M a k e sure w a t e r pump tensioner pulley fan hub and alternator turn freely Intake air or exhaust leaks Refer to Exces...

Page 738: ...Oil Capacity 3 8L 4 0 Qts with Filter Cooling System Liquid Cooled Forced Circulation Cooling Capacity 14 3L 15 1 Qts Cylinder Block Cast Iron Crankshaft Nodular Iron Cylinder Head Cast Iron Combustio...

Page 739: ...ixture while guiding the engine bracket cushion and thru bolt into support cushion brackets Fig 5 4 Install thru bolt nuts and tighten the nuts to 102 N m 75 ft lbs torque 5 Lower the vehicle 6 Remove...

Page 740: ...intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Remove the distributor cap and wiring 22 Disconnect the heater hoses 23 Disconnect the power steering hoses i f equipped 24 Dis...

Page 741: ...the intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Using a new gasket install throttle body Tighten the throttle body bolts to 23 N m 200 in lbs torque 22 Connect the throttl...

Page 742: ...he engine dur ing or immediately after rocker arm installation Al low the hydraulic roller tappets adequate time to bleed down about 5 minutes 2 Install the push rods in the same order as re moved 3 I...

Page 743: ...uld be 1 78 3 00 microns 70 125 microinches Inspect push rods Replace worn or bent rods INSTALLATION 1 Apply Perfect Sealant No 5 or equivalent to both sides of the gasket Fig 5 2 Position the new cyl...

Page 744: ...m lock grooves to prevent damage to the valve guides Identify valves to ensure installation in original location VALVE CLEANING Clean valves thoroughly Discard burned warped and cracked valves Remove...

Page 745: ...ts the seat To do this coat valve seat LIGHTLY with Prussian blue then set valve in place Rotate the valve with light pressure If the blue is transferred to the center of valve face contact is satisfa...

Page 746: ...guide DO NOT force seal against top of guide When installing the valve retainer locks compress the spring only enough to install the locks 11 Follow the same procedure on the remaining 5 cylinders usi...

Page 747: ...nder block is scored scuffed or shows signs of sticking ream the bore to next oversize Replace with oversize tappet CAUTION The plunger and tappet bodies are not interchangeable The plunger and valve...

Page 748: ...emove vibration damper 7 Remove fuel lines refer to Group 14 Fuel Sys tem 8 Loosen oil pan bolts and remove the front bolt at each side 9 Remove the cover bolts 10 Remove chain case cover and gasket u...

Page 749: ...surfaces of chain case cover and cylinder block are clean and free from burrs The water pump mounting surface must be cleaned INSTALLATION 1 Using a new cover gasket carefully install chain case cove...

Page 750: ...Tool 6635 Fig 6 Seat the oil seal in the groove of the tool 6 Position the seal and tool onto the crankshaft Fig 7 7 Using the vibration damper bolt tighten the bolt to draw the seal into position on...

Page 751: ...istributor drive gear Fig 12 Fig 12 Camshaft Holding Tool C 3509 Installed Position 3 Hold tool in position with a distributor lock plate bolt This tool will restrict camshaft from being pushed in too...

Page 752: ...nto the bore 2 Drive bushing and tool into position using a hammer Fig 15 Fig 15 Distributor Driveshaft Bushing Installation 3 As the burnisher is pulled through the bushing the bushing is expanded ti...

Page 753: ...9309 78 SLOT J9209 106 Fig 2 Position of Dowels in Cylinder Block 6 Install the oil pan bolts Tighten the bolts to 24 N m 215 in lbs torque 7 Remove the dowels Install the remaining oil pan bolts Tigh...

Page 754: ...ified clearance between the piston and the cylin der wall is 0 013 0 038 mm 0 0005 0 0015 inch Piston diameter should be measured at the top of skirt 90 to piston pin axis Cylinder bores should be mea...

Page 755: ...he ring compressor make sure the oil ring expander ends are butted and the rail gaps located properly Fig 5 3 Immerse the piston head and rings in clean en gine oil Slide Piston Ring Compressor Tool C...

Page 756: ...d the installation of rear cap INSTALLATION 1 Lightly oil the new upper seal lips with engine oil 2 Install the new upper rear bearing oil seal with the yellow paint facing towards the rear of the en...

Page 757: ...should be selectively fitted while all other main bearing caps are properly tight ened All bearing capbolts removed during service procedures are to be cleaned and oiled before instal lation When inst...

Page 758: ...n bearing cap Fig 7 DO NOT over apply sealant or allow the sealant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant appli cation Be sure the yellow paint fac...

Page 759: ...ressure 1 Remove oil pressure sending unit from back of block 2 Insert a 3 175 mm 1 8 inch finish wire or equivalent into passage 3 Plug should be 192 0 to 195 2 mm 7 1 2 to 7 11 16 inches from machin...

Page 760: ...icted coolant flow can result and cause se rious engine problems 2 Using proper drive plug drive plug into hole The sharp edge of the plug should be at least 0 50 mm 0 020 inch inside the lead in cham...

Page 761: ...5 in Nos 2 3 and 4 0 0127 0 0508 mm 0 0005 0 0020 in Max Allowable Nos 2 3 4 0 0635 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 6...

Page 762: ...n Weight 592 6 596 6 grams 20 90 21 04 oz Piston Pins Clearance In Piston 0 00635 0 01905 mm 0 00025 0 00075 in In Rod Interference 0 0178 0 0356 mm 0 0007 0 0014 in Diameter 24 996 25 001 mm 0 9841 0...

Page 763: ...alve Overlap 31 J9409 98 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 m m 0 001 in RorM M 2 3 etc indicatin...

Page 764: ...Service Manual Oil Pan Bolts 23 N m 200 in lbs Oil Pan Drain Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs Rear Mount Support Cushion to Crossm...

Page 765: ...city 4 7L 5 0 Qts with Filter Cooling System Liquid Cooled Forced Circulation Ceding Capacity 16 1 L 17 0 Qts Cylinder Block Cast Iron Crankshaft Nodular Iron Cylinder Head Cast Iron Combustion Chambe...

Page 766: ...xture while guiding the engine bracket cushion and thru bolt into support cushion brackets Fig 5 4 Install thru bolt nuts and tighten the huts to 102 N m 75 ft lbs torque 5 Lower the vehicle 6 Remove...

Page 767: ...intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Remove the distributor cap and wiring 22 Disconnect the heater hoses 23 Disconnect the power steering hoses if equipped 24 Disc...

Page 768: ...nstall the intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Using a new gasket install throttle body Tighten the throttle body bolts to 23 N m 200 in lbs torque 22 Connect the t...

Page 769: ...Install rocker arm and pivot assemblies in the same order as removed Tighten the rocker arm bolts to 28 N m 21 ft lbs torque 4 Install cylinder head cover 5 Connect spark plug wires CYLINDER HEADS The...

Page 770: ...ds onto head gaskets and cylinder block 4 Starting at top center tighten all cylinder head bolts in sequence to 68 N m 50 ft lbs torque Fig 6 Repeat procedure tighten all cylinder head bolts to 143 N...

Page 771: ...mm 0 002 inch replace the valve Measure valve stem guide clearance as follows a Install Valve Guide Sleeve Tool C 3973 over valve stem and install valve Fig 7 The special sleeve places the valve at t...

Page 772: ...valve face raise valve seat with a 60 stone 4 When seat is properly positioned the width of intake seats should be 1 016 1 524 mm 0 040 0 060 inch The width of the exhaust seats should be 1 524 2 032...

Page 773: ...ad test vehicle HYDRAULIC TAPPETS Before disassembling any part of the engine to cor rect tappet noise check the oil pressure If vehicle has no oil pressure gauge install a reliable gauge at the press...

Page 774: ...1 Lubricate tappets 2 Install tappets and push rods in their original positions Ensure that the oil feed hole in the side of the tappet body faces up away from the crankshaft 3 Install aligning yokes...

Page 775: ...over and gasket using ex treme caution to avoid damaging oil pan gasket 11 Place a suitable tool behind the lips of the oil seal to pry the oil seal outward Be careful not to damage the crankshaft sea...

Page 776: ...r Silicone Rubber Adhe sive Sealant or equivalent at the joint between tim ing chain cover gasket and the oil pan gasket Finger tighten the timing chain cover bolts at this time 2 Place the smaller di...

Page 777: ...ghten the bolt to draw the seal into position on the crankshaft Fig 8 8 Remove the vibration damper bolt and seal in stallation tool 9 Install the vibration damper 10 Connect the negative cable to the...

Page 778: ...g 12 3 Hold tool in position with a distributor lock plate bolt This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block Tool sho...

Page 779: ...top dead center on the firing stroke 2 When in this position the timing mark on vi bration damper should be under 0 on the timing in dicator 3 Coat shaft and drive gear with engine oil In stall the s...

Page 780: ...ug Tighten drain plug to 34 N m 25 ft lbs torque 10 Install the engine to transmission strut 11 Install exhaust pipe 12 Lower vehicle 13 Install dipstick 14 Connect the negative cable to the battery 1...

Page 781: ...is Cylinder bores should be measured halfway down the cylinder bore and trans verse to the engine crankshaft center line Pistons and cylinder bores should be measured at normal room temperature 21 C 7...

Page 782: ...ench part of Tool C 385 Be sure position of rings does not change during this operation 4 Install connecting rod bolt protectors on rod bolts the long protector should be installed on the numbered sid...

Page 783: ...ock 4 Lightly oil the new lower seal lips with engine oil 5 Install the new lower rear bearing oil seal into the bearing cap with the yellow paint facing towards the rear of the engine 6 Apply 5 mm 0...

Page 784: ...3059 3 Install the bearing caps Clean and oil the bolts Tighten the capbolts to 115 N m 85 ft lbs torque 4 Install the oil pump 5 Install the oil pan CRANKSHAFT REAR OIL SEALS The service seal is a 2...

Page 785: ...g Fig 8 Ap ply enough sealant until a small amount is squeezed out Withdraw nozzle and wipe excess sealant off the oil pan seal groove 14 Immediately install the oil pan LOWER SEAL REPLACEMENT 1 Remov...

Page 786: ...f location remove oil pan and rear main bearing cap Use suitable flat dowel to remove plug Coat outside diameter of plug with Mopar stud and bearing mount adhesive or equivalent Plug should be 54 0 to...

Page 787: ...embly 2 Install the oil pan 3 Install the cylinder head 2 Using proper drive plug drive plug into hole 4 I n g t a l l t h e e n g i n e i n t o t h e v e hicle The sharp edge of the plug should be at...

Page 788: ...No 1 0 0127 0 0381 mm 0 0005 0 0015 in Nos 2 3 4 and 5 0 0 1 2 7 0 0 5 0 8 mm 0 0 0 0 5 0 0 0 2 0 in Max Allowable Nos 2 3 4 5 0 0 6 3 5 mm 0 0 0 2 5 in End Play 0 051 0 178 mm 0 0 0 2 0 0 0 7 in M a...

Page 789: ...Weight 592 6 596 6 grams 20 90 21 04 oz Piston Pins Clearance In Piston 0 00635 0 01905 mm 0 00025 0 00075 in In Rod Interference 0 0178 0 0356 mm 0 0007 0 0014 in Diameter 24 996 25 001 mm 0 9841 0...

Page 790: ...50 Valve Overlap 3 1 0 J9409 99 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDINTlflCATlON LOCATION OF 1PINTIMCATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in RorM M 2 3 etc indi...

Page 791: ...Pan Bolts 23 N m 200 in lbs Oil Pan Drain Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs DESCRIPTION TORQUE Rear Mount Support Cushion to Crossme...

Page 792: ...tion system consists of a rotor type oil pump and a full flow oil filter The cylinders are numbered from front to rear 1 3 5 7 on the left bank and 2 4 6 8 on the right bank The firing order is 1 8 4...

Page 793: ...ixture while guiding the engine bracket cushion and thru bolt into support cushion brackets Fig 5 4 Install thru bolt nuts and tighten the nuts to 102 N m 75 ft lbs torque 5 Lower the vehicle 6 Remove...

Page 794: ...e the intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Remove the distributor cap and wiring 22 Disconnect the heater hoses 23 Disconnect the power steering hoses i f equipped 2...

Page 795: ...Install the intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Using a new gasket install throttle body Tighten the throttle body bolts to 23 N m 200 in lbs torque 22 Connect the...

Page 796: ...tall rocker arm and pivot assemblies in the same order as removed Tighten the rocker arm bolts to 28 N m 21 ft lbs torque 4 Install cylinder head cover 5 Connect spark plug wires CYLINDER HEADS The al...

Page 797: ...tween the valves and piston could occur 4 Install push rods and rocker arm assemblies in their original position Tighten the bolts to 28 N m 21 ft lbs torque 5 Install the intake manifold and throttle...

Page 798: ...g measured Fig 7 Fig 7 Measuring Valve Guide Wear c Move valve to and from the indicator The to tal dial indicator reading should not exceed 0 432 mm 0 017 inch Ream the guides for valves with oversiz...

Page 799: ...dth of the exhaust seats should be 1 524 2 032 mm 0 060 0 080 inch WALVE SPUING INSPECTION Whenever valves have been removed for inspection reconditioning or replacement valve springs should be tested...

Page 800: ...ther of these 2 conditions could be responsible for noisy tappets OIL LEVEL HIGH If oil level is above the FULL mark it is possible for the connecting rods to dip into the oil With the engine running...

Page 801: ...ect a solid tappet 3 Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular as pos sible Zero the indicator 4 Rotate the crankshaft clockwise normal run ning direct...

Page 802: ...shaft to prevent rotation 3 Hold a scale with dimensional reading even with the edge of a chain link With cylinder heads in stalled apply 14 N m 30 ft lbs torque in the re verse direction With the cyl...

Page 803: ...l on Installation Tool 6635 3 Position the seal and tool onto the crankshaft Fig 7 4 Using the vibration damper bolt tighten the bolt to draw the seal into position on the crankshaft Fig 8 5 Tighten c...

Page 804: ...camshaft has an integral oil pump and distrib utor drive gear Fig 9 THRUST PLATE OIL PUMP A N D DISTRIBUTOR DRIVE GEAR INTEGRAL WITH CAMSHAFT CAMSHAFT SPROCKET J9309 71 Fig 9 Camshaft and Sprocket As...

Page 805: ...ould be flat against thrust plate in order to catch oil for chain lubrication 5 Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line throu...

Page 806: ...oil dipstick 3 Raise vehicle 4 Drain engine oil 5 Remove exhaust pipe 6 Remove left engine to transmission strut 7 Loosen the right side engine support bracket cushion thru bolt and raise the engine...

Page 807: ...5 main bearing cap Finger tighten pump attaching bolts Tighten attaching bolts to 41 N m 30 ft lbs torque 3 Install the oil pan PISTON CONNECTING ROD ASSEMBLY The pistons are elliptically turned so t...

Page 808: ...0 0 050 inch c Rings with insufficient end gap may be prop erly filled to the correct dimension Rings with ex cess gaps should not be used 2 Install rings and confirm ring side clearance a Install oil...

Page 809: ...f the connecting rod bore must be installed toward crankshaft journal fillet 8 Install rod caps Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N m 45 ft lbs torque 9 Install the oi...

Page 810: ...l all cap bolts Install all main bearing caps Install all cap bolts and alternately tighten to 115 N m 85 ft lbs torque 9 Install oil pump 10 Install the timing chain cover 11 Install the vibration da...

Page 811: ...s 3 Lightly oil the new upper seal lips with engine oil 4 Install the new upper rear bearing oil seal with the yellow paint facing towards the rear of the en gine 5 Position the crankshaft into the cy...

Page 812: ...e oil 7 Install a new lower seal in bearing cap with yellow paint facing the rear of engine 8 Apply 5 mm 0 20 in drop of Loctite 515 or equivalent on each side of the rear main bearing cap Fig 7 DO NO...

Page 813: ...t idle REMOVAL 1 Using a blunt tool such as a drift or a screw driver and a hammer strike the bottom edge of the cup plug Fig 13 2 With the cup plug rotated grasp firmly with pliers or other suitable...

Page 814: ...learance No l 0 0127 0 0381 mm 0 00 5 0 0015 in Max Alb able No l 0 0381 mm 0 0015 in Nos 2 3 4 and 5 0 0127 0 0508 mm 0 0005 0 0020 in Max Allowable Nos 2 3 4 5 0 0635 mm 0 0025 in End Play 0 051 0 1...

Page 815: ...iston Pins Clearance In Piston 0 006 0 019 m m 0 00023 0 00074 in Diameter 25 007 25 015 m m 0 9845 0 9848 in End Play NONE Length 67 8 68 3 m m 2 67 2 69 in Piston Rings Ring Gap Compression Ring Top...

Page 816: ...9 1 0 0 O V E R S I Z E AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION 0 025 mm 0 001 inch U S Crankshaft R o r M M 2 3 etc Indicating No 2 3 main bearing...

Page 817: ...Procedure in Service Manual Oil Pan Bolts 23 N m 200 in lbs Oil Pan Drain Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs DESCRIPTION TORQUE Rear...

Page 818: ...Cast Aluminum Alloy Connecting R o d s Forged Steel J9409 3 Fig 1 Engine Description This engine is designed for unleaded fuel Engine lubrication system consists of a gerotor type oil pump mounted in...

Page 819: ...cushion and heat shields to the block Install new bolts and tighten to 81 N m 60 ft lbs torque 2 Install the thru bolt into the engine support bracket cushion 3 Lower engine with support lifting fixt...

Page 820: ...iator overflow bottle 11 Disconnect the top radiator hose 12 Remove the fan 13 Remove the fan shroud 14 Disconnect the lower radiator hose 15 Remove radiator refer to Group 7 Cooling System 16 Remove...

Page 821: ...nnect the fuel lines 16 Connect the transmission cooler lines 17 Connect the power steering hoses if equipped 18 Connect the heater hoses 19 Remove the coil assemblies with the ignition cables 20 Inst...

Page 822: ...em and Intake Man ifold 4 Install closed crankcase ventilation system and evaporation control system onto the proper head cover DO NOT switch the systems 5 Connect the negative cable to the battery RO...

Page 823: ...NE J9414 55 Fig 6 Coil Pack and Bracket 12 Disconnect the coil wires 13 Disconnect heat indicator sending unit wire 14 Disconnect heater hoses and bypass hose 15 Remove upper intake manifold and throt...

Page 824: ...hten the bolts to 28 N m 21 ft lbs torque 5 Install the side intake manifold gaskets Be sure that the locator dowels are positioned in the head Fig 8 INTAKE MANIFOLD GASKETS LOCATOR DOWELS J9409 64 Fi...

Page 825: ...ue 24 Place the cylinder head cover gaskets in posi tion tab marked TOP facing you and install cylinder head covers Tighten the bolts to 16 N m 144 in lbs torque 25 Install closed crankcase ventilatio...

Page 826: ...t exceed 0 432 mm 0 017 inch Ream the guides for valves with oversize stems if dial indicator reading is excessive or i f the stems are scuffed or scored Service valves with oversize stems are availab...

Page 827: ...by 2 This will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Re fer to specifications to obtain specified height and al lowable tensions...

Page 828: ...en oil level and leaks have been corrected engine should be operated at fast idle for sufficient time This allows all of the air inside of the tappets to be bled out TAPPET NOISE DIAGNOSIS 1 To determ...

Page 829: ...down giving in effect a solid tappet 3 Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular as pos sible Zero the indicator 4 Rotate the crankshaft clockwise norm...

Page 830: ...ith a torque applied to the camshaft sprocket bolt crankshaft should not be permitted to move It may be necessary to block the crankshaft to prevent rotation 3 Hold a scale with dimensional reading ev...

Page 831: ...S H A F T This procedure requires that the engine is removed from the vehicle REMOVAL 1 Remove cylinder head covers 2 Remove rocker arm assemblies 3 Remove push rods and tappets Identify each part so...

Page 832: ...he timing chain cover 14 Install the crankshaft pulley damper 15 Install the intake manifolds 16 Install the cylinder head covers OIL PAN REMOWAL 1 Disconnect the negative cable from the battery 2 Rai...

Page 833: ...crankcase with oil to proper level OIL PUMP REMOVAL 1 Remove the timing chain cover 2 Remove the relief valve plug gasket spring and valve Fig 4 Discard the gasket PLUG TIMING Fig 4 Oil Pressure Relie...

Page 834: ...between inner and outer rotors is 0 150 mm 0 006 inch or more replace both rotors Place a straightedge across the face of the timing chain cover pump body between bolt holes Fig 11 If a feeler gauge...

Page 835: ...l inder block Be sure to keep tops of pistons covered during this operation 5 Be sure the connecting rod and connecting rod cap are identified with the cylinder number Remove connecting rod cap Instal...

Page 836: ...t journals should be held to 0 025 mm 0 001 inch Bearings are available in 0 025 mm 0 001 inch 0 051 mm 0 002 inch 0 076 mm 0 003 inch 0 254 mm 0 010 inch and 0 305 mm 0 012 inch under size Install th...

Page 837: ...WER MAIN BEARINGS CRANKSHAFT UPPER MAIN BEARINGS J9409 72 Fig 15 Main Bearing Identification INSTALLATION 1 Lubricate crankshaft main bearings with clean engine oil 2 Install the crankshaft into the c...

Page 838: ...lowly rotate crankshaft counterclockwise slid ing the bearing into position Remove Tool C 3059 3 Lubricate the main journals with clean engine oil Install main bearing caps and bolts Follow the 2 step...

Page 839: ...NGINE CORE OIL CAMSHAFT PLUGS Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate This will reduce internal leakage and help maintain higher oil pressure at idl...

Page 840: ...er 53 950 53 975 mm 2 124 2 125 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Crankshaft Cant Main Bearing Diametrical Clearance No l No 6 0 0 51 0 058 mm 0 0002 0 0023 in Max Al...

Page 841: ...0218 in In Rod Interference 0 018 0 061 mm 0 0007 0 0024 in Diameter 24 996 25 001 mm 0 9841 0 9843 in End Play NONE Length 67 818 68 326 mm 2 670 2 690 in Piston Rings Ring Gap Compression Rings 0 25...

Page 842: ...69 405 N 41 66 mm 81 89 lbs 1 640 in Valve Open 865 956 N 30 89 mm 190 210lbs 1 216in Number of Coils 6 79 Wire Diameter 4 496 mm 0 177 in Valve Timing Exhaust Valve degrees Closes ATC 25 Opens BBC 60...

Page 843: ...c Tappet Yoke Retaining 22N m 16ft lbs Intake Manifold Bolts Lower 54N m 40ft lbs Description Torque Intake Manifold Bolts Upper 22 N m 16 ft lbs Oil Filter 9 N m 80 in lbs 45 Oil Filter Connector 46...

Page 844: ...107 Fig 2 Firing Order ENGINE FRONT MOUNTS REMOVAL 1 Disconnect the negative cable from the battery 2 Position fan to assure clearance for radiator top tank and hose 3 Install engine support lifting...

Page 845: ...5 Remove the bolts holding the support cushion to the transmission support bracket Remove the sup port cushion 6 I f necessary remove the bolts Holding the transmission support bracket to the transmis...

Page 846: ...emove the fan shroud 14 Disconnect the lower radiator hose 15 Remove radiator refer to Group 7 Cooling System 16 Remove the generator Fig 7 with the wire connections refer to Group 8B Battery Starter...

Page 847: ...the engine off of the stand 4 Position the engine in the chassis with the thru bolt installed 5 Remove the covers or tape covering the engine openings 6 Remove the jack stand from under the auto matic...

Page 848: ...the rocker lever shaft and pedestal The pedestal and shaft must be replaced as an assembly 3 Remove the locknut and adjusting screw Fig 1 4 Clean all parts in a strong solution of laundry detergent i...

Page 849: ...s re fer to Group 14 Fuel System 7 Remove the valve covers 8 Remove the rocker levers and push rods 9 Remove the fuel filter water separator Fig 4 Refer to Group 14 Fuel System for the proper pro cedu...

Page 850: ...The combined total of stock removed must not exceed 1 00 mm 0 03937 inch The amount of stock removed each time must be steel stamped above combustion deck edge on the lower right hand Fig 7 Cylinder...

Page 851: ...the rocker lever pedestal bolts and tighten to 24 N m 18 ft lbs torque 9 Adjust the valve clearance 10 Install the valve covers Tighten the bolts to 24 N m 18 ft lbs torque 11 Install the injector noz...

Page 852: ...required re surface the tip WALWE GUIDES INSPECTION Inspect the valve guides for scuffing or scoring Measure the valve guide bore Fig 5 The bore di ameter should be 8 019 8 089 mm 0 3157 0 3185 inch...

Page 853: ...sion above the cylinder head Ream the bores to 8 029 0 010 mm 0 3161 0 0004 inch Fig 7 WALWE SPRINGS Measure the valve spring length The approximate free length is 55 63 mm 2 190 inch with the maxi mu...

Page 854: ...ated locations and measure the depth of each The valve depth limit In tegral and Inserted Seats is 0 99 mm to 1 52 mm 0 039 inch to 0 060 inch Replace the valve i f the depth is over this limit Apply...

Page 855: ...to center the seat on the valve face Maintain the valve seat within limits SERVICE VALVE SEAT REPLACEMENT To replace service seat inserts machine the insert in the same manner as i f machining out th...

Page 856: ...l Fig 18 The timing pin is located at the back of the gear housing and below the injection pump Be sure to disengage the timing pin after locating top dead center J 9 1 0 9 3 3 Fig 18 Locating TDC us...

Page 857: ...he camshaft Make sure the alignment marks on the camshaft and crankshaft gears are aligned Fig 2 Fig 2 Camshaft Crankshaft Gear Alignment 3 I f a new housing is installed the timing pin as sembly must...

Page 858: ...damage to the seal carrier hit the align ment installation tool alternately at the 12 3 6 and 9 o clock positions 10 Install the oil fill tube and mounting bolts Tighten the bolts to 43 N m 32 ft lbs...

Page 859: ...lve to zero lash plus 5 turns CAUTION Use extreme care when rotating the crankshaft Use of too much force could damage the valve or push rod Fig 9 7 Rotate the crankshaft slowly in the opposite di rec...

Page 860: ...r cover 22 Remove the pointer Install the crankshaft vi bration damper INSTALLATION CYLINDER HEAD OFF The timing pin assembly is precisely located on the gear housing to correspond to TDC for Cylinder...

Page 861: ...lowing the tappet to fall into the trough Fig 1 7 Normally the tappet will fall over when it drops into the trough Use a flashlight to determine this I f the tappet does not fall over shake the troug...

Page 862: ...13 Install the camshaft CAMSHAFT REMOVAL 1 Remove the following parts Valve covers Rocker lever assemblies Push rods Drive belt Fan hub assembly Vibration damper Gear housing cover Lift pump 2 Insert...

Page 863: ...block 3 Remove the bushing from the No l bore using a universal cam bushing tool 4 Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing CAMSHAFT...

Page 864: ...ce 6 Install the following parts Lift pump Gear housing cover Vibration damper Fan hub assembly Drive belt Push rods Rocker lever assemblies Valve covers 7 Install the engine in the vehicle 8 Operate...

Page 865: ...TOP OF BLOCK J9109 124 Fig 5 Cylinder Bore Crosshatch Pattern 5 Use a drill a fine grit Flex hone and a mixture of equal parts of mineral spirits and SAE 30W engine oil to de glaze the bores 6 The C r...

Page 866: ...R Cylinder bore s can be repaired by one of two methods Method 1 Over boring and using oversize pistons and rings Method 2 Boring and installing a repair sleeve to return the bore to standard dimensio...

Page 867: ...ing bar to bore out the old sleeve DO NOT cut the cyl inder bore beyond the oversize limit BLOCK REBORE FOR REPAIR SLEEVE BORE DIA 104 500 0 015 mm 4 1142 0 0006 inch STEP DIM 6 35 mm 0 25 inch J9109...

Page 868: ...ining Dimensions A standard diameter piston and a piston ring set must be used with a sleeved cylinder bore CAM BORE REPAIR The front cam bushing bore can be bored to 57 740 Mm 0 018 mm 2 273 inch 0 0...

Page 869: ...ston 7 Remove the connecting rod bolts and rod caps Use care so the cylinder bores and connecting rods are not damaged 8 Use a hammer handle or similar object to push the piston and connecting rod thr...

Page 870: ...m eter is 40 025 mm 1 5758 inch I f the bore is over limits replace the piston Inspect the piston pin for nicks gouges and exces sive wear Measure the pin diameter Fig 5 The minimum diameter is 39 990...

Page 871: ...in the slot to the cap Use clean lubricating oil to coat the inside diam eter of the bearing shell 4 The four digit number stamped on the connect ing rod and cap at the parting line must match and be...

Page 872: ...dentification 6 Use a feeler gauge to measure the piston ring gap Fig 11 J9109 70 Fig 10 Position of Ring in Cylinder Bore 7 The top surface of all of the rings are identified with the word TOP or the...

Page 873: ...97 in 0 750 mm 0295 in 1 000 mm 0394 in Fig 15 Connecting Rod Bearing Size Location INSTALLATION 1 Lubricate the cylinder bore with clean engine oil 2 Generously lubricate the rings and piston skirts...

Page 874: ...installed If the crankshaft does not rotate freely check the installa tion of the rod bearing and the bearing size 12 Measure the side clearance between the con necting rod and the crankshaft Fig 19...

Page 875: ...haft main and rod journals may be ground in increments of 0 25 mm 0 0098 inch up to a total of 1 00 mm 0 0394 inch The only exception is the main journal thrust width surface This journal must be grou...

Page 876: ...lend a 4 20 0 020 mm 0 1654 0 0008 inch radius to the ground diameters Fig 8 CAUTION DO NOT use the Alternative Procedure when the thrust surface width is ground ALTERNATIVE PROCEDURE Smoothly blend a...

Page 877: ...1 The sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks JOURNAL SURFACE SURFACE FINISH 0 8 micrometer 32 0 microinch for a minimum of 45 into the fillet beyond...

Page 878: ...t seal leaks 2 Assemble the rear seal housing and gasket to the cylinder block with the bolts 3 Align the seal housing to the crankshaft with the alignment tool provided in the seal kit Fig 14 Make su...

Page 879: ...r O D use Loctite 277 or equivalent sealant 4 Use the alignment tool to install the seal to the correct depth in the housing Use a hammer to drive the seal into the housing until the alignment tool st...

Page 880: ...f the journal Calculate the main bearing journal to bearing clearance the clearance specifications are 0 119 mm 0 00475 inch I f the crankshaft journal is within MIN 82 962 mm 3 2662 inch MAX 83 103 m...

Page 881: ...ls 7 Install the lower main bearings in the caps 8 Lubricate the bearings with Lubriplate or equivalent 9 Numbers on the main bearings caps face the oil cooler side of the engine with number one at th...

Page 882: ...sealing washer and tighten to 80 N m 60 ft lbs torque 6 Install the engine assembly into the vehicle 7 Fill the engine with clean lubrication oil refer to Group 0 Lubrication and Maintenance Run the...

Page 883: ...0 080 0 380 mm 0 003 0 015 inch If the backlash is out of limits replace the oil pump Install the back plate OIL PUMP J9109 24 Fig 7 Measure Gear Backlash INSTALLATION 1 Lubricate the pump with clean...

Page 884: ...eal ing surface before installing the filter CAUTION Mechanical over tightening may distort the threads or damage the filter element seal 3 Install the filter as specified by the filter man ufacturer...

Page 885: ...ot be used on intercooled engines REMOVAL 1 Drain the cooling system refer to Group 7 Cooling System for the proper procedures 2 Remove the oil filter 3 Clean around the oil cooler cover 4 Disconnect...

Page 886: ...2 mm 0 0295 in 2 6855 in Machined 1 00 mm 67 962 mm 0 0394 in 2 6757 in Out of Round Max 0 050 mm 0 002 in Taper Max 0 013 mm 0 0005 in Oil Clearance 0 089 mm 0 0035 in End Clearance 0 100 0 430 mm 0...

Page 887: ...si Pistons Skirt Diameter 101 880 101 823 mm 4 0110 4 0088 in Ring Groove Depth Intermediate 0 150 mm 0 006 in Oil Control 0 130 mm 0 005 in 39 990 mm 1 5744 in 40 025 mm 1 5758 in Piston Pins Diamete...

Page 888: ...1 N m 95in lbs 137 N m 101 ft lbs 77 N m 57 ft lbs 102 N m 75 ft lbs 41 N m 30 ft lbs 41 N m 30ft lbs 80N m 59ft lbs 24N m 18ft lbs 24N m 18ft lbs 24N m 18ft lbs 24 N m 18 ft lbs Intercooler Attaching...

Page 889: ......

Page 890: ...de signed to last the life of the vehicle Excessive heat can result in bulging or other distortion but exces sive heat will not be the fault of the converter If un burned fuel enters the converter ove...

Page 891: ...r is used to force more air into the engine cylinders Exhaust gas energy is used to turn the turbine wheel and shaft At the other end of the shaft is the compressor wheel The compressor wheel draws ai...

Page 892: ...mps at leaking joints 2 Replace muffler assembly Check exhaust system 3 Replace exhaust pipe 4 Tighten connection attaching nuts 5 Replace exhaust manifold 6 Tighten exhaust manifold to cylinder head...

Page 893: ...s will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels page Exhaust Tailpipe 6 Intake Manifold V 10 Engine 9 Intake Manifold V 6 and V 8 Engines 6 Mu...

Page 894: ...ft lbs torque 4 Lower the vehicle 5 Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels Adjust the alignment i f needed MUFFLERS REMOVAL 1 Raise and support...

Page 895: ...t proper alignment of all parts 2 Connect the support hangers Fig 6 and 7 3 Position the exhaust tailpipe and extension pipe if used for proper clearance with the underbody parts 4 Tighten all clamp n...

Page 896: ...rail must be clean and dry free of all foreign material INSPECTION Inspect manifold for cracks Inspect mating surfaces of manifold for flatness with a straightedge INSTALLATION 1 Install the plenum pa...

Page 897: ...ows V 6 ENGINE Fig 5 Step 1 Tighten bolts 1 and 2 to 8 N m 72 in lbs torque Tighten in alternating steps 1 4 N m 12 in lbs torque at a time Step 2 Tighten bolts 3 through 12 in sequence to 8 N m 72 in...

Page 898: ...hrottle body to the plenum cham bers REMOVAL 1 Disconnect the negative cable from the battery 2 Drain the cooling system refer to Group 7 Cooling System for the proper procedures 3 Remove the accessor...

Page 899: ...ad Fig 12 2 Insert two dowels into the locator holes Peel the protective paper off and align the seal with the sticky side down Press firmly onto the block Fig 13 Repeat for the other end Front seal i...

Page 900: ...t the negative cable from the battery 2 Raise and support the vehicle 3 Remove the bolts and nuts attaching the ex haust pipe to the engine exhaust manifold 4 Lower the vehicle 5 Remove the exhaust he...

Page 901: ...NSPECTION Inspect manifold for cracks Inspect mating surfaces of manifold for flatness with a straight edge Gasket surfaces must be flat within 0 2 mm per 300 mm 0 008 inch per foot INSTALLATION 1 Usi...

Page 902: ...gers Fig 2 Align the exhaust pipe with the turbocharger exhaust pipe and the catalytic converter Install the bolts and nuts Tighten the nuts to 34 N m 25 ft lbs torque page Exhaust Tailpipe 14 Intake...

Page 903: ...nent with original equipment parts or equivalent This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels INSTALLATION 1 Connect the support hanger...

Page 904: ...bracket and install the nuts or bolts 2 Tighten the nuts and bolts 3 Lower the vehicle ENGINE EXHAUST MANIFOLD REMOVAL 1 Disconnect the air intake and exhaust pipes Fig 6 2 Disconnect the turbocharger...

Page 905: ...eater and gas kets Fig 11 Clean the mounting surface of the in take manifold cover 5 Disconnect the charge air temperature sensor from the intake manifold cover Fig 12 6 Disconnect the air temperature...

Page 906: ...ressure fuel line nuts to 24 N m 18 ft lbs torque TURBOCHARGER REMOVAL 1 Disconnect the negative cable from the battery 2 Disconnect the air intake pipe and exhaust pipe Fig 14 Fig 14 Air Intake Pipe...

Page 907: ...ssive wear 12 Remove the oil baffle Fig 19 13 Remove the thrust bearing and retainer screws Fig 19 Do not reuse the thrust bearing 14 Remove the thrust collar Fig 19 15 Inspect the collar for excessiv...

Page 908: ...use compressed air to dry the parts INSPECTION In addition to the inspection specified during disas sembly inspect all parts after cleaning J9111 14 Fig 22 Snap Rings and Shaft Bearing Measure the sha...

Page 909: ...pe Seal 12 Mark the top surface of the oil slinger line with the balance mark 13 Lubricate the oil slinger with engine oil and install it into the diffuser 14 Install the O ring into the diffuser 15 I...

Page 910: ...ger with a serial number of 840638 and after the end play should be 0 026 0 076 mm 0 001 0 003 inch 25 Measure radial clearance of the shaft Fig 33 The clearance should be 0 300 0 460 mm 0 012 0 018 i...

Page 911: ...ess wastegate assembly is damaged CAUTION DO NOT adjust the wastegate so that higher pressures are required to open the waste gate valve The turbocharger speed will be in creased and can cause damage...

Page 912: ...move the nuts holding the condenser to the charge air cooler intercooler Fig 37 Lift the condenser and sealing plate assembly away from the charge air cooler intercooler 4 Remove the inlet and outlet...

Page 913: ...Bolts Nuts 26 N m 19 ft lbs Fuel Heater Ground Bolt 12 N m 110 in lbs Fuel Line Nuts 24 N m 18 ft lbs Generator Mounting Bolt 41 N m 30 ft lbs Intake Manifold Capbolts Refer to Procedure in Service Ma...

Page 914: ...ve nuts and stud plates holding front bumper to end of frame rail 4 Disengage wire connectors from horns 5 Separate front bumper from vehicle INSTALLATION Reverse the preceding operation FRONT BUMPER...

Page 915: ...bottom of front bumper 2 Remove screws holding air dam to bottom of front bumper 3 Separate air dam from vehicle BUMPER AIR DAM SCREW J9413 4 Fig 4 Front Bumper Air Dam SKID PLATE REMOVAL FIG 5 1 Hois...

Page 916: ...le INSTALLATION Reverse the preceding operation REAR BUMPER REMOWAL FIG 7 1 Support rear bumper on a suitable lifting de vice 2 Remove bolts holding rear bumper braces to frame rails 3 Disengage licen...

Page 917: ...on a suitable lifting de vice 2 Remove fasteners holding trailer wiring connec tor to trailer hitch if equipped 3 Remove bolts holding trailer hitch to frame rails 4 Separate trailer hitch from vehic...

Page 918: ...Hinge Pins Allows the A Frame to pivot up and down The pins act as moldboard attaching points Cutting Edge Replaceable blade edge extends the life of the blade Runners Adjustable runners retain the c...

Page 919: ...It prevents fluid in the lift cylinder from leaking back through solenoid valve B If fluid leaks back it could angle the blade to the left This would force fluid through solenoid valve C into the rig...

Page 920: ...H 0 0 IGNITION SWITCH ANGLE TAN R E D ORANGE WITH WHITE TRACER LIGHT GREEN n n FUSE BATTERY O SOLENOID SWITCH MOTOR ENERGIZED MOTOR A N D B COIL C SOLENOID ANGLING CYLINDER B OPERATING PRESSURE EXHAUS...

Page 921: ...ANGE WITH F U S E WHITE TRACER LIGHT GREEN MOTOR _L BATTERY t o SOLENOID SWITCH ENERGIZED A COIL C SOLENOID POWER ANGLING CYLINDER LOWER A N D FLOAT FORCE APPLIED AGAINST LIFT RAM OPERATING PRESSURE E...

Page 922: ...LACK SWITCH o o RAISE A N D LOWER 0 TT TAN ORANGE WITH WHITE TRACER IGNITION SWITCH t ORANGE WITH FUSE WHITE TRACER jf_ BATTERY ENERGIZED MOTOR A N D C COIL Fig 4 Angle Blade Right Voltage Application...

Page 923: ...O O RAISE AND LOWER O ORANGE WITH WHITE TRACER TAN RED 6 f SWITCH j ORANGE WITH WHITE TRACER 5 ANGLE LIGHT GREEN P q FUSE IGNITION SWITCH BATTERY MOTOR SOLENOID SWITCH ENERGIZED MOTOR Fig 5 Angle Blad...

Page 924: ...rative solenoid switch d Malfunctioning control switch e Malfunctioning motor a No voltage at A coil b A cartridge jammed in closed position c Inoperative A coil a Leaking A cartridge b Leaking A cart...

Page 925: ...DOWN UP DOWN PLOW CONTROL SWITCH UP DOWN Dl 18RD YL SP4 18WT BR SP4 18WT BR PLOW CONTROL SWITCH LEFT TO RIGHT SP4 18WT BR D l 18RD YL TRANSMISSION OIL TEMPERATURE LAMP SP4 18WT BR SP4 18WT BR SP4 18W...

Page 926: ...RD fW SNOW PLOW DOWN SOLENOID FRONT SNOW PLOW FRAME SNOW PLOW RIGHT SOLENOID FRONT SNOW PLOW FRAME TRANSMISSION OIL TEMPERATURE LAMP TRANSMISSION OIL H H L TEMPERATURE SWITCH RIGHT SIDE BELOW RADIATOR...

Page 927: ...FRONT END WIRING SEE SH 22 BLACK BLACK BLACK RIGHT SIDE RADIATOR YOKE PANEL BLACK RIGHT UPPER SNOW PLOW FRAME BLACK LEFT AUXILIARY PARK AND TURN SIGNAL LAMP LEFT AUXILIARY HEADLAMP RIGHT AUXILIARY HE...

Page 928: ...Fig 9 Clean the solenoid valve Inspect it for external damage 23 Disassemble the three way valve Fig 9 Dis card the O ring seal 24 Remove and clean solenoid valve C with spe cial tool J 25399 Fig 9 In...

Page 929: ...Acorn N ut 25 Stud 26 Brass Washer 27 2 Way Solenoid 28 2 Way Coil 29 2 Way Valve 30 Base and Strainer 31 Valve Block 32 Socket Head Cap Screw 33 Filter 34 Plug 35 Strainer 36 Check Valve Retainer 37...

Page 930: ...BUMPERS AND FRAME 13 17...

Page 931: ...G RETAINER SPRING INSERT VALVE O RING BRASS NUT COIL LOCK NUT O RINGS VALVE CARTRIDGE SNAP RING O RINGS O RING NOTE NYLON WASHERS A N D O RINGS SHOULD TAPER DOWN TO VALVE SHAPE FROM VALVE DOWN NYLON W...

Page 932: ...Remove the nuts washers and bolts that attach the snow plow frame to the vehicle frame side rails and front crossmember Fig 15 5 Remove the snow plow frame and support from the front of the vehicle f...

Page 933: ...s aligned Fig 16 2 Install the pivot bracket attaching bolts wash ers and nuts finger tight Fig 16 3 Install the support strap attaching bolts and nuts Fig 15 Tighten the nuts to 68 N m 50ft lbs torqu...

Page 934: ...e switches in the switch cover openings Install the lock washers ring washers and nuts Fig 18 Tighten the nuts with 5 N m 45 in lbs torque 3 Insert the lamp holders in the switch cover openings Connec...

Page 935: ...45 Amperes Speed Min 10 000 rpm Under Load pump operating CAUTION Do not operate motor continuously for more than 5 seconds Applied Voltage 12 Volts DC Max Current 230 Amperes HYDRAULIC SPECIFICATIONS...

Page 936: ...not drill holes in top or bottom frame rail flanges frame rail failure can result Do Not use softer than Grade 3 bolts to replace production fasteners loosening or failure can re sult When using heat...

Page 937: ...in accessible frame com ponents perform the following procedures 1 Drill a hole at each end of the crack with a 3 mm 0 125 in diameter drill bit 2 Using a suitable die grinder with 3 inch cut off whe...

Page 938: ...99 76 ALL DIMENSIONS ARE SHOWN IN INCHES r 12 54 4 r 17 8S I _ r 27 23 REAR SPRING HANGER B R 1500 and 2500 119 and 135 WHEELBASE REAR WHEEL DRIVE DOWN BRKT REAR TRANS C MEMBER SPRING HANGER REAR FRA...

Page 939: ...ALL DIMENSIONS ARE SHOWN IN INCHES REAR FRAME SECTION Fig 5 BR 1500 and 2500 Four Wheel Drive J9413 16...

Page 940: ...BUMPERS AND FRAME 13 27 3565 75 7 9 3 4 REAR WHEELS ALL DIMENSIONS ARE SHOWN IN INCHES REAR FRAME SECTION Fig 6 BR 3500 Rear Wheel Drive J9413 17...

Page 941: ...28 BUMPERS AND FRAME ALL DIMENSIONS ARE SHOWN IN INCHES B R 3500 135 139 andl63 WHEELBASE FOUR WHEEL DRIVE REAR FRAME SECTION Fig 7 BR 3500 Four Wheel Drive J9413 18...

Page 942: ...nd die sel engines will be referred to as HDC Heavy Duty Cycle engine Either of the HDC gas powered engines can be eas ily identified by the use of an engine mounted air in jection pump The 3 9L 5 2L...

Page 943: ...cosol vents Problems that are the result of using methanol gas oline blends are not the responsibility of Chrysler Corporation They may not be covered by the vehicle warranty MTBE ETBE Gasoline and MT...

Page 944: ...The fuel pump module on all gas powered engines is installed in the top of the fuel tank Fig 1 The fuel pump module Figs 1 or 2 contains the follow ing A combination fuel filter fuel pressure regulato...

Page 945: ...connector should all be pointed to the drivers side of the vehicle before tightening locknut 2 Position new locknut over top of fuel pump module 3 Tighten locknut 4 Install fuel tank Refer to Fuel Tan...

Page 946: ...r regulator is pressed into a rubber grommet Remove by twisting and pulling straight up Fig 5 CAUTION Do not pull the filter regulator more than three inches from the fuel pump module Damage to the co...

Page 947: ...le 2 Remove the fuel tank filler tube cap to release fuel tank pressure 3 Remove unscrew the protective plastic cap from the pressure test port on the fuel rail Fig 9 On the 8 0L V 10 engine this test...

Page 948: ...sing before tool connection 3 Connect Fuel Line Pressure Test Adapter Tool number 6631 3 8 in or number 6539 5 16 in into the disconnected fuel supply line tube Insert the other end of Adapter Tool 66...

Page 949: ...d fittings to make sure they are secure and leaks are not present The component should be re placed immediately if there is any evidence of degra dation that could result in failure Never attempt to r...

Page 950: ...d fuel system component for damage Replace as necessary 9 Prior to connecting the quick connect fitting to component being serviced check condition of fitting and component Clean the parts with a lint...

Page 951: ...system compo nent being serviced The plastic retainer will remain on the component being serviced after fitting is dis connected The O rings and spacer will remain in the quick connect fitting connect...

Page 952: ...to disconnect fitting Use an open end wrench on the shoulder of the plastic retainer ring to aid in disconnection After disconnection the plastic retainer ring will remain with the quick connect fitt...

Page 953: ...odule Diesel Engine 12 Fuel Transfer Pump 15 Fuel Transfer Pump Capacity Test Diesel Engine 17 Fuel Tubes Lines Hoses and Clamps Low Pressure Type 17 General Information 12 High Pressure Fuel Lines 17...

Page 954: ...FOLD HIGH PRESSURE FUEL LINES HIGH PRESSURE FUEL INJECTION PUMP THROTTLE POSITION SENSOR AUTO TRANS ONLY FUEL SHUTDOWN SOLENOID WATER TEMPERATURE SENSOR FOR I R GAUGE FUEL FILTER WATER SEPARATOR FUEL...

Page 955: ...fore tightening locknut 2 Position new locknut over top of fuel tank mod ule 3 Tighten locknut 4 Install fuel tank Refer to Fuel Tank Installa tion in this section AUXILIARY FUEL SUPPLY FITTING An aux...

Page 956: ...r from the fuel tank Here the low pressure is raised by the fuel injection pump for operation of the high pressure fuel injectors The transfer pump is driven by an eccentric on the engine camshaft tha...

Page 957: ...om of the separator filter The fuel filter water separator is located on the left side of the engine above the starter motor Fig 1 Refer to the maintenance schedules in Group 0 in this manual for the...

Page 958: ...r is controlled by the powertrain control module PCM Refer to the Diesel Engine Component Description System Operation section of this group for an operational description Refer to the Diesel Engine G...

Page 959: ...l Engine General Diagnosis section of this group For removal and installation procedures refer to the Diesel Engine Component Removal Installation section of this group For injection pump timing refer...

Page 960: ...the coils in the shutdown solenoid from the fuel shutdown solenoid relay This high amperage current allows the solenoid shaft to pull up on the in jection pump lever The injection pump shutdown le ve...

Page 961: ...Fig 16 Fuel in the drain manifold is then routed back to the fuel filter water separator Fig 16 Fuel Drain Manifold Typical For removal and installation procedures refer to the Diesel Engine Component...

Page 962: ...astic cable retainer snaps into pedal the arm page Throttle Cable 22 Throttle Linkage Adjustment Diesel Engine 23 PEDAL RETURN SPRING MANUAL TRANS ONLY THROTTLE BODY CABLE PIN THROTTLE BODY C A M THRO...

Page 963: ...bs at the dash panel Fig 3 5 Remove cable housing from dash panel and pull the cable into the engine compartment 6 3 9L 5 2L 5 9L Gas Powered Engines Dis connect the cable from the routing holddown cl...

Page 964: ...grom met locks into position on the bracket b Connect cable end socket to the fuel injection pump lever ball snaps on 4 Install the remaining cable housing end into and through the dash panel opening...

Page 965: ...ased 9 Re sure of wide open throttle WOT when ac celerator pedal is pressed to the floor This is checked by observing throttle lever breakover position Pro ceed to the following a Key OFF and engine O...

Page 966: ...be replaced immediately i f there is any evidence of degradation that could result in failure Avoid contact with clamps or other components that cause abrasions or scuffing Be sure that the rubber hos...

Page 967: ...ile working over the left rear tire wheel a Disconnect the electrical connector from the fuel tank module Fig 3 b Disconnect the fuel supply and fuel return lines at the fuel tank module Fig 3 Refer t...

Page 968: ...when servicing the fuel tank fuel tubes lines or va por vent line It is very important that these heat shields be reinstalled after service They are used to protect lines and tank from heat of exhaus...

Page 969: ...second screwdriver as a support to pry valve and grommet assembly from tank 4 To remove grommet from valve place valve up right on a flat surface Push down on the grommet Peel the grommet off the valv...

Page 970: ...ke Manifold Air Temperature Sensor PCM Pin 21 PCM Input 39 Malfunction Indicator Lamp PCM Pin 32 PCM Output 43 Manifold Absolute Pressure MAP Sensor PCM Pin 1 PCM Input 36 Open Loop Closed Loop Modes...

Page 971: ...f the generator field and provides speed control operation The PCM contains a voltage convertor This con verts battery voltage to a regulated 8 0 volts It is used to power the crankshaft position sens...

Page 972: ...lectric fuel pump Generator field charging system operation Idle air control IAC motor Ignition coil s and ignition timing Malfunction indicator lamp Check Engine Lamp Overdrive solenoid electrical op...

Page 973: ...s TRANSMISSION OVERDRIVE INST PNL r 1 1 A i INDICATOR LAMP EVAP PURGE ELECTRIC EGR TRANSDUCER TRANS TEMP LAMP AUTO HPS TRANS ONLY FNGTNE STARTER BODY ENGINE GROUND GROUND C O m CO CO GENERATOR J9414 4...

Page 974: ...m m GENERATOR J9414 50 Fig 3 System Schematic 5 2U5 9L LDC V 8 Engine...

Page 975: ...WITCH BRAKE SWITCH SPEED CONTROL 1 o HISS PCM POWERTRAIN CONTROL MODULE i y y y y DATA I i 3 LINK REC DATA LINK TRANS CCD CCD EVAP PURGE SOL EETS TRANS TEMP LAMP RESUMEJACCEL ON OFF COAST SET SRI SIL...

Page 976: ...L _ j ENGINE STARTER T l m r CO CO GENERATOR J9414 52 Fig 5 System Schematic 8 0L HDC V 10 Engine...

Page 977: ...oolant temperatures its resistance is high As temperatures increase its resistance will decrease The coolant sensor provides an input voltage to the powertrain control module PCM relating engine coola...

Page 978: ...e operator presses the switch lamp will illuminate The transmission will not enter overdrive when the operator presses the override switch and the lamp is illuminated The transmission downshifts i f t...

Page 979: ...r the fuel injector on cylinder 2 on 3 9L 5 2L 5 9L engines Refer to Fuel Injectors PCM Pin 13 PCM Output for information 8 0L V f 0 ENGINE Pin 15 is used as the ground control circuit for the fuel in...

Page 980: ...l System voltage is supplied to the ignition coil pos itive terminal The powertrain control module PCM then operates the ignition coil through an on off ground signal Base initial ignition timing is n...

Page 981: ...rear of the throttle body just below the idle air control motor on the 8 0L V 10 engine Fig 19 The TPS is connected to the throttle blade shaft and is a variable resistor It provides the powertrain c...

Page 982: ...It then adjusts the injector pulse width accordingly During Open Loop operation the PCM ignores the 02S sensor input and adjusts injec tor pulse width to a preprogrammed value based on other sensor i...

Page 983: ...ect signal The PCM will then remove the ground from the A C relay This will deactivate the A C compressor clutch If the evaporator switch opens indicating that evaporator is not in proper temperature...

Page 984: ...correct signal or no signal from certain sensors or emission related systems the lamp is turned on This is a warning that the PCM has recorded a system or sensor malfunction In some cases when a probl...

Page 985: ...erdrive lamp On the 8 0L V 10 engine this circuit is controlled by pin 31 When the lamp is illuminated the overdrive is disengaged 8 0L V 1 0 ENGINE Pin 37 is used to supply a dwell gate signal for op...

Page 986: ...ed on models equipped with certain heavy duty options and an automatic transmission Its purpose is to help control transmission overheating I f transmission overheating has been determined by this sen...

Page 987: ...ed throttle deceleration to the PCM When the vehicle is stopped at idle a closed throttle signal is received by the PCM but a speed sensor signal is not received Under deceleration conditions the PCM...

Page 988: ...ay Battery voltage is applied to the fuel pump relay when the ignition key is ON The re lay is energized when a ground signal is provided by pin 51 on the PCM Refer to Automatic Shut Down Relay PCM Pi...

Page 989: ...ASD SENSE PCM PIN 5 7 P C M INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated The ASD relay is located in the power distribution center PDC The PDC is located n...

Page 990: ...he 3 9L V 6 and 5 2L 5 9L V 8 engines the throttle position sensor TPS idle air control IAC motor and manifold absolute pressure MAP sensor are attached to the throttle body On the 8 0L V 10 engine th...

Page 991: ...h and ignition timing for idle than it does for wide open throttle WOT There are several different modes of operation that deter mine how the PCM responds to the various input sig nals MODES Open Loop...

Page 992: ...or pulse width by turning the ground circuit to each individual injector on and off The PCM determines the proper ignition timing ac cording to input received from the crankshaft posi tion sensor ENGI...

Page 993: ...oolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Camshaft position sensor signal in the di...

Page 994: ...M page Oxygen 02S Sensor Heating Element Test 62 Powertrain Control Module PCM 60 Way Connector 56 Powertrain Control Module Testing 65 Relays Operation Testing 64 Starter Motor Relay Test 65 System S...

Page 995: ...for loose or dirty connections Refer to Group 8 Wiring for ground locations 8 3 9L 5 2L 5 9L Engines Verify positive crank case ventilation PCV valve operation Refer to Group 25 Emission Control Syst...

Page 996: ...ire harness connec tors are firmly connected to injectors in the correct order Each harness connector is numerically tagged with the injector number INJ 1 INJ 2 etc of its corresponding fuel injector...

Page 997: ...that battery cable and solenoid feed wire connections to the starter solenoid are tight and clean Inspect for chaffed wires or wires rubbing up against other components POWERTRAIN CONTROL MODULE PCM 6...

Page 998: ...FT POSITION SENSOR TEST Refer to Group 8D Ignition Systems for Crank shaft Position Sensor testing SENSOR ELECTRICAL CONNECTOR J9414 60 Fig 18 Vehicle Speed Sensor Typical ENGINE COOLANT TEMPERATURE S...

Page 999: ...trical connector to sensor The sensor connector is symmet rical not indexed It can be installed to the sensor in either direction TRANSMISSION TEMPERATURE SENSOR TEST 4 SPEED AUT01ATIC TRANSMISSIONS O...

Page 1000: ...the sensor terminals should be less than 1340 ohms with the engine warm Refer to the Sensor Resistance OHMS Engine Coolant Intake Air and Transmission Temperature Sensors resis Fig 25 Sensor Location...

Page 1001: ...dy Except 8 0L 10 Engine tion switch ON and the engine OFF output voltage should be 4 to 5 volts The voltage should drop to 1 5 to 2 1 volts with a hot neutral idle speed condition A Ground B Output V...

Page 1002: ...n gine not running check the sensor output voltage at the center terminal wire of the connector Check this at idle throttle plate closed and at wide open throt tle WOT At idle sensor output voltage sh...

Page 1003: ...and 900 rpm If the idle speed is outside of these specifications re place the throttle body Refer to Throttle Body in the Component Removal Installation section of this group 9 Disconnect the DRB scan...

Page 1004: ...ts Provide proper ventilation while operating the en gine Always return the engine idle speed to normal be fore disconnecting the exerciser tool Fig 38 IAC Motor 3 9L 5 2U5 9L Engines Typical Fig 39 I...

Page 1005: ...on as described in step 5 b I f the pintle operates properly check the IAC motor bore in the throttle body bore for blockage and clean as necessary Install the IAC motor and retest I f blockage is not...

Page 1006: ...5 on the relay to the ground side of a 12 Volt power source 6 Attach the other jumper wire to the positive side of a 12V power source Do not connect this jumper wire to relay at this time Terminals CA...

Page 1007: ...ion has occurred This may happen because one of the DTC criteria for the circuit has not been met Example assume that one of the criteria for the MAP sensor circuit is that the engine must be oper ati...

Page 1008: ...or will be monitored and a diagnostic trouble code DTC will be gener ated by the PCM Powertrain Control Module PCM System Ground The PCM cannot determine a poor system ground However a DTC may be gene...

Page 1009: ...hown in Fig 48 ERASING TROUBLE CODES After the problem has been repaired use the DRB scan tool to erase a Diagnostic Trouble Code DTC 3 J9214 20 D l GROUND D 2 N C D 3 SCI TRANS D 4 SCI RECEIVE D 5 IG...

Page 1010: ...oad load conditions Engine coolant temperature remains below normal operating temperatures during vehicle travel thermostat Neither rich or lean condition detected from the oxygen sensor input If equi...

Page 1011: ...njector 5 output driver does not respond properly to the control signal Injector 6 output driver does not respond properly to the control signal Injector 7 output driver does not respond properly to t...

Page 1012: ...low target charging during engine operation Also no significant change detected in battery voltage during active test of generator output Oxygen sensor signal input indicates lean air fuel ratio condi...

Page 1013: ...Tubes Lines Hoses and Clamps 78 Idle Air Control IAC Motor 78 Ignition Coil 78 Intake Manifold 78 Intake Manifold Air Temperature Sensor 72 Manifold Absolute Pressure MAP Sensor 79 Oxygen 02S Sensor 7...

Page 1014: ...the intake manifold near the thermo stat housing Fig 5 On the 8 0L V 10 engine the sensor is installed in the thermostat housing Fig 6 Fig 5 Coolant Temperature Sensor 3 9L V 6 or 5 2 5 9L V 8 Engine...

Page 1015: ...CTOR THE FUEL SYSTEM PRESSURE MUST BE RELEASED To release fuel pressure refer to the Fuel Delivery System section of this group See Fuel System Pres sure Release To remove one or more fuel injectors t...

Page 1016: ...moval in this group 5 If equipped with air conditioning remove the A C compressor to intake manifold support bracket three bolts Fig 10 6 Disconnect electrical connectors at all fuel in jectors Fig 11...

Page 1017: ...il fuel injectors have bottomed on injector shoulder 6 Install fuel rail mounting bolts 7 Install EVAP canister purge solenoid to intake manifold 8 Connect electrical connector to intake manifold air...

Page 1018: ...clip s to fuel rail The fuel injector electrical connectors on all 10 injectors should be facing to the right pas senger side of the vehicle Fig 16 3 Position the fuel rail fuel injector assembly to...

Page 1019: ...oup for remov al installation procedures Also refer to Quick Connect Fittings in the Fuel Delivery System section of this group for removal in stallation procedures IDLE AIR CONTROL IAC MOTOR The idle...

Page 1020: ...nsor is mounted into the right upper side of the intake manifold Fig 21 A rubber gasket is used to seal the sensor to the intake manifold The rubber gasket is part of the sensor and is not ser viced s...

Page 1021: ...o the exhaust mani fold Tighten to 30 N m 22 ft lbs torque 2 Connect the 02S sensor wire connector 3 Lower the vehicle PARK NEUTRAL SWITCH Refer to Group 21 Transmission and Transfer Case for removal...

Page 1022: ...throttle body electrical connectors at IAC motor and TPS 3 3 9L 5 2L 5 9L Engines Remove vacuum line at throttle body INTAKE MANIFOLD UPPER HALF NUTS 4 J9414 57 Fig 27 Throttle Body Mounting 8 0L V 10...

Page 1023: ...er side of the socket tangs The TPS will be under slight tension when rotated 1 Install the TPS and two retaining bolts THROTTLE POSITION SENSOR J9414 3 Fig 31 TPS Mounting Bolts 8 0L V 10 Engine Typi...

Page 1024: ...le speed sensor Fig 34 is located on the extension housing of the transmission on 2WD mod els It is located on the transfer case on 4WD models REMOVAL 1 Raise and support vehicle 2 Clean the area arou...

Page 1025: ...ator Fuel heater Fuel heater relay Fuel shutdown solenoid Fuel shutdown solenoid relay High pressure fuel injectors Fuel return line page Park Neutral Switch PCM Pin 30 PCM Input 90 PCM Schematics Die...

Page 1026: ...nly Power ground SCI receive DRB scan tool connection Sensor return Throttle position sensor auto trans only Transmission temperature sensor auto trans only Vehicle speed sensor Water in fuel sensor I...

Page 1027: ...THROTTLE POSITION SENSOR AUTO TRANS OILY 0 1 m m m HI m A C COMPRESSOR CLUTCH J9414 84 Fig 2 System Schematic 5 9L Diesel Engine...

Page 1028: ...input also provides the voltage that is needed to keep the PCM memory alive The memory stores diagnostic trouble code DTC messages mini mum and maximum TPS value from the previous key on and speed con...

Page 1029: ...t Cycle The heater is not energized during cranking PREHEAT CYCLE The PCM powers up when the ignition key is turned to the On position I f intake manifold air tem perature is 15 C 59 F or below the ai...

Page 1030: ...d Heater Relays PCM Pin 15 PCM Output for additional information Refer to the Diesel Engine General Diagnosis sec tion of this group for diagnostic procedures THROTTLE POSITION SENSOR PCM PIN 22 PCM I...

Page 1031: ...pressure switches are closed an input signal is POWERTRAIN CONTROL MODULE PCM J9414 11 Fig 10 PCM and Data Link Connector Typical sent to the powertrain control module PCM The PCM uses this input to...

Page 1032: ...rd Diagnostics in the General Diagnosis section of this group for more information SPEED CONTROL PCM PINS 33 AND 53 PCM OUTPUT These two circuits control vent and vacuum opera tion of the speed contro...

Page 1033: ...trol module PCM The PCM will then force a 4 3 down shift Once transmission temperature has cooled be low specifications a 3 4 upshift will be allowed An instrument panel mounted trai smission temperat...

Page 1034: ...ion of the speed control solenoids TORQUE CONVERTOR CLUTCH TCC SOLENOID PCM PIN 54 PCM OUTPUT AUTOMATIC TRANSMISSION This circuit Fig 17 controls operation of the transmission mounted torque convertor...

Page 1035: ...ir heater relays Fig 3 are tight and not corroded 4 Inspect the starter motor and starter solenoid connections for tightness and corrosion page Intake Manifold Air Heater Relay Test 106 Intake Manifol...

Page 1036: ...MANIFOLD HIGH PRESSURE FUEL LINES HIGH PRESSURE FUEL INJECTION PUMP WATER TEMPERATURE SENSOR FOR LP GAUGE FUEL FILTER WATER SEPARATOR THROTTLE POSITION SENSOR AUTO TRANS ONLY FUEL SHUTDOWN SOLENOID OI...

Page 1037: ...and not damaged 17 Be sure that the accessory drive belt is not damaged or slipping 18 Automatic Transmission Only Raise the vehi cle and check the electrical connection at the trans mission temperatu...

Page 1038: ...e test of this sensor and its circuitry refer to the appropriate Powertrain Diag nostic Procedures manual FUEL FILTER WATER SEPARATOR TEST A blocked or clogged fuel filter water separator can cause st...

Page 1039: ...ure When the fuel temper ature is below 40 degrees F the sensor allows cur rent to flow to the built in heater element to warm the fuel When the fuel temperature is above 80 de grees F the sensor stop...

Page 1040: ...he fuel heater refer to Fuel Heater Test in this section of the group FUEL INJECTOR TEST A leaking fuel injector can cause fuel knock poor performance black smoke poor fuel economy and rough engine id...

Page 1041: ...this group for procedures Also refer to the Fuel Transfer Pump Pressure Test section of this group for restriction tests HIGH PRESSURE LINES Restricted kinked or bent high pressure lines can cause st...

Page 1042: ...roup FUEL SHUTDOWN SOLENOID RELAY TEST Voltage to operate the fuel shutdown solenoid is supplied from the ignition switch and through the fuel shutdown solenoid relay The fuel shutdown so lenoid relay...

Page 1043: ...Volume Test FUEL VOLUME TEST Fuel volume versus engine cranking rpm are used for the test WARNING TO PREVENT THE ENGINE FROM STARTING DISCONNECT THE PIGTAIL HARNESS AT THE FUEL SHUTDOWN SOLENOID FIG 1...

Page 1044: ...e the flow line Fig 21 this indicates acceptable fuel flow 6 If fuel volume falls below specifications test for fuel line inlet restrictions before condemning the fuel transfer pump This is done by in...

Page 1045: ...ure fuel lines or to repair lines that are damaged Only use the recom mended lines when replacement of high pressure fuel line is necessary IDLE SPEED ADJUSTMENT The high speed idle screw is factory s...

Page 1046: ...testing do not energize the air heater relays more than once per 15 minutes with BATTERY LEFT SIDE Fig 26 Intake Manifold Air Heater Relays out running and operating the engine Due to the high amperag...

Page 1047: ...ily touch the jumper wires to the ve hicle battery and The relay should click and the ohmmeter should show a closed circuit across the large terminals I f not replace relay and bracket as sembly 7 Rep...

Page 1048: ...operations tests on all other relays refer to the appropriate section of this service manual The ASD relay is located in the power distribution center PDC The PDC is located in the engine com partment...

Page 1049: ...7A and 30 8 Disconnect jumper wires from relay and 12 Volt power source If continuity or resistance tests did not pass re place relay If tests passed refer to Group 8W Wiring Terminals Diagrams for fu...

Page 1050: ...circuit often enough to indicate an actual problem a diagnostic trouble code DTC is stored The DTC will be stored in the PCM memory for even SENSOH RESISTANCE OHMS TRANSMISSION TEMPERATURE SENSOR TEM...

Page 1051: ...r diagnostic trouble code DTC criteria are met a DTC will be stored in mem ory Other DTC criteria might include engine rpm limits or input voltages from other sensors or switches The other inputs migh...

Page 1052: ...TROUBLE CODE DESCRIPTIONS Diagnostic Trouble Code DRB Scan Tool Display Description of Diagnostic Trouble Code 11 12 15 23 24 No Crank Reference Signal at PCM Battery Disconnect No Vehicle Speed Senso...

Page 1053: ...ensor An open or shorted condition detected in the generator field control circuit An open or shorted condition detected in the auto shut down relay circuit An open or shorted condition exists in the...

Page 1054: ...es damaged lines or loose connections Replace damaged lines or tighten connections as necessary Bleed fuel system Wax buildup in fuel filter cold weather only Replace fuel filter use recommended diese...

Page 1055: ...stall injection lines in correct order Leaking high or low pressure fuel line Repair as necessary Low or uneven engine compression Repair as necessary Fuel injection pump malfunctioning or not adjusta...

Page 1056: ...clean or replace as necessary Restricted or blocked fuel supply lines Remove restrictions or replace lines Leaking injection lines damaged lines or loose connections Replace damaged lines or tighten...

Page 1057: ...utdown solenoid interrupted or fuel solenoid inoperative Correct voltage supply problem or replace solenoid Injection pump linkage damaged Repair as necessary Either poor performance block smoke or lo...

Page 1058: ...ove restriction or replace lines Restricted or blocked fuel supply lines Remove restriction or replace lines Wax buildup in fuel filter cold weather only Replace fuelfilter use recommended diesel fuel...

Page 1059: ...djustment Adjust as necessary Restricted or blocked fuel supply lines Remove restrictions or replace lines Wax buildup in fuelfiber cold weather only Inspect fuel heater electrical connector for damag...

Page 1060: ...em will have to be bleed manually if The fuel filter is not filled before installation The fuel injection pump is replaced High pressure fuel line connections are loosened or lines replaced Initial en...

Page 1061: ...UATE PRO TECTIVE CLOTHING AND AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH PRESSURE FUEL LINES WARNING DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE DO NOT ALLOW FUEL TO SPRAY ONTO THE EXH...

Page 1062: ...4 Place the feeler gauge between the sensor and the vibration dampener 5 Gently seat push down the sensor until it con tacts the feeler gauge Be sure the sensor is not near either of the notches Fig 4...

Page 1063: ...the filter separator Refer to the following Draining Water from Filter DRAINING WATER FROM FILTER The filter should be drained whenever the water in fuel warn ing lamp remains illuminated Note that th...

Page 1064: ...ght film of clean unused engine oil to the filter separator seal 5 Install a new O ring seal to the filter separator housing Fig 11 6 Install filter separator to housing Tighten fil ter separator one...

Page 1065: ...L b W J94U 91 Fig 16 Throttle Position Sensor Diesel 3 Disconnect the electrical connector at fuel shut down solenoid Fig 17 4 Disconnect the main engine wiring harness at top of injection pump and p...

Page 1066: ...ntake Manifold Air Heater 11 Remove the overflow valve and fuel return line at pump Fig 21 Place a rag beneath the fitting to catch excess fuel 12 Disconnect the six 6 high pressure fuel lines from th...

Page 1067: ...It is designed J9414 112 Fig 23 Engine Oil Supply Line Pump Mounting Nuts OIL FILL TUBE J9114 54 Fig 24 Oil Fill Tube Adapter and Mounting Bracket to position the engine to TDC Top Dead Center on the...

Page 1068: ...Fig 27 Rotating Engine with Barring Tool Typical Before proceeding to the next step and to prevent shearing of the timing pin temporarily remove the timing pin from the back of the gear 21 Remove the...

Page 1069: ...25 into the rear of the camshaft gear Rotate crankshaft if necessary Before injection pump installation it must be set pump shaft rotated to a certain position to attain accurate pump timing Remove th...

Page 1070: ...jection pump mounting flange opening in gear cover housing to al low easier pump installation Fig 34 Also apply en gine oil to the pump O ring seal at pump mounting area The injection pump shaft and i...

Page 1071: ...ck into pump Install access plug and its sealing washer Tighten plug to 15 N m 11 ft lbs torque 13 Install the engine oil supply line and fuel re turn line overflow valve to pump 14 Install the six hi...

Page 1072: ...nut Fig 36 the injector when being removed can rotate in the cylinder head This may cause damage to the cylinder head bore Use a rust pen etrating solvent before attempting to loosen a rusted holddow...

Page 1073: ...e on the top of the injector Fig 43 Installing Injector 5 Tighten the injector holddown nut to 60 N m 44 ft lbs torque 6 Connect the fuel drain manifold to the injec tors Refer to Fuel Drain Manifold...

Page 1074: ...T ADJUSTMENT After replacing the fuel shutdown solenoid the so lenoid shaft length must be checked and if neces sary adjusted 1 Turn the ignition switch ON 2 Pull up by hand and hold on the solenoid l...

Page 1075: ...PECTING FOR HIGH PRESSURE FUEL LEAKS INSPECT FOR HIGH PRESSURE FUEL L E A K S WITH A SHEET O F CARDBOARD HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN FUEL SY...

Page 1076: ...olts al ternately to prevent damage to the fuel pump housing 4 Install fuel line fittings to pump and fuel heater Tighten to 24 N m 18 ft lbs torque 5 Install starter motor Refer to Group 8B for proce...

Page 1077: ...the line clamp isolator and bracket holder bolts 3 Tighten each line at the delivery valve holder to 30 N m 22 ft lbs torque 4 Tighten each line at the fuel injector to 30 N m 22 ft lbs torque Be sur...

Page 1078: ...ube to the side 6 Remove the air heater from the intake mani fold INSTALLATION 1 Clean the mating surfaces of the air heater and intake manifold 2 Install a new lower and upper gasket to the air heate...

Page 1079: ...necessary adjusted Refer to the following Throttle Position Sensor Testing THROTTLE POSITION SENSOR TESTING CAUTION Before attempting to test the TPS verify the linkage adjustment dimension shown in f...

Page 1080: ...is test b Two people are needed for this test From in side of the vehicle press the accelerator pedal about half way to the floor Movement of both the throttle lever and throttle lever to injection pu...

Page 1081: ...640 720 110 230 480 540 120 248 370 410 LOW IDLE SPEED HIGH IDLE SPEED Wilh automatic transmission 750 800 RPM with transmission in drive and air conditioning on Do not attempt to adjust high idle spe...

Page 1082: ...N m 22 ft lbs High pressure fuel lines at fuel injector 30 N m 22 ft lbs High pressure fuel line clamp holders 6 N m 4 ft lbs Injector pump access plug 15 N m 11 ft lbs Injection pump to injection pu...

Page 1083: ......

Page 1084: ...an ufacturer with weights spot welded to the tube The propeller shaft is designed and built with the yoke lugs in line with each other This is called phas ing This design produces the smoothest runnin...

Page 1085: ...s systems are used Single cardan universal joint Fig 2 Double cardan universal joint Fig 3 FLANGE YOKE J9416 4 Fig 3 Double Cardan Universal Joint Typical LUBRICATION All U joints should be inspected...

Page 1086: ...unbalance Defective U joints or an incorrect propeller shaft angle are usually the cause UNBALANCE If propeller shaft unbalance is suspected it can be verified with the following procedure Removing a...

Page 1087: ...clamps so the screws will not loosen 15 Install the wheel and tire Remove supports and lower the vehicle 16 I f the vibration remains unacceptable apply the procedures at the front end of propeller sh...

Page 1088: ...to the amount of load in the vehicle Always check an gles in loaded and unloaded conditions Check the condition of all suspension components Verify all fasteners are torqued to specifications Check t...

Page 1089: ...easured with Special Tool 7663 The front half shaft must be parallel to the rear axle pinion gear shaft The front and rear half shafts must be offset by a minimum of 1 2 of a degree From the transmiss...

Page 1090: ...r Suspension and Axle for ad ditional information Fig 10 Adjustment at Leaf Springs Typical gle Two Piece Shaft ADJUSTMENT AT CENTER BEARING WITH TWO PIECE SHAFT Drive away shudder is the vibration th...

Page 1091: ...be used for installation reference Fig 2 3 Remove the U joint strap bolts at the pinion shaft yoke 4 Remove bolts from transfer case yoke flange and remove the propeller shaft INSTALLATION 1 Position...

Page 1092: ...icle CENTER BEARING SERVICE Vehicles equipped with a two piece rear propeller shaft have a rubber insulated center bearing The bearing supports the shafts where they join together Thh two piece propel...

Page 1093: ...of the bear ing assembly to loosen snap ring 4 Remove snap rings from both sides of yoke Fig 2 5 Set the yoke in an arbor press or vise with a large socket beneath it Place a smaller socket on the upp...

Page 1094: ...e the yoke with a soft hammer to seat the needle bearings In stall a snap ring 6 Install the propeller shaft Refer to Propeller Shaft Replacement in this group DOUBLE CARDAN U JOINT REMOVAL DISASSEMBL...

Page 1095: ...g ball spring and bearing for wear 4 Inspect the centering ball boot for tears or cracks ASSEMBLY INSTALLATION During installation ensure that all yokes are aligned to the reference marks 1 Fit a cros...

Page 1096: ...group FLANGE YOKE J9416 10 Fig 12 Press In Bearings Assembly TORQUE SPECIFICATIONS P R O P E L L E R SHAFT AND U JOINT I Description Torqu H Center Bearing to Support Bracket Bolts 68 N m 50 ft lbs Ce...

Page 1097: ......

Page 1098: ...at the lower end and a bearing assembly at the upper end When the worm shaft is turned the rack piston moves The rack piston teeth mesh with the pitman sector shaft Turning the worm shaft turns the pi...

Page 1099: ...on switch and steer ing shaft cannot be operated The lock mechanism also prevents operation of the automatic transmis sion gear shift lever Both columns are energy ab sorbing collapse from impact in t...

Page 1100: ...STEERING 19 3 PUMP LEAKAGE DIAGNOSIS J9419 33...

Page 1101: ...s no metal to metal contact within the coupling by performing an electrical continuity check Remove coupling for check 3 If hiss is still extremely objectionable replace steering gear RATTLE OR CLUNK...

Page 1102: ...system SUCKING AIR SOUND 1 Loose return line clamp 2 Missing O ring on hose connection 3 Low fluid level 4 Air leak between reservoir and pump 1 Tighten or replace clamp 2 Inspect connection and repla...

Page 1103: ...te shaft Service Procedure 8 Steering column coupling binding 8 Realign as necessary 9 Excessive friction in gear 9 Replace gear SHAKE SHUDDER VIBRATION CONDITION POSSIBLE CAUSE CORRECTION VIBRATION O...

Page 1104: ...teering gear is at fault replace steering gear POOR RETURN TO CINTIR C O N D I T I O N POSSIBLE CAUSI C O R R E C T I O N STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Tires not properly...

Page 1105: ...ft if worn 4 Check and replace as required 5 Check and replace as required 6 Tighten hub nut or replace with new parts as necessary 7 Check and replace as required 8 Replace gear 9 Replace gear VEHICL...

Page 1106: ...g and replace as required 3 Identify location of leak and repair or replace as indicated in Power Steering Pump and or Gear sections of this service manual FOAMY OR MILKY FLUID CONDITION POSSIBLE CAUS...

Page 1107: ...REPLACE THE SIDE COVER SEAL IF THE LEAKAGE PERSISTS 2 ADJUSTER PLUG SEAL REPLACE THE ADJUSTER PLUG SEALS 3 PRESSURE UNE FITTING TOR QUE THE HOSE FITTING NUT TO 31N m 23 FT LBS IF LEAKAGE PERSISTS REPL...

Page 1108: ...Power Steering Cooler Cap hose open ends and pump steering gear fit tings to prevent entry of foreign material WARNING POWER STEERING FLUID AND PUMP COMPONENTS AND THE EXHAUST SYSTEM CAN BE EXTREMELY...

Page 1109: ...nder unit from engine block and plug hole in block PUMP ENGINE BLOCK Fig 4 Oil Pressure Sending Unit 4 Disconnect and cap the oil feed line from the bottom of the vacuum pump Fig 5 5 Remove the lower...

Page 1110: ...ket to steering pump nuts Tighten to 24 N m 18 Ft lbs torque STEERING 19 13 PUMP BRACKET SPACERS J9119 69 Fig 9 Steering Pump Removal Installation Fig 10 Steering Vacuum Pump Assembly 4 Position new g...

Page 1111: ...ering pump Cap the fit tings 3 Remove battery ground cable and nut at stud Unthread stud from cylinder head do not remove from bracket Loosen upper bracket bolt Remove the lower bracket to engine bloc...

Page 1112: ...Do not use the tool adapters 2 Ensure that the tool and the pulley remain aligned with the pump shaft Prevent the pulley from being cocked on the shaft 3 Force pulley flush with the end of the shaft W...

Page 1113: ...I O N Follow this procedure to remove air from the sys tem CAUTION The fluid level should be checked with en gine off to prevent injury from moving components Use only MOPAR Power Steering Fluid Do no...

Page 1114: ...and nut from the tie rod 2 Remove the tie rod end ball studs from steering knuckle arms Fig 1 and 2 Use care to avoid damaging the seals 3 Remove inner tie rod ends from center link Fig 2 4 If equippe...

Page 1115: ...steering knuckle and pitman arm Fig 4 STEERING DAMPER DRAG LINK STEERING GEAR PITMAN ARM TIE ROD TIE ROD END J9419 24 Fig 4 Steering Linkage Link Coil Use care to avoid damaging the seals 3 Mark the...

Page 1116: ...liers CAUTION Use care not to score the housing bore when prying out seals a n d washers 4 Remove backup washer and double lip seal with screwdriver Start the engine and turn the steering wheel fully...

Page 1117: ...Fig 2 Power Steering Gear...

Page 1118: ...hten to 49 N m 36 ft lbs torque 3 Align and install the pitman arm 4 Install the washer and retaining nut on the pit man shaft Tighten the nut to 251 N m 185 ft lbs torque 5 Connect fluid hoses to ste...

Page 1119: ...and tighten locknut to 109 N m 80 ft lbs torque Be sure adjustment plug does not turn while tightening the locknut FIRST MARK J9219 30 Fig 8 Aligning To The Second Mark O V E R C E N T E R A D J U S...

Page 1120: ...ighten the adjuster lock nut to 58 N m 43 ft lbs G E A R D I S A S S E M B L Y INFORMATION CAUTION Cleanliness is extremely important when repairing a power steering gear Keep the bench tools and comp...

Page 1121: ...LOCK NUT PlTAAAN SHAFT NUT RACK PISTON BALL GUIDE BALL RETURN 2 36 CLAMP BALL RETURN GUIDE 37 SCREW ASSY LOCKWASHER 2 14 SPACER THRUST BEARING 38 PLUG RACK PISTON 15 RACE UPPER THRUST BEARING SAAALL 3...

Page 1122: ...t until after pitman shaft adjustment has been made 3 Install gasket to side cover and bend tabs around edges of side cover 4 Install pitman shaft assembly and side cover to housing 5 Install side cov...

Page 1123: ...2 Install pitman arm onto steering gear Refer to Steering Linkage in this group ADJUSTER PLUG ASSEMBLY REPLACEMENT REMOVE 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement...

Page 1124: ...retainer to ad juster plug Fig 20 CAUTION When installing adjuster plug care should be taken NOT to cut the seals 8 Install adjuster plug into housing with Spanner Wrench C 4381 9 Adjust bearing prel...

Page 1125: ...valve spool by pulling and rotating from valve body Fig 24 Remove valve spool O ring seal Remove valve body teflon rings and O ring seals Fig 25 ASSEMBLE 1 Install valve spool O ring seal to valve spo...

Page 1126: ...PISTON AND WORM SHAFT REPLACEMENT R E M O V E 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement in this section VALVE BODY PIN J9319 38 Fig 26 Stub Shaft Installation DISAS...

Page 1127: ...lign worm shaft spiral groove with rack piston ball guide hole Fig 30 INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING WORM COUNTERCLOCKWISE J9319 39 Fig 30 Installing Balls in Rack Piston WARNING MAK...

Page 1128: ...in this section PITMAN SHAFT SEALS AND BEARING REPLACEMENT REMOVE 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement in this section DISASSEMBLE 1 Remove pitman arm from gea...

Page 1129: ...FLUSH WITH HOUSING SPECIAL TOOL C4328 J9119 42 Fig 35 Pitman Shaft Seal Installation CHECK VALVE REPLACEMENT REMOVE 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement in thi...

Page 1130: ...uid Storing Gear Adjustments Wormshaft Bearing Preload Torque 0 45 1 13 N m 10 to 15 in lbs Pitman Shaft Overcenter Drag Torque New Gear less than 400 miles 640 km 0 45 0 90 N m 6 to 10 in lbs in addi...

Page 1131: ...AIRBAG MODULE ATTACHED NEVER PLACE THE COLUMN ON THE FLOOR OR OTHER SURFACE WITH THE STEERING WHEEL OR MODULE FACE DOWN CAUTION Bumping jolting and hammering on steering column shaft and gear shift tu...

Page 1132: ...g wheel with the scored marks or master splines aligned 3 Install the retaining nut and tighten to 61 N m 45 ft lbs torque Force the steering wheel down on the shaft with the retaining nut only Do not...

Page 1133: ...ing tape within the clockspring is not positioned properly the clockspring may fail during use The following procedures MUST BE USED to center the clockspring 1 Place the front wheels in the straight...

Page 1134: ...in removal of the upper fixed shroud 12 Remove electrical connections from Key in light Ignition Switch Horn and Clock Spring Speed Control Fig 13 STEERING COLUMN ASSY J918J 1 MULTI FUNCTION SWITCH CO...

Page 1135: ...tor needs adjusting turn recessed hex head screw un derneath cable retainer Fig 15 13 Install the lock housing shrouds Install the tilt lever if equipped 14 Install the lower dash panel column cover 1...

Page 1136: ...J9419 30 Description Torque Flow Control Valve High Pressure Fluid Line Oil Cooler Bolt Pump Bracket to Engine Pump to Brocket Pump to Rear Bracket Nuts 8 0 L Rear Bracket to Front Bracket 8 0 L Pump...

Page 1137: ......

Page 1138: ...he shaft is supported in the front and rear housings by bushings and one bearing Internal shift components consist of the forks shaft shift lever socket anti rotation bracket bias spring and detent co...

Page 1139: ...2 NV3500 MANUAL TRANSMISSION Fig I NV3500 Manual Transmission J9421 1...

Page 1140: ...tightening or use of a non recom mended sealer A leak at the front of the transmission will be from either a loose or damaged front bearing retainer or retainer seal Lubricant may also drip from the t...

Page 1141: ...r noisy shifts In most cases this condition will decline as the rings wear in TRANSMISSION NOISE Most manual transmissions make some noise dur ing normal operation Rotating gears can generate a mild w...

Page 1142: ...press on style and must be removed from shift lever refer to following procedure a Obtain Remover Installer Tool 6783 b Scribe mark position of extension on shank of shift lever c Position notched low...

Page 1143: ...ch housing mount ing surface is clean before installation 2 Lubricate release fork pivot ball release fork release bearing hub and transmission bearing re tainer surface with Mopar high temperature gr...

Page 1144: ...ck used to support transmission 14 Install strut bolts nuts if removed 15 Install transfer case Align and position trans fer case with transmission jack or aid of helper Tilt case upward and work into...

Page 1145: ...nd plate assembly from shift lever opening in rear housing Fig 3 Plate assem bly is one way fit Note position of plate for in stallation reference before removal Narrow side of plate goes toward drive...

Page 1146: ...ning Bearing Retainer Sealer Bead 12 Remove shift shaft detent plug Fig 10 Use crowfoot bar and hammer to lightly pry and tap plug out of housing NV3500 MANUAL TRANSMISSION 21 9 Fig 8 input Shaft Bear...

Page 1147: ...earing from front case Fig 14 Use hammer Fig 13 Front Housing Removal handle to tap input shaft bearing out of case Coun tershaft bearing can be removed by hand Fig 14 Input Shaft And Countershaft Fro...

Page 1148: ...Fig 17 Disengaging Anti Rotation Bracket Bias Spring b Remove reverse idler segment but leave gear in case c Remove input shaft bearing and 3 4 synchro ring d Remove 3 4 shift fork and 3 4 synchro sle...

Page 1149: ...on 1 2 and fifth re verse forks Then remove 3 4 fork Fig 24 10 Support geartrain and rear housing on Assem bly Fixture Tool 6747 with aid of helper as follows SHIFT SHAFT SHAFT LEVER r AND BUSHING 3...

Page 1150: ...cks un der legs of fixture tool Blocks are needed to raise fixture high enough for input shaft to clear work bench surface SPECIAL SPECIAL T O O L T O O L PEDESTAL J9421 45 Fig 25 Installing Assembly...

Page 1151: ...sing i f any of these components are damaged REAR ADAPTER HOUSING REMOVAL 4 WHEEL DRIVE TRANSMISSION 1 A tool is required to remove the rear seal from the adapter housing Use either a dent puller or f...

Page 1152: ...sion mm mmm mm immm L WBDVMAZE mum immsw J942M99 Fig 33 Rear Seal Remover Tool 4 Wheel Drive Transmission LOCATION OF DIMPLES J9421 200 Fig 36 Rear Seal Removal 4 Wheel Drive Transmission 6 Remove rea...

Page 1153: ...AIN DISASSEMBLY The synchronizer hubs and sleeves are differ ent and must not be intermixed It is recom mended that each synchronizer unit be removed as an assembly to avoid intermixing parts It is al...

Page 1154: ...WASHER 2 PIECE J94 l 25 Fig 44 Second Gear And Needle Bearing Remowal SECOND GEAR SYNCHRO RING SYNCHRO HUB SNAP RING 2 SYNCHRO HUB AND SLEEVE J9421 26 Fig 45 Second Speed Synchro Ring And Synchro Hub...

Page 1155: ...erse gear and needle bearing Fig 54 R E V E R S E IDLEm DISASSEMBLY FIG SSI 1 Remove idler gear snap rings 2 Remove thrust washer wave washer thrust plate and idler gear from shaft SPACER AS REQUIRED...

Page 1156: ...CIAL TOOL 1130 MARK HUB FOR INSTALLATION REFERENCE J9421 34 Fig 53 Fifth Rewerse Synchro Hub And Sleeve Remowal REVERSE GEAR AND NEEDLE BEARING J9421 35 Fig 54 Rewerse Gear And Needle Bearing Remowal...

Page 1157: ...e contact surfaces Fig 57 Replace any fork ex hibiting wear or damage in these areas Do not at tempt to salvage shift forks Inspect the shift shaft bushings and front bearing carefully The bushings an...

Page 1158: ...nd free of distortion Replace the retainer if the threads are damaged or if the retainer is bent or cracked 1 2 SHIFT FORK Forks And Shaft 3 4 SHIFT FORK J9421 54 Countershaft Bearings And Races The c...

Page 1159: ...faces are deeply scored worn or brinnelled BRACKET ROLLERS ANTI ROTATION BRACKET J9421 43 Fig 59 Shift Lever Components TRANSMISSION ASSEMBLY Assembly Information Gaskets are not used in the NV3500 tr...

Page 1160: ...D SYNCHRO RING 0 FIFTH REVERSE SYNCHRO HUB 0 THIRD GEAR STRUT SPRING DETENT BALL 3 SETS FIFTH REVERSE SYNCHRO THIRD GEAR NEEDLE BEARING 0 SLEEVE FIFTH REVERSE SYNCHRO 0 RETAINING RING 0 SNAP RING FIFT...

Page 1161: ...correct installation Fig 61 One side of the sleeve is marked first gear side Be sure this side is facing the first gear after installation CORRECT POSITION IS MARKED ON SLEEVE J9421 56 Fig 61 Locatio...

Page 1162: ...verse gear needle bear ing on shaft Fig 63 Slide bearing up against shoul der on output shaft as shown REVERSE Fig 63 Reverse Gear Bearing Installation 6 Install reverse gear over needle bearing Fig 6...

Page 1163: ...stall fifth gear on shaft and onto bearing Fig 70 14 Install output shaft bearing with shop press and suitable size pipe tool Fig 71 15 Install output shaft bearing snap ring Fig 72 Use heavy duty sna...

Page 1164: ...alls CAUTION The 1 2 synchro hub and sleeve can be installed backwards if care is not exercised One side of the hub has a small diameter shoulder around the hub bore Make sure this side of the hub fac...

Page 1165: ...ig 78 Installing 1 2 Synchro Hub Snap Ring 24 Install second speed synchro ring in 1 2 syn chro hub and sleeve Fig 79 Be sure synchro ring is properly seated in sleeve p p n i i i j i SECOND Fig 79 Se...

Page 1166: ...s side of the hub is facing the front of the shaft In addition one side of the sleeve has grooves in it Be sure this side of sleeve is also fac ing the front of the shaft NV3500 MANUAL TRANSMISSION 21...

Page 1167: ...est snap ring that will fit in shaft groove Use heavy duty snap ring pliers to install new ring c Verify that snap ring is completely seated in groove before proceeding 3 4 SYNCHRO Fig 90 Installing 3...

Page 1168: ...sed to hold ball in place if desired IDLER GEAR BEARING REAR OF SHAFT J9421 87 Fig 92 Idler Gear And Bearing Installation 5 Slide thrust rear thrust washer onto shaft and over lock ball Fig 93 6 Insta...

Page 1169: ...rain Buildup 2 Position wood block under each leg of assembly fixture Fig 96 Blocks are needed to provide clear ance for input shaft and can be made from 2 x 4 lum ber 3 Install input shaft in fixture...

Page 1170: ...ding Fig 101 10 Check alignment of countershaft and output shaft gear teeth Note that gears may not align per fectly A difference in height of 1 57 to 3 18 mm 1 16 to 1 8 in will probably exist This d...

Page 1171: ...fth reverse fork goes through slot in 1 2 fork INSERT ARM THROUGH 1 2 FORK FIFTH REVERSE FORK Fig 104 Assembling 1 2 And Fifth Reverse Shift Forks 14 Install assembled shift forks in synchro sleeves F...

Page 1172: ...RACE J9421 103 Fig 107 Lubricating Countershaft Rear Bearing Fig 108 Countershaft Rear Bearing Seated In Seated in Race 7 Install rear housing onto geartrain Fig 109 Be sure bearing retainer pilot stu...

Page 1173: ...ng race 5 Install countershaft rear bearing in bearing race Fig 108 CAUTION The countershaft bearings can be in stalled backwards if care is not exercised Be sure the large diameter side of the roller...

Page 1174: ...is allowed to shift out of position in the housing SHIFT SHAFT SHAFT LEVER AND BUSHING AND SHIFT SOCKET INSTALLATION 1 Remove geartrain and housing assembly from fixture with aid of helper Fig 115 In...

Page 1175: ...ugh 1 2 fork and part way into shift lever opening in rear housing Fig 121 9 Slide bias spring on shift shaft Be sure spring ends are facing rearward as shown Fig 121 10 Assemble anti rotation bracket...

Page 1176: ...l pin is approximately 22 mm 7 8 in long Shift socket roll pin is approxi mately 33 mm 1 1 4 in long 15 Align roll pin holes in shift shaft lever and bushing Then start roll pin into shaft lever by ha...

Page 1177: ...lever and bushing downward out of fork arms to expose detent bore in lever Fig 129 22 Insert detent spring in lever bore with pencil magnet Fig 130 23 Install detent ball on top of spring in lever bor...

Page 1178: ...BE O N LONG END OF SPRING J942M18 Fig 133 Positioning Short End Of Bias Spring Against Pin c Grasp brakeline and pry long end of spring around tab on anti rotation bracket Then seat spring end in tab...

Page 1179: ...Fig 138 6 Apply 1 8 in wide bead of Mopar Gasket Maker or Loctite 518 to mating surfaces of front and rear housings Fig 138 7 Have helper hold rear housing and geartrain in upright position Then insta...

Page 1180: ...rside of bolt head before in stallation CAUTION If the lock bolt cannot be fully installed do not try to force it into place Either the shift shaft is not in Neutral Or the shaft bushing or le ver is...

Page 1181: ...shaft Fig 144 installing Shift Shaft Detent Plunger 15 Install detent spring inside plunger Fig 145 Fig 145 Installing Detent Plunger Spring 16 Install detent plug Fig 146 Start plug in bore by hand...

Page 1182: ...Retainer And Housing 21 Align and install front bearing retainer over input shaft and onto housing mounting surface Fig 151 Although retainer is one way fit on hous ing be sure bolt holes are aligned...

Page 1183: ...mounting surface and rubber coated side faces upward Fig 155 NARROW Fig 155 Correct Positioning Of isolator And Plate Assembly 3 Apply 1 8 to 3 16 in wide bead of Mopar Gas ket Maker or Loctite 518 t...

Page 1184: ...sion to bottom edge of fill plug hole with required lubricant 10 Install and tighten fill plug to 19 27 N m 14 20 ft lbs torque 11 Check transmission vent Fig 158 Be sure vent is open and not restrict...

Page 1185: ...NSMISSION IDENTIFICATION The NV 500 transmission identification tag is at tached to the driver side PTO cover Fig 2 The tag provides the transmission model number build date and part number Be sure to...

Page 1186: ...ever extension is also new The lever is now a press fit on the shift lever A new service tool for removal installation is required and is described in the transmission removal installation procedures...

Page 1187: ...assembly will also contribute to gear disen gagement LOW LUBRICANT LEVEL Insufficient transmission lubricant is usually the result of leaks or inaccurate fluid level check or refill method Leaks will...

Page 1188: ...and jack rearward until drive gear clears clutch housing 20 Lower transmission jack and remove trans mission from under vehicle 21 I f transmission will be overhauled clean transmission exterior with...

Page 1189: ...repair remove drain bolt at bottom of PTO cover and drain lubricant from transmission 8 Mark propeller shafts and yokes for assembly reference 9 Disconnect propeller shafts and remove propel ler shaft...

Page 1190: ...ion or rear crossmember 12 Install transfer case shift mechanism on transmission Fig 7 13 Install rear crossmember 14 Remove transmission jack and engine support fixture 15 Install transfer case on tr...

Page 1191: ...d remove them Use a 10 mm 12 point socket or box end wrench only Fig 4 Extension Adapter Housing Bolts 2 Remove extension adapter housing Fig 5 Tap housing with rubber mallet to loosen it Then break s...

Page 1192: ...ng Countershaft Fifth Gear Components As Assembly 1 Remove snap ring that secures fifth speed clutch gear on countershaft Fig 9 CLUTCH SEAR J9221 89 Fig 9 Removing Countershaft Fifth Speed Clutch Gear...

Page 1193: ...is loose it can be removed by hold ing nut wrench with breaker bar and rotating out put shaft with socket wrench and ratchet g Remove fifth gear nut and coned washer from shaft Fig 14 Note position of...

Page 1194: ...Assembly 11 Remove mainshaft fifth gear with Puller Tool Set 6444 Note that puller set can be used on both standard and heavy duty transmissions Gear removal procedure is as follows THRUST WASHER PIN...

Page 1195: ...Retaining Collar Over Puller Jaws f Install Puller and Bolt 6444 on puller rods Then secure puller to rods with retaining nuts Fig 22 g Tighten puller bolt to remove gear from shaft splines Fig 22 12...

Page 1196: ...CIAL TOOL 6453 1 J9221 178 Fig 26 Assembling Puller Rods Flange And Jaws c Install assembled tools in front retainer Fig 27 Be sure puller jaws are seated under bearing cup d Place Insert Tool 6453 2...

Page 1197: ...gear and in notch of puller flange Fig 31 e Slide Retaining Collar 6444 8 over puller jaws to hold them in place Fig 31 f Install Puller 6444 on puller rods Then se cure puller to rods with retaining...

Page 1198: ...ec tion to rotate shaft and geartrain out of case c Once mainshaft gears roll clear of counter shaft gears shaft and gear assembly can be tilted outward and removed from gear case Fig 37 Fig 37 Mainsh...

Page 1199: ...444 8 over puller jaws to hold them in place Fig 41 Note that re taining collar has small lip on one end and only fits one way over jaws f Install Puller 6444 on puller rods Then se cure puller to rod...

Page 1200: ...cleaning and inspection J9221 159 6444 6 Fig 43 Removing Countershaft Front Bearing GEAR CASE DISASSEMBLY 1 Remove countershaft front bearing cap Use mallet or hammer to remove cap from inside case F...

Page 1201: ...d 2 Remove fourth gear synchro struts and springs from 3 4 hub and sleeve Fig 50 Three struts and springs are used Keep springs and struts together for inspection and cleaning Store parts in a paper c...

Page 1202: ...R NEEDLE BEARING ASSEMBLIES J922M21 Fig 53 Third Gear Needle Bearing Removal SECOND GEAR THRUST WASHER THRUST WASHER SNAP RING THIRD GEAR BEARING SPACER J922M22 Fig 54 Bearing Spacer And Snap Ring Loc...

Page 1203: ...synchro sleeve and hub for assembly reference Side of hub with flat hub spring goes toward front Fig 62 Note that tapered side of sleeve also goes toward front 17 Remove 1 2 synchro sleeve hub struts...

Page 1204: ...a Assemble Puller Flange 6444 1 and Puller Rods 6444 3 Fig 66 b Position first Puller Jaw 6445 on bearing cone Fig 66 c Seat Puller Flange 6444 1 in notch of first puller jaw Fig 66 d Install second P...

Page 1205: ...21 68 N 4560 MANUAL TRANSMISSION Fig 66 Assembling Mainshaft Rear Bearing Puller Tools SPECIAL REVERSE Fig 67 Removing Mainshaft Rear Bearing...

Page 1206: ...inshaft Fig 71 30 Remove first gear snap ring Fig 71 Tension of this snap ring is considerable Heavy duty snap ring pliers will be required to spread the ring far enough to remove it Fig 71 Reverse Ge...

Page 1207: ...ck the release bearing slide surface of the retainer carefully Minor corrosion nicks or pitting can be smoothed with 400 grit emery and polished out with crocus cloth Wet the abrasive paper and crocus...

Page 1208: ...splines ADAPTER HOUSING 4 WHEEL DRIVE J922M86 Fig 80 Gear Case And Extension Adapter Housings are excessively worn or damaged The synchro sleeve should also be replaced if worn or damaged in any way D...

Page 1209: ...the synchro struts and springs clutch gears Replace any part that exhibits wear Replace these parts if worn cracked or distorted distortion or damage Replace the clutch rings if the friction material...

Page 1210: ......

Page 1211: ...RD GEAR BEARING ASSEMBLIES 2 42 THIRD GEAR SYNCHRO STOP RING 43 3 4 SYNCHRO SLEEVE 44 SYNCHRO STRUTS AND SPRINGS 3 EACH 45 3 4 SYNCHRO HUB 46 FOURTH GEAR SYNCHRO STOP RING 47 FOURTH SPEED CLUTCH GEAR...

Page 1212: ...IDLER GEAR FRONT THRUST WASHER ON BOSS Fig 7 8 idler 0 J9221 162 89 Positioning Idler Gear Front Thrust Washer In Case Install reverse idler gear in case Fig 90 Install idler gear rear thrust washer b...

Page 1213: ...c mallet i f necessary ADJUSTING COUNTERSHAFT END PLAY 1 Install countershaft rear bearing plate Fig 96 Be sure plate is seated in notch in reverse idler shaft before tightening bearing plate bolts CO...

Page 1214: ...l shift lug on rail Note position of 4 Position shift rail so roll pin notches are at ap proximately 5 o clock position Fig 99 5 Install roll pin that secures lug to rail Fig 99 NOTCHES LUG ROLL SHIFT...

Page 1215: ...acer on main shaft Fig 103 Bearing spacer seats against first gear snap ring WOOD BLOCKS REVERSE GEAR STOP RING CLUTCH GEAR FIRST GEAR r A S i u J9221 191 i Fig 102 Clutch Gear Stop Ring Installation...

Page 1216: ...in mainshaft Fig 106 Use needle nose pliers to install pin 14 Install reverse gear thrust washer Fig 107 Be sure locating pin is seated in thrust washer notch 15 Install rear bearing on mainshaft Use...

Page 1217: ...are aligned and seated in first gear hub 1 2 synchro hub will not seat properly if clutch ring tabs are misaligned Fig 112 First Speed Clutch And Stop Ring Installation 21 Support mainshaft in upright...

Page 1218: ...compress struts with your fingers and move Fig 116 Installing 1 2 Synchro Sleeve On Hub sleeve upward until struts are started in sleeve Verify that struts are engaged in sleeve before pro ceeding g...

Page 1219: ...ed clutch gear Or first speed clutch gear is slightly misaligned Realign as needed to fully seat snap ring Fig 121 Installing 1 2 Synchro Snap Ring 28 Reinstall flat weight spring in 1 2 synchro hub F...

Page 1220: ...pliers to insert pin in shaft hole 35 Install second gear thrust washer Be sure washer is seated on gear and pin Fig 129 36 Install second gear thrust washer snap ring Fig 130 Be sure snap ring is fu...

Page 1221: ...226 Fig 132 Third Gear Installation SYNCHRO STOP RING THIRD GEAR J9221 227 Fig 133 Third Gear Stop Ring Installation 41 If 3 4 synchro was disassembled for service reassemble synchro components as fol...

Page 1222: ...ar bearing Then lift assembly and guide rear of shaft through bearing bore at rear of case 3 Continue holding front of shaft but switch grip at rear to shaft output splines Lift mainshaft assem bly sl...

Page 1223: ...stalling Bearing Retainer Oil Seal 7 Apply Mopar Gasket Maker to flange surface of front bearing retainer Fig 143 8 Install front bearing retainer over drive gear and start it into case 9 Start front...

Page 1224: ...ig 145 Checking Mainshaft End Play 9 If end play adjustment is required remove bearing plate and install necessary shim 10 Reinstall rear bearing plate Fig 146 11 Apply Mopar Lock W Seal or Loctite 24...

Page 1225: ...nch 6443 with heavy copper mallet then checking with torque wrench COUNTERSHAFT FIFTH GEAR AND SYNCHRO INSTALLATION 1 Install thrust washer pin in countershaft Fig 150 Fig 150 Installing Fifth Gear Th...

Page 1226: ...slots first Then install springs by compressing them with screwdriver and working springs into hub and struts 10 Assemble and install fifth synchro clutch gear and stop ring in fifth gear hub Fig 157...

Page 1227: ...ar Lock N Seal or Loctite 242 to threads of extension adapter housing bolts 11 Install and tighten housing bolts to 54 N 40 ft lbs torque Use a twelve point 10 mm socket a ratchet wrench and necessary...

Page 1228: ...he cover or any shift components are worn or damaged Shift Cover Inspection Inspect the cover and shift components whenever the cover is removed from the gear case Or when ever diagnosis indicates ins...

Page 1229: ...plug bores with solvent and dry with clean shop towel 4 Apply small bead of sealer to outer edge of each new plug Use Mopar silicone adhesive sealer or equivalent 5 Position each new plug in bore and...

Page 1230: ...install lever so heavy mark on lever shank is facing forward c On standard duty transmissions install lever so standard mark on lever shank is facing for ward CAUTION Verify correct lever installation...

Page 1231: ...disengage it from align ment dowels in gear case Fig 176 5 Raise front of shift cover and lift cover up and off gear case Fig 176 6 Set cover assembly aside for inspection I f cover components are da...

Page 1232: ...ase dowels or shift forks are not aligned with sleeves and shift lug 12 Apply Mopar Lock 1 S T Seal or Loctite 242 to threads of shift cover bolts 13 Install and tighten shift cover bolts to 27 31 N m...

Page 1233: ...sed with 36RH and 37RH transmissions is also equipped with a converter clutch A 241 or 273 mm 9 5 or 10 75 in converter is used for 3 9L 5 2L and 5 9L gas engine applications A 310 mm 12 2 in converte...

Page 1234: ...RONT CLUTCH REAR PLANETARY GEAR SET LOW AND REVERSE REAR BAND LOCK UP CLUTCH ENGINE CRANKSHAFT BUSHING EXTENSION HOUSING KICKDOWN FRONT BAND SUN GEAR DRIVING SHELL FLEXIBLE DRIVE PLATE O L IS 39 39 m...

Page 1235: ...IMPELLER FLEXIBLE DRIVE PLATE ENGINE CRANKSHAFT Fig 2 36RH 37RH Automatic Transmission...

Page 1236: ...valve throttle pressure plug provides 3 2 downshifts with varying throttle openings and de pending on vehicle speed The 1 2 shift control valve transmits 1 2 shift pres sure to the accumulator piston...

Page 1237: ...rive unit Overdrive ratio is 0 69 1 The overdrive unit contains an overdrive clutch di rect clutch planetary gear set and overrunning page Recommended Fluid 103 Temperature Sensor and Indicator Lamp 1...

Page 1238: ......

Page 1239: ...VALVE BODY J9321 2G5 Fig 2 46RH 47RH Transmission And Overdrive Unit...

Page 1240: ...ase The 47RH transmission case is readily identifiable by the extra reinforcing ribs around the rear servo area of the case The converter housing bolt pattern is unique for diesel and gas engine versi...

Page 1241: ...sure chamber for the overdrive piston The intermediate shaft is splined to the overdrive direct clutch sliding hub planetary assembly and overrunning clutch The governor components and speedometer dri...

Page 1242: ...upshift The boost valve provides increased fluid apply pres sure to the overdrive clutch during the 3 4 upshift and during fourth gear operation The amount of boost is determined by throttle opening...

Page 1243: ...th engagement dur ing lift foot 2 3 upshifts The second is to regulate front clutch and band application during 3 2 down shifts The 3 4 shuttle valve uses a combination of throttle and governor pressu...

Page 1244: ...ctronic con trol of converter clutch operation includes clutch re lease at closed throttle during warmup and during part throttle acceleration The boost valve provides additional apply pressure for co...

Page 1245: ...rratic or harsh shifts 3 Road test and note how transmission upshifts downshifts and engages page Gearshift Linkage 110 General Information 108 Hydraulic Pressure Test 111 Overdrive Fourth Gear Electr...

Page 1246: ...e 2 pints or morequart FLUID CONTAMINATION Transmission fluid contamination is generally a re sult of adding incorrect fluid failure to clean dipstick and fill tube when check ing level engine coolant...

Page 1247: ...units are applied in the various gear ranges The Clutch and Band Applica tion charts Figs 1 and 2 provide a basis for analyz ing road test results ANALYZING THE ROAD TEST Refer to the Clutch and Band...

Page 1248: ...293 to check pressure at the rear servo and at the overdrive port in fourth gear P R E S S U R E TEST PORT LOCATIONS There are pressure test ports at the accumulator front servo and rear servo Figs 3...

Page 1249: ...from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure at both gauges 5 Line pressure should be 54 60 psi 372 414...

Page 1250: ...e to 620 827 kPa 90 120 psi at 1 2 to 3 4 throttle Note that pressure will increase to 896 kPa 130 psi or more at full throttle 8 Refer to pressure test charts Figs 6 and 7 for pressure diagnosis CONV...

Page 1251: ...d release brakes 9 Stall speeds should be in 1800 2100 rpm range STALL TEST ANALYSIS S T A L L S P E E D TOO H I G H If the stall speed exceeds specifications by more than 200 rpm transmission clutch...

Page 1252: ...ve hub and onto the rear of the converter Pump O ring or pump body leaks follow the same path as a seal leak Fig 12 Pump vent or pump attaching bolt leaks are gener ally deposited on the inside of the...

Page 1253: ...moved a shipping plug can used to close off this opening The torque converter hub opening in the pump and the pump vent require special tools to close them off The converter hub seal cup is made from...

Page 1254: ...s or similar devices Do not close off rear cooler line fitting Hand operated air pump will be attached to this fitting 3 Attach Air Pump 7700 to rear cooler line fit ting Connect a length of copper tu...

Page 1255: ...ged in any way 6 Loosen kickdown lever pin access plug three turns Apply Permatex No 2 or equivalent to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump s...

Page 1256: ...band or planetary component is damaged 8 Check pressures remove overhaul or adjust valve body as needed repair oil pump if necessary 9 Remove valve body and replace piston seal or spring as needed 10...

Page 1257: ...metal particles an overhaul may be necessary 6 Drain fluid to correct level if overfilled If fluid is highly aerated full of bubbles and foamy oil pump gasket or seal may have failed or pump body is p...

Page 1258: ...rts NO DRIVE OR REVERSE VEHICLE WILL NOT MOVE 1 Low fluid level 2 Gearshift linkage loose damaged or misassembled 3 Failure of driveline component such as U joint axle shaft transfer case component et...

Page 1259: ...ines 5 Accumulator piston cracked spring broken or seal worn 6 Clutch or servo malfunction leaking seals or worn plates 7 Overrunning clutch worn not holding slips in 1 only 1 Add fluid and check for...

Page 1260: ...shift or throttle linkage or cable out of adjustment 2 Front band out of adjustment 3 Governor valve stuck closed loose output shaft support or governor housing bolts worn pump leaking seal rings or v...

Page 1261: ...ect clutch repair as required GROWLING GRATING O R SCRAPING NOISES 1 Planetary gear set broken or seized 2 Overrunning clutch worn seized or broken 3 Oil pump components scored binding or broken 4 Out...

Page 1262: ...fittings 5 Valve body manual lever shaft seal 6 Pressure port plug loose 7 Rear bearing access plate 8 Gasket damaged or bolts are loose 9 Adapter extension gasket damaged 10 Neutral switch 11 Conver...

Page 1263: ...etc If vehicle is not so equipped it should not be used for severe service operation 2 Drain fluid change filter and install auxiliary cooler 3 Cut down on idling time shift into neutral every so oft...

Page 1264: ...such as a gear failure or a clutch pack failure Note Flushing the cooler and lines is mandatory after a failure of the converter lockup clutch 2 Incorrect fluid used in transmission 3 Main cooler in...

Page 1265: ...ors with test lamp or volt ohmmeter and replace faulty sensor 8 Test switch as described in service section and replace if necessary 9 Check with DRB II scan tool and replace if necessary 10 Adjust or...

Page 1266: ...t proper spacer 4 Remove unit and rebuild clutch pack 5 Replace T P S 6 Disassemble transmission and replace orifice 3 4 UPSHIFT OCCURS BEFORE COMPLETION OF 2 3 UPSHIFT 1 Overdrive solenoid connector...

Page 1267: ...eplace solenoid if seized or shorted 4 Remove valve body remove and disassemble lower housing and 3 4 accumulator housing replace seals and clean valves as necessary be sure all valves slide freely in...

Page 1268: ...ir wiring and connectors as necessary NOISY OPERATION IN FOURTH GEAR ONLY 1 Overdrive clutch discs plates or snap rings damaged 2 Overdrive piston or planetary thrust bearing brinnelled installed wron...

Page 1269: ...alfunction 5 Overdrive thrust bearing failure 1 Remove and disassemble unit check clutch pack and replace spring 2 Disassemble unit and rebuild clutch pack 3 Adjust band 4 Air pressure test clutch ope...

Page 1270: ...FAULTY TORQUE CONVERTER X X X X X OUT OF BALANCE X FAILED CONVERTER CLUTCH X X X LEAKING TURBINE HUB SEAL X X ALIGN EXHAUST SYSTEM X X TUNE ENGINE X X X FAULTY INPUT SHAFT OR SEAL RING X X THROTTLE CA...

Page 1271: ...HYDRAULIC FLOW IN PARK POSITION 32RH 36RH 37RH OIL FILTER ENGINE RUNNING...

Page 1272: ...AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21 135...

Page 1273: ...HYDRAULIC FLOW IN DSEGOMD GEAR 32RH 36RH 37RH GOVERNOR VALVE ACCUMULATOR LOCK UP ONLY SELECTOR LEVER IN TORQUE CONVERTER DRIVE SECOND HALF THROTTLE J 9 0 2 1 1 6 2...

Page 1274: ...HYDRAULIC FLOW IN D THIRD GEAR 32RH 36RH 37RH...

Page 1275: ...RD GEAR AFTER CONVERTER CLUTCH ENGAGEMENT 32RH 36RH 37RH GOVERNOR VALVE REAR SERVO E S J O o M O O ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH IMBRICATION SELECTOR LEVER IN TORQUE CONVERTER D...

Page 1276: ......

Page 1277: ...L E 3 2 KICKDOWN 32RH 36RH 37RH GOVERNOR VALVE REAR SERVO FRONT SERVO ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH UBRICATION 1 2 SHIFT CONTROL 55 70 n f GOVERNOR 30 73 PSI f SELECTOR LEVER I...

Page 1278: ...HYDRAULIC FLOW IN 2 POSITION MANUAL SECOND 32RH 36RH 37RH GOVERNOR VALVE y ACCUMULATOR LOCK UP ONLY SELECTOR LEVER IN TORQUE CONVERTER TWO MANUAL SECOND CLOSED THROTTLE J902M67...

Page 1279: ...f POSITION MANUAL LOW 32RH 36RH 37RH REAR SERVO r n 1 T 1 W FRONT SERVO REAR CLUTCH FRONT CLUTCH ACCUMULATOR LOCK UP ONLY h v OIL FILTER TO UBRICATION FRONT i CLUTCH UBRICATION SELECTOR LEVER IN ONE M...

Page 1280: ...HYDRAULIC FLOW IN R E V E R S E 32BH 36HH 37mH GOVERNOR VALVE REAR CLUTCH REAR SERVO FRONT SERVO ACCUMULATOR SELECTOR LEVER IN REVERSE...

Page 1281: ......

Page 1282: ...HYDRAULIC FLOW IN NEUTRAL 42RH 46RH 47RH J9421 156...

Page 1283: ...R LEVB1 IN REVERSE U N E P R E S S U R E 1 6 0 2 7 0 psi THROTTLE PRESSURE 0 9 4 psi 1 2 SHIFT C O N T R O L 2 5 7 0 psi U N E PRESSURE T O THROTTLE V A L V E 5 0 1 0 0 psi C O N V E R T E R LUBE PRES...

Page 1284: ...ELECTOR LEVER IN DRIVE FtiSTGEAR PART THROTTLE LINE P R E S S U R E 7 0 7 8 psi I G O V E R N O R P R E S S U R E 0 7 5 psi THROTTLE P R E S S U R E To 4 0 psi C O N V E R T E R LUBE P R E S S U R E 5...

Page 1285: ...OR LEVER IN DRIVE SECOND GEAR PART THROTTLE LINE P R E S S U R E 57 94 psi G O V E R N O R PRESSURE 0 5 7 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIFT PRESSURE 2 5 7 0 psi C O N V E R T E R LUBE PRESSURE...

Page 1286: ...DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED U N E PRESSURE 5 7 9 4 psi G O V E R N O R PRESSURE 0 6 0 psi THROTTLE PRESSURE 0 9 4 psi C O N V E R T E R LUBE PRESSURE 5 5 7 psi PUMP S U C T I O N O...

Page 1287: ...RH 47RH ro OVERDRIVE CLUTCH SELECTOR LEVER IN DRIVE OVERDRIVE 4TH GEAR CONVERTER CLUTCH NOT APPLIED CJI UNE PRESSURE 57 94 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIFT CONTROL 25 70 psi GOVERNOR PRESSURE...

Page 1288: ...H APPLIED 42RH 46RH 47RH CONveneaurcH AmjED U N E P R E S S U R E 9 5 1 3 0 psi GOVERNOR P R E S S U R E 0 6 0 psi THROTTLE P R E S S U R E 0 1 0 0 psi C O N V E R T E R LUBE P R E S S U R E 5 6 0 psi...

Page 1289: ...CUMULATOR OVERDRIVE CLUTCH SELECTOR LEVER EN MANUAL 1 HRSTGEAR CLOSED THROTTLE tmmm LINE PRESSURE 55 62 psi 1 2 SHIFT CONTROL 25 35 psi GOVERNOR PRESSURE 0 30 psi CcJvERiER LUBE PRESSURE 5 57 psi PUMP...

Page 1290: ...R B i MANUAL 2 SECOND GEAR CLOSED THROTTLE U N E P R E S S U R E 5 5 6 2 psi 1 2 SHIFT C O N T R O L 2 5 3 5 psi G O V E R N O R P R E S S U R E 6 5 7 psi C O N V E R T E R LUBE P R E S S U R E 5 5 7...

Page 1291: ...ill cause shift problems and reduce the life of the fluid significantly 8 If fluid level is too high excess fluid can be drained with suction gun and flexible tubing Tubing will have to be adapted to...

Page 1292: ...sion to move simul taneously with the throttle control lever from the idle position Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ah...

Page 1293: ...ever on throttle body is at curb idle position 5 Locate cable lock button Button is part of cable retainer at engine end of cable 6 Press cable lock button inward to release cable Lock button only has...

Page 1294: ...t properly i f spring is not connected T V LEVER BRACKET J9421 250 11 Check and adjust throttle valve cable Refer to procedures in this section T V LEVER BRACKET J9421 250 Fig 9 V10 Diesel Throttle Va...

Page 1295: ...peedometer pinion from adapter 7 Inspect sensor and adapter O rings Fig 13 Remove and discard O rings i f worn or damaged 8 Inspect terminal pins in speed sensor Clean pins with Mopar electrical spray...

Page 1296: ...tests bad SWITCH REPLACEMENT 1 Raise vehicle and position drain pan under switch 2 Disconnect switch wires 3 Remove switch from case 4 Move shift lever to Park and Neutral positions Verify that switch...

Page 1297: ...sion is in 1 position Park lock rod is easier to disengage engage with sprag in this position 10 Remove access plate and gasket from under side of extension housing Plate must be removed for access to...

Page 1298: ...pliers 6 Hold locating in spread position Tap or work housing into place and release locating ring Be very sure locating ring is fully seated in rear bearing 7 Install and tighten housing to transmis...

Page 1299: ...eights and spring Secure inner weight and spring in outer weight with snap ring 8 Install weight assembly in governor body and install retaining snap ring 9 Place governor valve on valve shaft Insert...

Page 1300: ...manual lever detent ball and spring throttle lever fluid filter solenoid and connector assembly switch valve spring and adjusting screw bracket park rod and E clip transfer plate solenoid overdrive co...

Page 1301: ...justments on the valve body which are Line pressure and throttle pressure The valve body must be removed from the trans mission in order to perform the adjustments Refer to the valve body removal inst...

Page 1302: ...h type of fitting A plastic tool is clipped directly to one of the cooler lines on models with the type 2 and 3 fittings This tool can also be used to disconnect type 1 fit TRANSMISSION FITTING COOLER...

Page 1303: ...the retainer clip as described in step 4 above TRANSMISSION COOLER SERVICE FLUSHING COOLERS AND LINES If a transmission malfunction contaminates the fluid the cooler and lines must be reverse flushed...

Page 1304: ...nds 6 If fluid flow is intermittent flows less than one quart in 20 seconds or fails to flow at all cooler is plugged or damaged and should be replaced MAIN COOLER REPLACEMENT The main transmission co...

Page 1305: ...tainless steel thread inserts Repair consists of drilling out the worn or damaged threads tapping the hole with a special tap and installing a thread in sert in the tapped hole The procedure returns t...

Page 1306: ...o remove the transmission and converter as an assembly TRANSMISSION REMOWAL 1 Disconnect battery negative cable 2 Disconnect and lower or remove necessary ex haust components 3 Remove engine to transm...

Page 1307: ...mbly rearward off engine block dowels and disengage torque converter hub from end of crankshaft Attach a small C clamp to edge of bell housing to hold torque converter in place during transmission rem...

Page 1308: ...spect gear teeth and remove any nicks raised metal weld spatter or rough surfaces PUMP OIL SEAL REPLACEMENT Seal Removal On 32RH 42RH pumps remove the seal with Spe cial Tool C 3981B Fig 5 On 36RH 37R...

Page 1309: ...e plate i f cracked distorted or damaged If driveplate replacement was necessary be sure transmission dowel pins are seated in engine block and protrude far enough to held trans mission in alignment 1...

Page 1310: ...be Fig 12 Install new seal on tube before installation 28 Install exhaust components 29 Align and install propeller shaft 30 Adjust gearshift linkage and throttle valve ca ble if necessary 31 Lower ve...

Page 1311: ...Shaft Selective Spacer Location 7 Install overdrive piston in retainer If re moved Lubricate piston seals with Ru Glyde Door Eze or petroleum jelly to ease installation Be sure piston locating lugs a...

Page 1312: ...2 Then work extension housing off rear bearing and output shaft Remove housing gasket after removing housing 6 Remove rear bearing and snap ring from out put shaft Fig 3 7 Remove oil pan bolts and rem...

Page 1313: ...in pump body flange Fig 10 17 Bump slide hammer weights outward to re move pump and reaction shaft support assembly from case Fig 10 VALVE BODY ASSEMBLY J9121 117 Fig 7 Removing Installing Valve Body...

Page 1314: ...SSION OVERHAUL 21 177 Fig 13 Removing Installing Front Band Lever 32RH 23 Remove front and rear clutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 14...

Page 1315: ...aft and remove valve and shaft from governor body Fig 19 Reinstall E clip on shaft to avoid losing it 30 Loosen bolts attaching governor body to park gear 31 Mark position of governor body on park gea...

Page 1316: ...rns 35 Remove snap ring that secures low reverse drum to rear support hub however do not remove drum at this time Fig 22 36 Remove rear band lever pins with parallel jaw snap ring pliers Fig 23 Spread...

Page 1317: ...ed or nicked if care is not exercised 45 Remove compressor tools and remove front servo rod guide spring and servo piston Fig 27 Compressing Front Servo Rod Guide 32RH 46 Compress rear servo spring re...

Page 1318: ...ents and will circulate through out the transmission after assembly A sufficient quantity of lint can block fluid passages and in terfere with valve body operation Inspect the case for cracks porous s...

Page 1319: ...ition for assembly refer ence Bolt holes in clutch cam are countersunk on one side Be sure this side of cam will face rearward when installed Fig 33 CLUTCH RACE ON HUB O F DRUM OVERRUNNING CLUTCH J912...

Page 1320: ...8 Compress the reaction plug spring clip only enough to remove or install it The clip is easily distorted i f overcompressed Replace the clip i f it becomes bent or distorted Do not straighten and reu...

Page 1321: ...spotfaced for governor valve end clearance The new aluminum valve must only be used with an output shaft that has a spotface In addition the governor body and spotfaced side of the valve shaft hole i...

Page 1322: ...port components Replace the housing or support if the seal ring grooves or machined surfaces are worn scored pit ted or damaged Replace the pump gears if pitted worn chipped or damaged Inspect the thr...

Page 1323: ...ER GEAR J9321 217 Fig 47 Measuring Pump Gear Tooth Clearance 2 Install new pump bushing with Tool Handle C 4171 and Bushing Installer SP 5117 Fig 48 Bushing should be flush with pump housing bore 3 St...

Page 1324: ...ller SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing SPECIAL T O O L SP 1191 SPECIAL TOOL C 4171 SPECIAL T O O L A SP 5325 BUSHING INSTALLATION J9221 243 Fig 50 Repl...

Page 1325: ...ws a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible b Secure pump assembly in case with 2 or 3 bolts or with pilot studs H9321 221...

Page 1326: ...Spring 32RH dry them with compressed air only Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to the component surfaces and could restrict or block f...

Page 1327: ...push the piston straight in This could fold the seals over causing leakage and clutch slip 5 Position spring on clutch piston Then place spring retainer on top of spring 6 Compress return spring and...

Page 1328: ...arts Lint from such J912M50 Fig 64 Pressing Input Shaft Out Of Rear Clutch Retainer 32RH materials will adhere to component surfaces and could restrict or block fluid passages after assembly Replace t...

Page 1329: ...haft front seal ring is teflon with chamfered ends The rear ring is metal with interlocking ends Check the input shaft for wear or damage Replace the shaft if worn scored or damaged in any way ASSEMBL...

Page 1330: ...a clutch disc until entire clutch pack is in stalled Total of 4 discs and 3 plates are required Fig 62 12 Install top pressure plate Fig 62 13 Install selective snap ring Fig 62 Be sure snap ring is f...

Page 1331: ...t bore P L A N E T A R Y G E A R T R A I N INSPECTION Clean the planetary components in solvent and dry them with compressed air Check sun gear and driving shell condition Re place the gear if damaged...

Page 1332: ...sun gear and at front rear of shell Fig 76 Installing Driving Shell Front Thrust Plate On Sun Gear 32RH 9 Hold sun gear in place and install thrust plate over sun gear at rear of driving shell Fig 77...

Page 1333: ...sure washer tabs are all prop erly seated REAR TABBED THRUST WASHER FRONT PLANETARY GEAR J912M66 Fig 81 Installing Rear Thrust Washer On Front Planetary Gear 32RH 14 Install front planetary gear on ou...

Page 1334: ...fully seated SELECTIVE Fig 86 Installing Planetary Selective Snap Ring 32RH 22 Turn planetary geartrain assembly over so driving shell is facing workbench Then support geartrain on wood block position...

Page 1335: ...eplace any servo component if doubt exists about its condition Do not reuse suspect parts ASSEMBLING F R O N T S E R V O PISTON 1 Lubricate seal rings and O rings with petro leum jelly Lubricate other...

Page 1336: ...Fig 91 4 Lubricate piston seal with petroleum jelly Lu bricate other servo parts with transmission fluid VALVE BODY SERVICE AND ADJUSTMENT VALVE BODY DISASSEMBLY CAUTION Do not clamp any part of the v...

Page 1337: ...RK ROD J9121 81 Fig 96 Park Rod Removal 32RH 9 Remove screws attaching converter clutch mod ule to valve body and remove module and connecting tube Fig 97 MODULE A N D CONNECTING TUBE J9121 178 Fig 97...

Page 1338: ...ID J9321 124 Fig 99 Transfer Plate Removal Installation 32RH 15 Remove converter clutch solenoid from separa tor plate Fig 100 16 Note position of filter clutch solenoid and rear clutch rear servo che...

Page 1339: ...m valve body Fig 103 24 Remove 1 2 shift control valve and spring from valve body Fig 104 25 Remove 2 3 shift valve and spring from valve body Fig 104 26 Remove 1 2 shift valve and spring from valve b...

Page 1340: ...valve and 1 2 governor plug are made of coated aluminum These components are identified in Figure 105 with the abbreviation Alum Alumi num components can be identified by the dark color of the specia...

Page 1341: ...ECTING TUBE SHUTTLE VALVE COVER REGULATOR VALVE THROTTLE PRESSURE PLUG LINE PRESSURE ADJUSTING SCREW ADJUSTING SCREW BRACKET THROTTLE PRESSURE ADJUSTING SCREW SWITCH VALVE AND SPRING PRESSURE REGULATO...

Page 1342: ...ernately in a diagonal pattern to 4 N m 35 in lbs torque 8 Assemble converter clutch module and valves Then install assembly on valve body Fig 108 9 Assemble regulator valve line pressure plug sleeve...

Page 1343: ...r over throttle lever and start man ual lever into valve body 26 Align manual lever detent with detent ball and align lever arm with manual valve Hold throttle lever upward Then press down on manual l...

Page 1344: ...ustment 32RH TRANSMISSION ASSEMBLY AND ADJUSTMENT Assembly Tips Do not allow dirt grease or foreign material to en ter the case or transmission components during as sembly Keep the transmission case a...

Page 1345: ...threading a clutch cam bolt into each hole Adjust cam position if necessary before proceeding 8 Install clutch cam bolts Note that cam bolts are shorter than rear support bolts Tighten cam bolts to 17...

Page 1346: ...and park gear seal rings with transmission fluid 32RH TRANSMISSION OVERHAUL 21 209 Fig 118 Installing Output Shaft Planetary Geartrain 32RH Fig 119 Aligning Seating Rear Planetary In Low Reverse Drum...

Page 1347: ...st E clip on governor valve shaft Then install governor valve and shaft in governor body Fig 122 Be sure valve shaft moves freely in valve and in output shaft If valve shaft binds governor park gear i...

Page 1348: ...sher faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Fig 128 Installing Output Shaft Thrust Washer 32RH 33 Align drive teeth on rear clutch discs with...

Page 1349: ...1 39 Install front band lever strut lever pin and adjusting screw Fig 132 40 Tighten front band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still seated b...

Page 1350: ...g oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft lbs Fig 136 Installing Oil Pump And Reaction Shaft Support 32RH 48 Measure input shaft end play Fig 137 At tach dial indi...

Page 1351: ...n output shaft 59 Install extension housing on transmission case Tighten housing fasteners to 33 N m 24 ft lbs Be sure park lock rod is properly engaged in sprag before tightening fasteners 60 Adjust...

Page 1352: ...re mounting transmission on jack and before moving transmission back under vehicle Use metal strapping C clamp or locking pliers to hold converter in place Attach hold ing tool to converter housing CA...

Page 1353: ...ith parallel jaw snap ring pliers Fig 1 Then work extension housing off bearing and output shaft Remove hous ing gasket after removing housing 5 Remove rear bearing and snap rings from out put shaft F...

Page 1354: ...hing bolts Fig 9 11 Lift valve body upward guide park rod out of case opening and remove valve body Fig 10 12 Remove accumulator spring and piston Fig 11 Note position of piston and spring for assembl...

Page 1355: ...ossibly damaging clutch or pump com ponents Fig 13 Tightening Front Band To Hold Front Clutch In Place 36RH 37RH b Remove oil pump bolts c Thread Slide Hammer Tools C 3752 into threaded holes in flang...

Page 1356: ...case bore Use pencil magnet to complete pin removal Fig 20 21 Remove triangular shaped thrust washer from output shaft hub if washer remained on hub during 36RH 37RH TRANSMISSION OVERHAUL 21 219 Fig...

Page 1357: ...aft And Planetary Geartrain 36RH 37RH 24 Remove planetary gear retaining snap ring from output shaft Fig 24 Retain snap ring if in good condition it is reusable Fig 24 Removing Planetary Snap Ring 36R...

Page 1358: ...Annulus Gears 36RH 37RH TABBED THRUST WASHER FRONT ANNULUS GEAR FRONT PLANETARY GEAR J9121 27 Fig 26 Disassembling Front Planetary And Annulus Gears 36RH 37RH erence DRIVING SHELL J9121 26 Fig 27 Rem...

Page 1359: ...ust plate from rear annulus gear Fig 31 J9121 29 Fig 29 Removing Rear Planetary Thrust Washer 36RH 37RH 30 Remove rear planetary gear from annulus gear Fig 30 J9121 30 Fig 30 Removing Rear Planetary G...

Page 1360: ...REAR BAND LOW REVERSE DRUM REAR SUPPORT DRUM RETAINING SNAP RING J9121 34 Fig 34 Removing Low Reverse Drum Snap Ring 36RH 37RH 36 Slide low reverse drum off rear support hub and out of rear band Fig 1...

Page 1361: ...Remove band adjusting lever reaction lever and reaction pin Fig 39 REAR BAND ADJUSTING LEVER REAR BAND REACTION PIN y J9121 37 Fig 39 Removing Rear Band Levers And Reaction Pin 36RH 37RH SELECT FIT P...

Page 1362: ...n and spring Fig 41 Removing Front Servo Retaining Snap Ring 36RH 37RH 46 Compress rear servo piston with C clamp and Tool C 4470 or Valve Spring Compressor C 3422 B Fig 42 Compress servo spring retai...

Page 1363: ...to hold parts in place during reas sembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and a...

Page 1364: ...227 Fig 48 Governor Snap Rings 36RH 37RH CLEANING AND INSPECTION Clean the governor and park gear components in solvent and dry with compressed air Examine the governor components carefully Fig 49 Di...

Page 1365: ...Assemble and install governor weights and spring in governor body but do not install shaft and valve at this time These parts will not be installed until after governor and park gear are installed on...

Page 1366: ...during removal Fig 52 Removing Overrunning Clutch Cam 3 Clean clutch cam bore and case Be sure to re move all chips shavings generated during cam re moval 4 Install rear support in case Align support...

Page 1367: ...l to stake case 15 Clean case and cam thoroughly Be sure any chips shavings generated during cam installation are removed from case Fig 57 Installing Overrunning Clutch Cam INSTALLING OVERRUNNING CLUT...

Page 1368: ...pect parts FRONT SERVO PISTON OVERHAUL FIG 60 1 Remove seal ring from rod guide 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discar...

Page 1369: ...ned surfaces are worn scored pitted or damaged Replace the pump gears if pitted worn chipped or damaged Inspect the fiber thrust washer Replace the washer if worn or damaged Inspect the pump and react...

Page 1370: ...mp bushing in two places with blunt punch Remove burrs from stake points with knife blade Fig 66 36RH 37RH TRANSMISSION OVERHAUL 21 233 SPECIAL BUSHING J9221 244 Fig 65 Oil Pump Bushing Replacement 36...

Page 1371: ...4 Install bolts attaching reaction shaft support to pump Tighten bolts to 20 N m 175 in lbs torque 5 Install new pump seal with Seal Installer C 3860 A and Tool Handle C 4171 6 Install new O ring on p...

Page 1372: ...aight out of piston retainer 3 Mount Bushing Installer SP 5511 on tool han dle Fig 70 4 Slide new bushing onto installer head and start bushing in retainer 5 Install new bushing until installer head b...

Page 1373: ...damaged or if the fac ing is flaking off FEELER GAUGE RH288 Fig 72 Measuring Front Clutch Pack Clearance Typical Replace the steel plates and the pressure plate i f heavily scored warped or broken Be...

Page 1374: ...sure wave spring is fully seated Tap spring into place if necessary 9 Lubricate clutch plates with transmission fluid 10 Install inner pressure plate 11 Install first clutch disc followed by a steel p...

Page 1375: ...surfaces of the output shaft Be sure the oil passages are open and clear Replace the shaft if scored pitted or damaged PLANETARY GEARTRAIN ASSEMBLY AND ADJUSTMENT 1 Lubricate sun gear and planetary g...

Page 1376: ...during installation 9 Install tabbed thrust washer in driving shell Fig 82 be sure washer tabs are seated in tab slots of driving shell Use extra petroleum jelly to hold washer in place if desired Fi...

Page 1377: ...ig 82 Installing Driving Shell Thrust Washer 36RH 37RH Fig 83 Installing Thrust Washer On Front Planetary Gear 36RH 37RH Fig 84 Assembling Front Planetary And Annulus Gears 36RH 37RH Fig 85 Installing...

Page 1378: ...BLY CAUTION Do not clamp any part of the valve body in a vise This practice will distort the valve body and transfer plate resulting in valve bind Slide valves and plugs out carefully Do not use force...

Page 1379: ...ttle valve primary spring and shuttle valve throttle plug Fig 93 15 Remove shift valve end plate and 3 2 down shift housing Fig 93 Keep housing screws with housing for installation reference 16 Remove...

Page 1380: ...ALVE PRESSURE PLUG REGULATOR VALVE THROTTLE PRESSURE PLUG 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE PLUG ALUM LINE PRESSURE ADJUSTING SCREW ADJUSTING SCREW BRACKET SWITCH THROTTLE f f L SPRING ADJUS...

Page 1381: ...special coating and cause the valves and plugs to stick and bind Inspect the valves and plugs for scratches burrs nicks or scores Also inspect the coating on the alu minum valves and plugs I f the coa...

Page 1382: ...late screws to 4 N m 35 in lbs torque 9 Install 1 2 and 2 3 shift valves and springs Fig 99 10 Install 1 2 shift control valve and spring Fig 99 11 32 DIAMETER CHECK BALL J9121 84 Fig 97 Correct Posit...

Page 1383: ...e bracket screws to 4 N m 35 in lbs torque 26 Install throttle lever in valve body Then in stall manual lever over throttle lever and start man ual lever into valve body g Installation 36RH 37RH 27 Al...

Page 1384: ...e it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turn ing the adjusting screw counterc...

Page 1385: ...cants on any part These types of lubricants can eventually block or restrict fluid passages and valve operation Do not force parts into place Most of the transmis sion components sub assemblies are ea...

Page 1386: ...Rear Servo Snap Ring 36RH 37RH Fig 106 Installing Rear Band And Link 36RH 37RH 8 Install snap ring that secures low reverse drum to rear support hub Fig 108 Fig 107 Installing Low Reverse Drum 36RH 37...

Page 1387: ...roove and ease installation Fig 111 Rotate piston into bore at same time Rock piston slightly to ease piston ring past snap ring groove and into bore Fig 111 Installing Front Servo Piston 36RH 37RH 13...

Page 1388: ...or valve will seat in this spotface Install governor body and park as follows to ensure proper alignment and opera tion a Rotate output shaft until spotface at gover nor valve shaft hole is facing upw...

Page 1389: ...e Shaft E Clips 36RH 37RH 22 Lubricate output shaft thrust plate with pe troleum jelly and install plate on output shaft hub Fig 118 Fig 118 Installing Output Shaft Thrust Plate 36RH 37RH 23 Check inp...

Page 1390: ...nsmission repair stand to tilt case rearward This makes it easier to install front rear clutch assembly 29 Align discs in rear clutch Then install and en gage assembly in front planetary and driving s...

Page 1391: ...t pump in case Then final tighten pump bolts to 20 N m 15 ft lbs torque 38 Verify correct assembly Rotate input and out put shafts and check for bind I f bind exists compo nents are either misassemble...

Page 1392: ...ll park neutral position switch in case Tighten switch to 34 N m 25 ft lbs torque 45 Align valve body on case Fig 129 Tighten valve body bolts alternately and evenly to 12 N m 105 in lbs torque Start...

Page 1393: ...stall rear bearing locating ring access cover and gasket 56 Remove repair stand and turn transmission over 57 Install new valve body manual shaft seal in case Fig 132 Lubricate seal lip and manual sha...

Page 1394: ...e protection during cleaning op erations 3 Remove shift and throttle levers from valve body manual lever shaft 4 Remove bolts attaching overdrive unit to trans mission Fig 1 Fig 1 Overdrive Unit Attac...

Page 1395: ...tely into seal before using puller bolt to withdraw seal Fig 6 Oil Pump Seal Removal 10 Remove park neutral position switch Fig 7 Fig 7 Park Neutral Position Switch Removal Installation 11 Remove oil...

Page 1396: ...ve extension to remove plug as shown 42RH TRANSMISSION OVERHAUL 21 259 ACCUMULATOR OUTER Fig 12 Accumulator Piston And Springs Fig 13 Removing Installing Front Band Reaction Pin Access Plug 17 Loosen...

Page 1397: ...ing Front Band Reaction Pin 24 Remove front band lever Fig 17 Fig 17 Removing Installing Front Band Lever 25 Slide front band rearward and onto driving shell Band will not be removed until after front...

Page 1398: ...re moval Do not allow machined surfaces on intermedi ate shaft or overdrive piston retainer to become nicked or scratched 32 Loosen rear band adjusting screw 4 5 turns J9121 127 Fig 22 Front Band Rem...

Page 1399: ...ith Valve Spring Compressor C 3422 B Fig 30 A C clamp and Special Tool C 4470 can also be used to compress rod guide Fig 26 Rear Band Pivot And Reaction Pin Location Fig 27 Low Reverse Drum And Rear B...

Page 1400: ...shings correctly The bushing replacement tools are included in Bushing Tool Set C 3887 B Pre sized service bushings are available for replace ment purposes Only the sun gear bushings are not serviced...

Page 1401: ...compressed air or allow them to air dry after clean ing Inspect condition of each clutch part after cleaning Replace the rollers and the retainer and spring as sembly if the rollers springs or spring...

Page 1402: ...removed during transmis sion disassembly remove seal with punch and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 40 OIL PUMP AND REACTION SHAFT SUPPORT CLEANING AND INSPECTION Cle...

Page 1403: ...housing and measure end clearance with a feeler gauge and straightedge Fig 41 Clearance should be 0 010 0 06 mm 0 0004 0 0025 in STRAIGHT EDGE FEELER GAUGE J9321 215 Fig 41 Measuring Pump Gear End Cle...

Page 1404: ...r cup to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of bushing 5 Assemble Bushing Installer To...

Page 1405: ...0 9 Align reaction support on pump housing Use alignment marks made at disassembly Or rotate SUPPORT S HUB Fig 49 Hub Seal Ring Position support until bolt holes in support and pump housing are all al...

Page 1406: ...Clean the front clutch components in solvent and dry them with compressed air only Do not use rags or shop towels to dry any of the clutch parts Lint SPRING RETAINER RETAINER SNAP RING J912M47 RETAINE...

Page 1407: ...fluid while assembling other clutch parts 2 Install spring in clutch piston Fig 56 CLUTCH SPRING PISTON J9321 466 Fig 56 Piston Spring Installation 3 Install new seals on piston and in hub of re taine...

Page 1408: ...the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs on the pressure and clutch plates are 42RH TRANSM...

Page 1409: ...ogether c Lubricate retainer and shaft seal rings with light coat of petroleum jelly after installation J912M50 Fig 62 Removing Input Shaft From Rear Clutch Retainer 3 Lubricate splined end of input s...

Page 1410: ...wn 9 Install wave spring in retainer Fig 66 Be sure spring is completely seated in retainer groove CLUTCH PISTON J9V2M52 Fig 65 Pressing Input Shaft Into Rear Clutch Retainer REAR CLUTCH RETAINER PIST...

Page 1411: ...s in solvent and dry them with compressed air Check sun gear and driving shell condition Re place the gear if damaged or i f the bushings are scored or worn The bushings are not serviceable Re place t...

Page 1412: ...NG SHELL FRONT THRUST PLATE OVERDRIVE PISTON RETAINER DRIVING SHELL CLUTCH CAM BOLTS INTERMEDIATE SHAFT THRUST PLATE INTERMEDIATE SHAFT J922M8 Fig 69 Transmission Planetary Gear Train Fig 70 Assemblin...

Page 1413: ...late on sun gear and rear of driving shell Fig 73 Installing Sun Gear Spacer 9 Insert sun gear into driving shell Fig 75 10 Hold sun gear in position and install rear thrust plate Plate goes over sun...

Page 1414: ...re washer tabs are seated Fig 79 Installing Rear Thrust Washer On Front Planetary Gear Fig 80 Installing Thrust Plate On Front Annulus Support 19 Assemble front annulus gear and support Be sure suppor...

Page 1415: ...rs may have to be replaced Snap ring is available in three different thicknesses for ad justment purposes Fig 85 Checking Planetary Geartrain End Play FRONT SERVO AND BAND OVERHAUL FRONT SERVO DISASSE...

Page 1416: ...reference 2 Compress cushion spring in vise only enough to allow piston plug snap ring removal Fig 87 Use wood block between vise jaws and end of piston plug to keep plug aligned and in position 3 Re...

Page 1417: ...ings with a pencil magnet Do not use pliers to remove any of the valves plugs or springs and do not force any of the components out or into place The valves and valve body housings will be damaged if...

Page 1418: ...Rod Removal 10 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Hold bracket firmly against spring tension while removing last screw 11 Remove adjusting screw...

Page 1419: ...USING HOUSING ATTACHING SCREWS Fig 102 Removing 3 4 Accumulator Housing 16 Remove following parts from valve body lower housing 3 4 shift valve and spring pressure regula tor valve spring clutch valve...

Page 1420: ...reference LOWER HOUSING VALVE BODY SCREWS 13 BOOST VALVE TUBE BRACE J9321 148 Fig 105 Valve Body Screw And Tube Brace Location 20 Remove lower housing and overdrive separa tor plate from transfer plat...

Page 1421: ...check balls are used 2 Remove E clip that secure shuttle valve second ary spring on valve stem Fig 112 3 Remove governor plug and shuttle valve covers Fig 113 4 Remove throttle plug primary spring sh...

Page 1422: ...42RH TRANSMISSION OVERHAUL 21 28S E CLIP Fig 114 Control Valve Locations Upper Housing...

Page 1423: ...ve retainer and valve spring Remove 3 4 timing valve and spring Remove quick fill valve spring and throttle Remove 3 4 shift valve and spring Remove converter clutch valve spring and 3 4 ACCUMULATOR H...

Page 1424: ...s burrs or distortion Use a straight edge to check surface flatness Minor scratches may be removed with crocus cloth using only very light pressure Minor distortion of a valve body mating surface may...

Page 1425: ...portant The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Re plac...

Page 1426: ...NG RETAINER BOOST VALVE SPRING SHUTTLE VALVE COVER 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE PLUG LINE PRESSURE ADJUSTING SCREW BOOST VALVE COVER ADJUSTING SCREW BRACKET THROTTLE PRESSURE ADJUSTING...

Page 1427: ...Align and position upper housing separator plate on transfer plate Fig 109 4 Install brace plate Fig 108 Tighten brace at taching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate...

Page 1428: ...sing port Fig 122 Seat both ends of tube once in position TUBE BRACE UPPER LOWER HOUSING PORT J9321 162 Fig 122 Boost Valve Tube Installation 3 4 Accumulator Installation 1 Position converter clutch v...

Page 1429: ...with Re tainer Tool 6583 Fig 93 8 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove de tent ball retainer tool...

Page 1430: ...ttle Pressure Adjustment clean Also make sure the tools and workbench area used for assembly operations are equally clean Shop towels used for wiping off tools and hands must be made from lint free ma...

Page 1431: ...oles in overrunning clutch cam Note that one hole is not threaded Fig 133 This hole must align with blank area in clutch cam bolt circle Fig 134 Mark hole location on clutch cam and blank area in case...

Page 1432: ...sure pin is fully seated in case Fig 136 Installing Rear Band Reaction Pin 8 Install rear band in case Fig 137 Be sure twin lugs on band are seated against reaction pin 9 Install low reverse drum and...

Page 1433: ...e drum to hub of piston retainer Fig 141 Fig 141 Installing Low Reverse Drum Retaining Snap Ring 13 Install rear band lever and pivot pin Fig 142 Align lever with pin bores in case and push pivot pin...

Page 1434: ...clutch on rear clutch Fig 147 Rotate front clutch retainer back and forth until completely seated on rear clutch 6 Coat intermediate shaft thrust washer with pe troleum jelly Then install washer in r...

Page 1435: ...hrust washer and thrust plate are not displaced during installation 10 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Also be sure front cl...

Page 1436: ...Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer Position 2 Thread two Pilot Stud Tools C 3288 B into bolt holes in oil pump flange Fig 155 3 Align and install oil pump gasket Fig 154...

Page 1437: ...ub Fig 159 Use liberal quantity of petro leum jelly to hold thrust bearing in place Note that one side of bearing has dark coated surface This surface faces overdrive piston Also be sure raised should...

Page 1438: ...neutral position switch has not been installed in case Valve body can not be in stalled i f switch is in position 3 Install valve body as follows 42RH TRANSMISSION OVERHAUL 21 301 ACCUMULATOR OUTER F...

Page 1439: ...c to prevent dirt en try 13 Install torque converter Use C clamp or metal strap to hold converter in place for installation Ver ify that converter is fully seated before installing re taining clamp 14...

Page 1440: ...rive case and transmission rear servo boss Fig 2 6 Work overdrive unit rearward and off transmis sion intermediate shaft Fig 3 a If overdrive unit does not require service in sert Alignment Tool 6227...

Page 1441: ...ON THRUST BEARING Fig 7 Removing Installing Overdrive Piston Thrust Bearing 11 Remove pump oil seal with Special Tool C 3861 Fig 8 Be sure to tighten tool threads completely into seal before using pul...

Page 1442: ...head valve body attaching bolts Fig 14 A total of 10 hex head bolts are used to se cure valve body to case 16 Lift valve body upward Push solenoid connec tor and manual lever shaft out of case Then ra...

Page 1443: ...ccess Plug 19 Remove oil pump and reaction shaft support assembly as follows a Tighten front band adjusting screw until band is tight around front clutch retainer Fig 18 This will prevent retainer fro...

Page 1444: ...lever and out of case bore with pin punch Then use pencil magnet to withdraw pin com pletely Fig 25 46RH 47RH TRANSMISSION OVERHAUL 21 307 Fig 23 Front Band Removal Fig 24 Removing Installing Front An...

Page 1445: ...her Fig 27 Removing Intermediate Shaft Thrust Plate c Slide low reverse drum off piston retainer hub and out of rear band Fig 30 ASSEMBLY J9121 508 Fig 28 Removing Intermediate Shaft And Planetary Gea...

Page 1446: ...nd back off adjusting screw 4 5 turns b Remove rear band lever pivot pin Use Allen wrench or similar tool to push pivot pin out rear of case Fig 34 Fig 33 Rear Band Adjusting Screw And Locknut 4 7 R H...

Page 1447: ...n Out Of Case 47RH Fig 36 Removing Rear Band Reaction Pin 47RH Fig 37 Removing Low Reverse Drum Snap Ring 47RH R E A C T I O N P I N LUGS J9421 445 Fig 38 Removing Low Reverse Drum And Rear Band As As...

Page 1448: ...ool around back of ring until free of ring groove Ex ercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 35 Remove tools and remove servo piston and s...

Page 1449: ...seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bo...

Page 1450: ...ch cam requires replacement install a new cam as described in the following procedure OVERRUNNING CLUTCH CAM REPLACEMENT 1 Remove clutch cam setscrew Fig 46 2 Tap old cam and spring retainer out of ca...

Page 1451: ...re cam is drawn into case evenly and does not become cocked 12 Install clutch cam setscrew Fig 46 Fig 51 Positioning Puller Plate On Clutch Cam Fig 52 Installing Overrunning Clutch Cam 13 Remove clutc...

Page 1452: ...er springs on 46RH or single spring on 47RH Fig 55 Replace the spring s if any coil is cracked distorted or collapsed ACCUMULATOR PISTON INNER SPRING 46RH ONLY OUTER SPRING SEAL RINGS J9421 447 Fig 55...

Page 1453: ...l I f doubt exists about the condi tion of any servo component replace it Do not reuse suspect parts REAR SERVO PISTON OVERHAUL FIG 57 1 Remove small snap ring and remove plug and spring from servo pi...

Page 1454: ...ot need to be replaced unless cracked severely worn or no longer hooked together Inspect the pump and support components Replace the pump or support if the seal ring grooves or ma chined surfaces are...

Page 1455: ...l and start bush ing into shaft 5 Tap bushing into place until Installer Tool SP 5118 bottoms in pump cavity Keep tool and bushing square with bore Do not allow bushing to become cocked during install...

Page 1456: ...tion shaft support seal rings will break if overspread or twisted If new rings are be ing installed spread them only enough for installa tion Also be very sure the ring ends are securely SPECIAL TOOL...

Page 1457: ...5 Remove clutch piston from retainer with a twisting motion 6 Remove and discard clutch piston inner and outer seals F R O N T CLUTCH INSPECTION Clean and inspect the front clutch components Re place...

Page 1458: ...clutch retainer 3 Mount Bushing Installer SP 5511 on tool han dle 4 Slide new bushing onto installer tool and start bushing into retainer 5 Tap new bushing into place until installer tool bottoms agai...

Page 1459: ...f the input shaft seal rings It is not necessary to remove or replace rings unless they are broken cracked or no longer securely hooked to gether Inspect the input shaft splines and machined sur faces...

Page 1460: ...aight in This could distort seals causing leakage and clutch slip 4 Assemble piston retainer and clutch retainer h Components 5 Support clutch retainer with wood blocks or in sert input shaft through...

Page 1461: ...nd front annulus gear as assembly Fig 79 Fig 79 Removing Front Planetary And Annulus Gears 3 Remove front planetary gear and thrust washer from front annulus gear Fig 80 Note thrust washer position fo...

Page 1462: ...the teeth are chipped broken or worn or the gear is cracked Replace the planetary thrust plates and the tabbed thrust wash ers if cracked scored or worn 48RH 47RH TRANSMISSION OVERHAUL 21 325 INTERME...

Page 1463: ...SSEMBLY AND ADJUSTMENT 1 Lubricate sun gear and planetary gears with transmission fluid during assembly Use petroleum jelly to lubricate intermediate shaft bushing surfaces thrust washers and thrust p...

Page 1464: ...during installation Fig 92 Installing Sun Gear And Driving Shell 9 Install tabbed thrust washer in driving shell Fig 93 be sure washer tabs are seated in tab slots of driving shell Use extra petroleu...

Page 1465: ...ERHAUL TAB DRIVING Fig 93 Installing Driving Shell Thrust Washer Fig 94 Installing Thrust Washer On Front Planetary Gear Fig 95 Assembling Front Planetary And Annulus Gears Fig 96 Installing Front Pla...

Page 1466: ...play should be 0 15 to 1 22 mm 0 006 to 0 048 in 17 If end play is incorrect install thinner thicker planetary snap ring as needed FEELER GAUGE Fig 98 Checking Planetary Geartrain End Play VALVE BODY...

Page 1467: ...lever far enough to clear detent housing 6 Remove retaining tool and remove detent ball and spring Fig 103 AND SPRING J9321 139 Fig 103 Detent Ball And Spring Removal 7 Remove washer at top of manual...

Page 1468: ...enoid wires for assembly reference Fig 109 14 Remove screws attaching solenoid assembly to valve body lower housing and remove solenoid and connector assembly Fig 110 15 Remove 3 4 accumulator housing...

Page 1469: ...VALVE TUBE BRACE J9321 148 Fig 114 Valve Body Screw And Tube Brace Location 20 Remove lower housing and overdrive separa tor plate from transfer plate Fig 115 OVERDRIVE SEPARATOR PLATE TRANSFER PLATE...

Page 1470: ...FILTER SCREEN BRACE J932M51 Fig 118 Upper Housing Separator Plate Removal REAR CLUTCH CHECK BALL J932M53 Fig 119 Rear Clutch Check Ball Location VALVE BODY UPPER HOUSING DISASSEMBLY 1 Note location o...

Page 1471: ...ickdown detent kickdown valve and throttle valve and spring Fig 123 8 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 123 Also remove shuttle valve primary spring if not removed in prior step...

Page 1472: ...ANSMISSION OVERHAUL 21 335 Fig 123 Control Valve Locations Upper Housing UPPER HOUSING PRESSURE VALVE UMIT PLUG RETAINER AND VALVE COVER SPRING COVER J932M57 Fig 124 Shift Valves And Pressure Plugs Up...

Page 1473: ...lug 4 Remove 3 4 shift valve and spring 5 Remove converter clutch valve spring and plug 6 Remove converter clutch timing valve retainer and valve spring 3 4 ACCUMULATOR HOUSING DISASSEMBLY FIG 126 1 R...

Page 1474: ...he dark color of the special coating applied to the surface or by testing with a magnet Do not 4IRH 47RH TRANSMISSION OVERHAUL 21 337 polish or sand aluminum valves or plugs with any type of material...

Page 1475: ...BOOST VALVE SPRING SHUTTLE VALVE COVER 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE PLUG LINE PRESSURE ADJUSTING SCREW BOC BOOST VALVE COVER ADJUSTING SCREW BRACKET THROTTLE PRESSURE ADJUSTING SCREW PR...

Page 1476: ...Align and position upper housing separator plate on transfer plate Fig 118 4 Install brace plate Fig 117 Tighten brace at taching screws to 4 N m 35 in lbs torque 5 Install remaing separator plate att...

Page 1477: ...er housing port Fig 130 5 Seat each end of tube in housings TUBE BRACE UPPER LOWER HOUSING PORT J9321 162 Fig 130 Boost Valve Tube Installation 3 4 Accumulator Installation 1 Position converter clutch...

Page 1478: ...with Re tainer Tool 6583 Fig 101 8 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove de tent ball retainer too...

Page 1479: ...sure Adjustment clean Also make sure the tools and workbench area used for reassembly operations are equally clean Shop towels used for wiping off tools and your hands must be made from lint free mate...

Page 1480: ...p is not available have helper install snap ring while compressing re tainer and spring by hand 5 Lubricate front servo piston components and servo bore in case with transmission fluid 6 Install front...

Page 1481: ...cannot be installed over retainer Fig 143 Installing Case Gasket 2 Install overdrive piston retainer Be sure gover nor tube bores in retainer are aligned with governor feed passages in gasket and cas...

Page 1482: ...alling Low Reverse Drum Snap Ring 46RH d Install new O rings on band reaction pin Then insert pin into case and part way into band link Fig 148 e Install rear band lever reaction lever and strut Fig 1...

Page 1483: ...g Low Reverse Drum Snap Ring 47RH d Install reaction pin in case Fig 154 Then roll band around drum until reaction lugs are seated against reaction pin Be sure pin is fully seated Fig 154 Installing R...

Page 1484: ...ch splined hub ASSEMBLY J9121 508 Fig 157 Installing Intermediate Shaft And Planetary Geartrain Fig 158 Installing Intermediate Shaft Thrust Plate 5 Install intermediate shaft thrust washer in hub of...

Page 1485: ...at front rear clutch assembly is still properly seated before tightening adjusting screw Fig 161 Installing Intermediate Shaft Thrust Washer Fig 162 Installing Front Rear Clutch Assemblies OIL PUMP IN...

Page 1486: ...Work pump into case by hand Do not use a mallet or similar tools to seat pump 7 Remove pilot studs and install oil pump bolts Tighten pump bolts alternately and evenly to fully Fig 165 Front Clutch Th...

Page 1487: ...petro leum jelly to hold thrust bearing in place Note that one side of bearing has dark coated surface This surface faces overdrive piston Also be sure raised shoulder on inside diameter of bearing f...

Page 1488: ...r inner spring pis ton and outer spring Fig 173 On 47RH install ac cumulator piston and single spring 2 Verify that park neutral position switch has not been installed in case Valve body can not be in...

Page 1489: ...e fittings filler tube bore etc to prevent dirt en try 13 Install torque converter Use C clamp or metal strap to hold converter in place for installation Be sure converter is fully seated before insta...

Page 1490: ...2 Intermediate Shaft Spacer Location 3 Remove overdrive piston from retainer Fig 3 4 Remove overdrive piston thrust bearing from direct clutch hub Fig 4 page Overdrive Unit Assembly and Adjustment 367...

Page 1491: ...output shaft bearing snap ring with snap ring pliers and push output shaft forward to re lease shaft front bearing from locating ring Fig 10 OVERDRIVE CLUTCH REACTION SNAP RING J9121 283 Fig 8 Removin...

Page 1492: ...ing and reaction plug Fig 14 16 Remove output shaft rear bearing snap ring Fig 15 Extra long internal type snap ring pliers are best for removing snap ring Or rotate snap ring until one end is adjacen...

Page 1493: ...RIVE UNIT OVERHAUL 42RH 46RH 47RH Fig 16 Governor Valve And Shaft Removal Installation F 9 1 9 Removing Governor Drive Key Fig 17 Removing Installing Governor Snap Ring 2 0 Removing Installing Front B...

Page 1494: ...hop press 8 Position Compressor Tool 6227 1 on clutch hub Fig 22 Support output shaft flange with steel press plates as shown and center assembly under press ram 9 Use Bushing Tool MB990891 or similar...

Page 1495: ...ARY THRUST BEARING CLUTCH SPRING PLATE SPRING PLATE SNAP RING SUN GEAR J9121 312 Fig 26 Removing Sun Gear Thrust Bearing Planetary Gear 17 Remove overrunning clutch assembly with ex panding type snap...

Page 1496: ...s sembly alignment reference Fig 32 24 Remove annulus gear from output shaft Fig 33 Use rawhide or plastic mallet to tap gear off shaft 25 Remove output shaft front bearing if not pre viously removed...

Page 1497: ...severely scored or worn Also replace the case seal if loose distorted or damaged Examine the overdrive and direct clutch discs and plates Fig 34 Replace the discs if the facing is worn severely scored...

Page 1498: ...earance Inspect the governor support and the two oil pres sure tubes Fig 36 The tubes are an integral part of the support Do not attempt to remove them 1 Park Lock Components The oil tubes must not be...

Page 1499: ...US GEAR Fig 37 Output Shaft Bushing Location 2 Soak direct and overdrive clutch discs in trans mission fluid before installation 3 Install new pilot bushing and clutch hub bush ing in output shaft if...

Page 1500: ...netary gear in annulus gear Fig 43 Be sure planetary pinions are fully seated in annulus gear before proceeding 14 Install direct clutch spring plate on sun gear Shoulder side of plate should face out...

Page 1501: ...SPRING PLATE PLANETARY THRUST BEARING J9121 326 Fig 45 Installing Planetary Thrust Bearing 17 Install assembled sun gear spring plate and thrust bearing Fig 46 Be sure sun gear and thrust bearing are...

Page 1502: ...ng discs and plates alternately until required number of discs and plates are in stalled c Check direct clutch pack Fig 48 42RH requires 6 discs and 5 steel plates 46RH requires 8 discs and 7 steel pl...

Page 1503: ...VEL OF 5 6 INCHES THE P R E S S MUST ALSO HAVE A BED THAT CAN B E ADJUSTED UP OR DOWN AS R E QUIRED R E L E A S E CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 25 Position Compr...

Page 1504: ...alling Direct Clutch Pack Snap Ring SPECIAL TOOL C 6227 2 CLUTCH HUB RETAINING RING J9221 5 Fig 55 Installing Clutch Hub Retaining Ring OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENT 1 Install front bearing a...

Page 1505: ...sure snap ring is fully seated 10 Position park pawl and spring in case and in stall park pawl shaft Fig 14 Verify that spring end is hooked to pawl and straight end of spring Fig 59 Installing Govern...

Page 1506: ...t bearing locating ring in case Fig 65 Fig 65 Front Bearing Locating Ring Installation 18 Support geartrain on Tool 6227 1 Fig 66 Be sure tool is securely seated in clutch hub 19 Install compounder ge...

Page 1507: ...utch pack pressure plate Fig 68 h Install clutch pack wire type retaining ring Fig 67 23 Place overdrive unit in vertical position and mount it in vise or in appropriate size hole cut into workbench B...

Page 1508: ...e pis ton thrust plate as follows a Position Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 71 b Measure distance to clutch hub thrust bear ing se...

Page 1509: ...A standard duty version is used for 3 9L 5 2L and 5 9L gas en gine applications A heavy duty version is used for VIO and diesel engine applications Except for dimensional differences the two ver page...

Page 1510: ...g to repair a suspected transfer case malfunction check all other driveline compo nents beforehand se HD Version Shown The actual cause of a problem may be related to such items as front hubs axles pr...

Page 1511: ...d sensor 3 Remove adapter clamp and screw Fig 4 4 Remove speed sensor and speedometer adapter as assembly 5 Remove speed sensor retaining screw and re move sensor from adapter 6 Remove speedometer pin...

Page 1512: ...dge of fill hole with MOPAR ATF PLUS Type 7176 or DEXRON II Automatic Transmission Fluid e Disassemble unit and replace worn or damaged components as necessary a Drain and refill to edge of fill hole...

Page 1513: ...nel lock style pliers to press rod out of lever grommet 8 Support transmission with jack stand 9 Remove rear crossmember 10 Mark front and rear propeller shafts for as sembly reference 11 Remove front...

Page 1514: ...from under transmission 6 Align and connect propeller shafts 7 Connect speed sensor wires vacuum harness and vent hose 8 Connect shift rod to transfer case lever or floor shift arm Use channel lock s...

Page 1515: ...e that screw has O ring seal Remove and dis card seal this seal 10 Remove poppet plunger with magnet Fig 8 11 Remove rear extension bolts Fig 9 A 13 or 15 mm socket is required for removal 12 Remove r...

Page 1516: ...gear and front retaining ring Figs 16 and 17 Fig 12 Removing Rear Extension Bolts 15 Loosen rear retainer with pry bar placed un der flange Fig 13 REAR RETAINING RING SPEEDOMETER GEAR J9421 279 Fig 15...

Page 1517: ...with pry tool to break sealer bead Insert tool in slot at each end of case Fig 19 J9421 282 Fig 19 Loosening Rear Case Breaking Sealer Bead 21 Unseat rear case from alignment dowels Fig 20 CASE DOWELS...

Page 1518: ...assembly out of input gear slid ing clutch and case Fig 27 7 Remove mode fork sliding clutch and shift rail as assembly Fig 28 Note which way clutch fits in fork long side of clutch goes to front 8 Re...

Page 1519: ...liding Clutch Removal J9421 292 Fig 29 Range Fork Retaining Ring Removal J9421 293 Fig 30 Range Fork And Support Sleeve Removal J9421 294 Fig 31 Shift Sector Removal Fig 32 Removing Sector Shaft O Rin...

Page 1520: ...gear out of bearing with plastic mal let Fig 36 INPUT GEAR J9421 299 Fig 36 Removing Input Gear Retaining Ring J9421 300 Fig 37 Input Gear And Planetary Assembly Removal PLANETARY AND INPUT GEAR DISAS...

Page 1521: ...ary carrier Fig 40 Lift gear straight up and out of carrier INPUT GEAR PLANETARY CARRIER J9421 303 Fig 40 Removing Input Gear From Planetary Carrier 5 Remove support sleeve from carrier Fig 41 6 Remov...

Page 1522: ...bridge on puller bolt Then in stall flat washer and nut on puller bolt Fig 46 Fig 46 Installing Puller Bridge d Hold puller bridge from turning by hand or with pliers Then tighten nut on puller bolt i...

Page 1523: ...emoval 5 Remove drive sprocket Fig 52 Note that sprocket does not have needle bearings like prior transfer case models Fig 51 Synchro Stop Ring Removal J9421 315 Fig 52 Drive Sprocket Removal FRONT RE...

Page 1524: ...Output Shaft Needle Bearing Location TRANSFER CASE CLEANING AND INSPECTION Wash all parts thoroughly in clean solvent Be sure all old lubricant sealant metal particles dirt and foreign material are re...

Page 1525: ...ings Inspect the two case halves Fig 58 for cracks po rosity damaged mating surfaces stripped bolt threads or distortion Replace either case half if nec essary However stripped threads can be repaired...

Page 1526: ...ar teeth on heavy duty models If pinion tooth wear is evident it will also be necessary to check condition of the annu lus gear teeth A PTO gear is only used on heavy duty ver sions of the NP241 The s...

Page 1527: ...and O ring re tainer in sector shaft bore Fig 65 Lubricate O ring with transmission fluid or petroleum jelly after in stallation 6 Install new oil seals in input bearing retainer and oil pump with Han...

Page 1528: ...thrust washer in carrier Fig 70 Lube washer with petroleum jelly before installation 4 Support carrier with wood blocks under PTO gear Fig 71 NP241 TRANSFER CASE 21 391 J9421 328 Fig 67 Shift Sector...

Page 1529: ...all second thrust washer in planetary car rier Be sure washer tabs are seated in carrier slots Fig 73 9 Install lock ring Fig 74 10 Install retaining ring Fig 75 T H R U S T W A S H E R T A B S IN SLO...

Page 1530: ...INSTALLATION 1 Support front case on wood blocks so case inte rior is facing up Place blocks between mounting studs on forward surface of case Be sure blocks will not interfere with input gear install...

Page 1531: ...roperly secure them Fig 82 d Turn hub over and install remaining spring in hub Position hooked end of second spring 180 away from first spring end Fig 82 Correct Position Of Struts And Springs 6 Insta...

Page 1532: ...6 Assembling Range Fork And Sliding Hub 10 Install sliding hub and retaining ring Fig 80 Be sure ring is fully seated before proceeding 11 Install mode and shift rail in sliding clutch Fig 89 12 Insta...

Page 1533: ...eat synchro hub in sliding clutch Press synchro struts inward to ease clutch back onto hub 6 Install front sprocket retaining ring Fig 93 FRONT SPROCKET FRONT SHAFT J9421 352 Fig 92 Drive Chain And Fr...

Page 1534: ...Fig 97 3 Position oil pickup tube and filter in rear case Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches Fig 98 Be sure hose that connects tube to filte...

Page 1535: ...installing any bolts Case could be cracked if shaft rail or dowels are misaligned Fig 101 Shift Rail Seated In Rear Case Bore 8 Verify that oil pump is aligned and seated on rear case Reposition pump...

Page 1536: ...l and tighten bolts to 27 34 N m 20 25 ft lbs torque 11 Apply Mopar silicone adhesive sealer to mat ing surface of PTO cover and to cover bolt shanks and underside of bolt heads Then install and tight...

Page 1537: ...bolts to 47 61 N m 35 45 ft lbs all other bolts nuts to 27 34 N m 20 25 ft lbs 10 Install companion flange seal on front shaft Fig 115 11 Install companion flange on front shaft Fig 116 Then install...

Page 1538: ...Fig 115 installing Flange Seal On Front Shaft...

Page 1539: ...power take off accessory oper ation N range is used for towing purposes A floor mounted shift lever Fig 2 is used for selecting de sired operating range The NV 021 is similar in appearance and mountin...

Page 1540: ...ures are provided in this section Gaskets are not used in the PTO adapter All mat ing surfaces are to be coated with Mopar Gasket Maker Mopar Silicone Adhesive Sealer black or Loctite 518 SHIFT LINKAG...

Page 1541: ...O accessory not compatible with adapter no gear mesh PTO accessory loose or misaligned PTO accessory damaged inoperative adapter shift lever or shift rod disconnected transmission not in drive range N...

Page 1542: ...l vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do thi...

Page 1543: ...ock N Seal or Loc tite 242 to adapter mounting nuts SHIFT ROD SPEED SENSOR WIRES LEVER VEHICLE SPEED SENSOR SPEEDOMETER J9421 224 TRANSMISSIONS EXTENSION HOUSING PTO SHIFT ROD Fig 10 Shift Rod And Spe...

Page 1544: ...2 Retaining Ring Access Cover Removal 3 Remove input bearing retainer bolts Fig 3 Fig 3 Removing Input Bearing Retainer Bolts 4 Remove input bearing retainer as follows In sert pry tool in retainer sl...

Page 1545: ...SHIFT LEVER NUT J9421 383 Fig 9 Loosening Shift Lever Nut 10 Remove bolts attaching front case to rear ex tension Fig 11 Two attaching bolts require a flat washer Fig 12 Note position of these bolts f...

Page 1546: ...Breaking Sealer Bead 12 Remove rear extension as follows a Spread mainshaft bearing retaining ring with snap ring pliers Fig 14 LIFT EXTENSION UPWARD AS LOCATING RING IS RELEASED SNAP RING PLIERS J942...

Page 1547: ...gear from mainshaft Fig 20 18 Remove speedometer gear front snap ring from mainshaft Fig 21 Fig 20 Speedometer Gear Removal Fig 21 Speedometer Gear Front Snap Ring Removal 19 Remove shift rail by pul...

Page 1548: ...ear Fig 28 26 Remove sector shaft O ring retainer Fig 29 and O ring Fig 30 NV 021 PTO ADAPTER 21 411 Fig 26 Removing PTO lnput Gear Assembly Fig 27 Removing PTO Gear Retaining Ring Fig 28 Removing PTO...

Page 1549: ...e and turn puller nut clock wise to draw bearing out of gear Fig 33 Note that bearing has built in cup plug Fig 34 PULLER BOLT SPECIAL TOOL MD998346 J9421 4H Fig 32 Tightening Puller Bolt To Seat Jaws...

Page 1550: ...in the adapter should be replaced during overhaul This is recommended as some of the snap rings can be distorted during re moval A distorted snap ring will not seat properly Inspect the bearings caref...

Page 1551: ...Fig 39 Use driver Handle C 4171 and Installer C 4210 5062 or 7828 to install bearing Seat bearing until locating ring is flush against case SPECIAL TOOL C 4171 SPECIAL TOOL C 4210 5062 OR 7828 J9421 4...

Page 1552: ...44 Fig 44 Assembling Input And PTO Gears 8 Install PTO gear retaining ring Fig 45 SNAP RING PLIERS PTO GEAR RETAINING RING J9421 420 Fig 45 Installing PTO Gear Retaining Ring 9 Install input PTO gear...

Page 1553: ...ft fork and sleeve Fig 48 Then install fork and sleeve Fig 49 Be sure sleeve is seated in input gear Fig 48 Assembling Shift Fork And Sleeve 15 Align and install sjjift fork pin in sector slot Fig 50...

Page 1554: ...And Washer 19 Install magnet in case pocket 20 Install mainshaft Fig 54 Guide shaft through sleeve and into input gear bearing 21 Install first speedometer snap ring on shaft Fig 55 followed by speedo...

Page 1555: ...Retaining Ring Installation 24 Install new seal in rear extension if necessary Use suitable size installer tool and be sure seal is fully seated 25 Apply bead of Mopar Gasket Maker Loctite 518 or Mop...

Page 1556: ...aining Ring 30 Install access cover and gasket in rear exten sion Fig 63 Then install and tighten torx screws to 8 11 N m 75 95 in lbs Fig 64 Fig 63 Access Cover And Gasket Installation Fig 64 Install...

Page 1557: ...ll screw in front case Fig 69 Tighten screw to 16 24 N m 12 18 ft lbs torque 35 Install indicator switch in front case Tighten switch to 20 34 N m 15 25 ft lbs torque 36 Install and tighten drain plug...

Page 1558: ...Clutch Disc Usage 32RH 42RH 36RH 37RH 4 6 RH 47RH Front Clutch 4 4 3 3 4 Rear Clutch 4 4 4 4 4 Overdrive Clutch 4 4 5 Direct Clutch 6 8 9 Front Clutch Spring Usage 1 9 9 11 9 11 Band Adjustments back...

Page 1559: ...ion procedures in Overdrive Unit Assembly and Adjustment Intermediate Shaft Spacer Thrust plate and spacer are select fit components Refer to size charts and selection procedures in Overdrive Unit Ass...

Page 1560: ...bs 10 0 in 4 lug converter 74 N m 55ft lbs 10 75 in 4 lug converter 31 N m 270 in lbs Crossmember Bolts Nuts 68 N m 50ft lbs Driveplate Bolts 75 N m 55ft lbs Extension Housing Bolts 43 N m 32ft lbs Fr...

Page 1561: ...ft lbs 34 47 N m 25 35ft lbs 27 34 N m 235 305 in lbs 19 26 N m 170 230 in lbs 27 54 N m 20 40ft lbs 41 68 N m 30 50ft lbs 8 14 N m 75 115 in lbs 27 31 N m 216 276 in lbs J9221 12 ITEM TORQUE Companio...

Page 1562: ...ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire Refer to the chart to decipher the tire identification code Fig 1 Performance tires will have a sp...

Page 1563: ...economy Unsatisfactory ride Cause the vehicle to drift Refer to the Tire Inflation Pressure brochure for in formation regarding proper tire inflation This infor mation is provided with the Owner s Man...

Page 1564: ...maintenance schedule in the Owners Manual This will improve tread life traction and maintain a smooth quiet ride The recommended method of tire rotation is the same side front to rear Fig 4 Other meth...

Page 1565: ...ensity as speed varies Tire noise will usually remain constant TIRE WEAR PATTERNS Under inflation will increase wear on the shoulders of the tire Over inflation will increase wear at the center of the...

Page 1566: ...MENT TOE CASTER CAMBER ALIGNMENT NOT OK ADJUST ALIGNMENT TO PREFERRED SETTINGS OK 1 CAR LEADS OPPOSITE DIRECTION PROBABLE CAUSE TIRES SWITCH TIRES FRONT TO REAR LEFT FRONT TO LEFT REAR LEFT REAR TO LE...

Page 1567: ...provide access to the valve stem Fig 3 Fig 2 Flat Face Wheel The wheel studs and nuts are designed for specific applications Do not use replacement parts of lesser quality or a substitute design Fig...

Page 1568: ...n lug nut to specified torque following same number sequence Fig 5 Tighten lug nuts in same numbered sequence a second time to the specified torque This will ensure that the wheels are thoroughly mate...

Page 1569: ...hese precautions Limited slip rear axle differential remove the op posite wheel tire Before balancing the wheels tires on a vehicle equipped with a transfer case disconnect the drive shafts MATCH MOUN...

Page 1570: ...ay be out of spec ifications Refer to Wheel and Tire Runout If the high spot is NOT within 101 6 mm 4 0 in of either high spot draw an arrow on the tread from second high spot to first Break down the...

Page 1571: ...lon overlay flat spots performance tires only Incorrect wheel bearing adjustment if applicable Loose or worn suspension steering components Certain tire tread patterns Incorrect drive shaft angles or...

Page 1572: ...ive mechanical vibration Static tire wheel unbalance will not cause vibration below 30 mph 46 km h Dy namic tire wheel unbalance will not cause vibration below 40 mph 64 km h TLR Tire Wheel Lateral ru...

Page 1573: ...al gears and bearings will cause noise Replace the defective component s as necessary TORQUE SPI SSC Suspension and Steering Components Vehicle speed sensitive mechanical vibration Worn suspension ste...

Page 1574: ...P LIGHTS OR TOOLS IN WATER TEST AREA PERSONAL IN JURY CAN RESULT When the conditions causing a water leak has been determined simulate the conditions as closely as pos sible If a leak occurs with the...

Page 1575: ...se is the result of most air leaks Air leaks can be caused by poor sealing improper body compo nent alignment body seam porosity or missing plugs in the engine compartment or door hinge pillar areas A...

Page 1576: ...oid corrosion For best results use Mopar Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Introduction group of this manual for Body Code Plate information TOUCH UP PROCEDURE 1 Scrape...

Page 1577: ...CH 4784 24073 B9452 48538 CHA94 PCH Black C C DX8 9700 15214 99 34858 90 5950 CHA85 DX8 Dk Silver Met C C KS7 4274 21077 B9137 44046 CHA91 KS7 Silver Star Met C C KAC 4276 21083 B9141 44048 CHA91 KAC...

Page 1578: ...the structural support for the roof The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface If the moldings are set in urethane it would also be unlike...

Page 1579: ...sition windshield bonding compression spac ers on lower fence above the support spacers at the edge of the windshield opening Fig 5 7 Apply a 10 mm 0 4 in bead of urethane around perimeter of windshie...

Page 1580: ...dge of replace ment rear glass frame 3 Apply black out primer to rear glass opening frame 4 Apply a 10 mm 0 4 in bead of urethane around perimeter of windshield along the inside of the moldings 5 Plac...

Page 1581: ...2 Remove bolts holding guide loop for hood safety catch release rod to grille frame 3 Remove grille 4 Remove nuts holding grille frame to hood 5 Separate grille frame from vehicle INSTALLATION Reverse...

Page 1582: ...the under hood lamp wire connector 3 Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to pro vide reference marks for installation When installing hood align...

Page 1583: ...lts 4 Remove hood hinge to cowl panel attaching bolts and separate hinge from vehicle HOOD HINGE INSTALLATION Reverse the preceding operation If necessary paint new hinge before installation HOOD LATC...

Page 1584: ...holding cowl cover to cowl box 5 Pull cowl seal from pinch flange a front of cowl 6 Separate cowl cover from vehicle INSTALLATION Reverse the preceding operation FRONT WHEELHOUSE LINER REMOWAL FIG 11...

Page 1585: ...move bolts holding front fender to cowl re inforcement Fig 13 11 Remove bolts holding front fender to radiator closure panel Fig 14 12 Remove bolts holding bottom of front fender to rocker panel lower...

Page 1586: ...oor latch and open door 2 Remove cowl trim panel 3 Disengage door wire harness connector of in strument panel harness and push door harness through access hole in pillar 4 Remove hidden bolts holding...

Page 1587: ...replacement door hinge before installation Fig 20 Door Hinge DOOR TRIM PANEL REMOVAL 1 Release door latch and open door 2 Roll window down 3 Remove window crank Fig 21 if equipped 4 Disengage clips ho...

Page 1588: ...from adhesive around pe rimeter of inner door panel INSTALLATION Reverse the preceding operation INNER DOOR BELT WEATHERSTRIP REMOVAL FIG 25 1 Remove door trim panel 2 Lift inner door belt weatherstr...

Page 1589: ...S REMOVAL FIG 28 1 Remove door trim panel 2 Remove weather shield as necessary to gain ac i yJ J9423 41 Fig 27 Door Glass Run Weatherstrip cess to door glass lift plate 3 Remove inner door belt weathe...

Page 1590: ...un channel to inner door panel 4 Slide channel downward to disengage it from the upper glass frame 5 Separate door glass run channel from door INSTALLATION Reverse the preceding operation OUTSIDE DOOR...

Page 1591: ...r latch 5 Separate lock button from vehicle INSTALLATION Reverse the preceding operation DOOR LATCH LOCK REMOVAL FIG 34 1 Remove door trim panel 2 Remove water dam 3 Disengage clips holding lock and l...

Page 1592: ...se the preceding operation MIRROR FLAG COVER REMOVAL FIG 38 1 Remove door trim panel 2 Remove flag door seal 3 Remove nuts holding door flag cover to door frame 4 Separate flag cover from vehicle INST...

Page 1593: ...jamb to aid installation 3 Remove screws holding striker to door jamb 4 Separate striker from vehicle INSTALLATION Reverse the preceding operation RETAINING PLATE SCREW J9423 49 Fig 40 Door Latch Str...

Page 1594: ...mly press seal to body surface to assure adhesion Fig 42 Door Secondary Seal ROOF RAIL WEATHERSTRIP AND RETAINER REMOVAL FIG 43 1 Release door latch and open door 2 Starting from rearward end of weath...

Page 1595: ...ts holding rear of seat tracks to floor 5 Move seat track to rearward position 6 Remove bolts holding front of seat tracks to floor 7 Separate seat from vehicle INSTALLATION Reverse the preceding oper...

Page 1596: ...t off shifter INSTALLATION Reverse the preceding operation FLOOR SHIFT Fig 4 9 Floor Shift Boot 4WD Manual FLOOR SHIFT BOOT 4WD AUTOMATIC REMOVAL FIG 50 1 Pull edge of floor shift boot upward to expos...

Page 1597: ...MOVAL FIG 53 1 Remove A pillar grab handle if equipped 2 Disengage clips holding A pillar molding to A pillar 3 Separate A pillar molding from vehicle INSTALLATION Reverse the preceding operation J942...

Page 1598: ...e clips holding top of rear closure panel trim to rear cab wall 8 Separate rear closure panel trim from vehicle INSTALLATION Reverse the preceding operation Fig 56 Rear Closure Panel Trim FLOOR CARPET...

Page 1599: ...ER PLUG J9423 177 Fig 59 Coat Hook 3 Remove screw holding sun visor hook to roof header 4 Separate sun visor hook from roof INSTALLATION Reverse the preceding operation SCREW BODY CLIP SUN VISOR ARM S...

Page 1600: ...or equivalent Wipe molding dry with lint free cloth Apply new body side molding two sided adhesive tape to back of molding 5 Clean roof joint with Mopar Super Kleen sol vent or equivalent Wipe dry wi...

Page 1601: ...mm 0 5 in for edges of doors and open ings CAUTION Do not overheat overlay when perform ing step 12 12 Apply heat to overlay to evaporate residual moisture from edges of overlay and to allow overlay t...

Page 1602: ...from adhesive tape on back of emblem 8 Position emblem properly on body 9 Press emblem firmly to body with palm of hand 10 If temperature is below 21 C 70 F warm em blem with a heat lamp or gun to ass...

Page 1603: ...the applique to use as a guide if necessary 7 Remove protective cover from tape on back of applique Apply applique to body below the masking tape guide 8 Remove masking tape guide and heat tailgate a...

Page 1604: ...Remove tail lamp refer to Group 8L Lamps for proper procedures 4 Remove nuts holding rear fender to cargo box side panel through tail lamp opening 5 Remove clearance lamps refer to Group 8L Lamps for...

Page 1605: ...ON Reverse the preceding operation TAILGATE HANDLE ESCUTCHEON REMOVAL FIG 74 1 Lift and hold tailgate latch release handle 2 Using a trim stick C4755 pry bottom of es cutcheon outward to disengage cli...

Page 1606: ...Mark outline of striker on cargo box jamb to aid installation 3 Using a Torx drive wrench remove striker from cargo box INSTALLATION Reverse the preceding operation TAILGATE PROTECTOR REMOVAL FIG 78 1...

Page 1607: ...ide wall 3 Separate fuel fill neck from cargo box 4 Disengage tail lamp wire connector from main body harness at left rear frame rail 5 Remove bolts holding cargo box to frame rails 6 Using a suitable...

Page 1608: ...er through the cowl opening and passes through a plenum chamber to the heater core Air intake openings must be kept free of snow ice TEMPERATURE EVAPORATOR BLOWER PANEL HEAT HEATER AIR DOOR DEFROST DE...

Page 1609: ...s is done by rotating the MODE control knob into the RECIRC position REFRIGERANT This vehicle uses a new type of refrigerant called R 134a It is a non toxic non flammable clear color less liquified ga...

Page 1610: ...cooling system is designed to develop internal pressure of 97 to 124 kPa 14 to 18 psi Al low the vehicle 15 minutes to cool down or until a safe temperature and pressure are attained before opening th...

Page 1611: ...is the plate fin type with a multi pass refrig erant flow path A mixture of refrigerant and oil en ters the bottom of the core It then flows through the evaporator inlet tube and is routed so that it...

Page 1612: ...f indicator ring is to be used 6 Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting If plastic indicator ring is used it will snap out of the cage...

Page 1613: ...l the evaporator core refriger ant flow This is at a point where the plate fin surface temperature will be maintained slightly above freezing This also prevents evaporator icing and the blockage of ai...

Page 1614: ...icle must be 21 C 70 F minimum for this test 1 Connect an engine tachometer and manifold gauge set 2 Set control to A C RECIRC PANEL tempera ture knob on full cool and blower on HIGH Compres sor ON 3...

Page 1615: ...3to3 C 27 38 F 1 to 7 C 33 44 F 3to9 C 37 48 F 6 to 13 C 43 55 F 10tol8 C 50 64 F Evaporator Inlet Pressure at Charge Port 172 241 IcPa 25 35 psi 221 276 kPa 32 40 psi 255 310 kPa 37 45 psi 269 345 k...

Page 1616: ...CHARGE BYPASS CYCLING CLUTCH PRESSURE SWITCH USING JUMPER WIRE REFER TO GROUP 8 WIRING DIAGRAMS CORRECT EVAPORATOR INLET GAUGE PRESSURE CORRECT COMPRESSOR DISCHARGE GAUGE PRESSURE PRESSURES OK SYSTEM...

Page 1617: ...selection is made I f the gauge cannot achieve the calibrated setting a vacuum cir cuit or component has a leak LOCATING VACUUM LEAKS To locate a vacuum leak disconnect 7 way vacuum connector behind...

Page 1618: ...the accumulator If voltage is not detected refer to Group 8W Wiring Diagrams The appropriate Powertrain Diagnostic Procedures Manual for diagnostic information If voltage is detected at the cut off sw...

Page 1619: ...NGINE ON SHUT BLOWER MOTOR OFF NOISE STILL PRESENT NOISE GONE RE CHECK OK PROBLEM NOT IN BLOWER SYSTEM VIBRATION STILL PRESENT CHECK BLOWER SCROLL AREA FOREIGN AAATERIAL IN FAN OR SCROLL YES REMOVE FO...

Page 1620: ...EPLACE SWITCH MOTOR O K INSTALL FUSE MOTOR SHORTED OR STALLED REPLACE FUSE TEST VOLTAGE AT BOTH ENDS OF FUSE REPLACE MOTOR VOLTAGE NO VOLTAGE CHECK FOR OPEN CIRCUIT FUSE BLOCK TO MOTOR CHECK FOR BAD C...

Page 1621: ...COMPRESSOR WON T TURN PROPERLY CLUTCH ENGAGES BUT SLIPS OR S M O f C i l I CLUTCH SLIPPING LOW VOLTAGE AT CLUTCH CHECK WIRING SWITCHES CLUTCH AMPERAGE AND GROUND AMPERAGE GREATER THAN 5 AMPS CLUTCH CO...

Page 1622: ...system by 2 heater hoses With engine idling at normal running temperature set the control to maximum heat floor and high blower setting Using a test thermometer check the air temperature coming from t...

Page 1623: ...refrigerant from being release into the atmosphere MANIFOLD GAUGE SET CONNECTIONS CAUTION DO NOT use an R 12 manifold gauge set on an R 134a system The refrigerants are not com patible and system dama...

Page 1624: ...to be oily usually will indicate a refrigerant leak To in spect the evaporator core for leaks it is possible to insert the leak detector probe into the recirculating air door opening With the blower...

Page 1625: ...tem with 0 91 kg 2 00 lbs or 32 oz of R 134a refrigerant DISCHARGING REFRIGERANT SYSTEM R 134a refrigerant is a hydrofluorocarbon HFC that does not contain chlorine R 134a refrigerant re cycling devic...

Page 1626: ...ystem The oil used in the SD 709 compressor is a poly alkylene glycol synthetic oil SP20 PAG wax free re frigerant oil Only refrigerant oil of the same type should be used to service the system Do not...

Page 1627: ...fer to Group 7 Cooling System 3 Disconnect compressor clutch wire lead 4 I f the compressor must be removed from the ve hicle discharge the A C system into a recovery recy cle device refer to Refriger...

Page 1628: ...he compressor shaft REMOVAL 1 Insert the pins of the Front Plate Spanner Tool 6462 into any 2 threaded holes of the clutch front plate Fig 1 Hold clutch plate stationary Remove hex nut Fig 1 Magnetic...

Page 1629: ...s Finger tighten bolts J8924 22 Fig 6 Install Puller Plate 9 Turn puller center bolt clockwise until rotor pulley is free 10 Loosen coil lead wire from clip on top of com pressor front housing Fig 7 J...

Page 1630: ...place on compressor shaft b Replace compressor shaft key c Align front plate keyway to compressor shaft key 10 Using Shaft Protector Tool 6141 2 tap front plate over compressor shaft until it has bot...

Page 1631: ...e the A C clutch 20 times 5 sec on and 5 sec off During this procedure set the system to the A C mode engine RPM at 1500 2000 and high blower speed This pro cedure burnishing will seat the opposing fr...

Page 1632: ...nt Panel and Gauges Fig 1 HEATER A C CONTROL PANEL VACUUM LINES T E M P E R A T U R E B L E N D A I R D O O R C A B L E J9424 6 Fig 1 Heater A C Control Panel 3 Disconnect the vacuum connector on heat...

Page 1633: ...seal is installed on the blower mo tor housing Fig 5 4 Install the blower motor and wheel assembly 5 Install and tighten blower motor and wheel as sembly screws BLOWER MOTOR J9324 33 Fig 5 Blower Mot...

Page 1634: ...9 Remove the instrument panel refer to Group 23 Body 10 Remove the defrost duct Fig 8 11 Disconnect the electrical connections 12 Remove the attaching nuts from the studs in the passenger compartment...

Page 1635: ...and tighten the screws 3 Install the heater A C unit into the vehicle re fer to Heater A C Unit Installation EVAPORATOR CORE REMOVAL 1 Remove the heater A C unit from the vehicle refer to Heater A C U...

Page 1636: ...emove the recirculating door through the top opening INSTALLATION 1 Install the recirculating door through the top opening and position in place 2 Press the recirculating door shaft retainer onto the...

Page 1637: ...on the lower center air duct 5 Install the heater A C unit into the vehicle re fer to Heater A C Unit Installation HEAT DEFROST DOOR ACTUATOR REMOVAL 1 Remove the heater A C unit from the vehicle ref...

Page 1638: ...vot connection onto the door pivot pin 4 Connect the vacuum line 5 Install the heater A C unit into the vehicle re fer to Heater A C Unit Installation PANEL DEFROST DOOR REMOVAL 1 Remove the instrumen...

Page 1639: ...fer to Refrigerant Service Procedures 6 Connect the negative cable to the battery J 9 4 2 4 3 6 Fig 20 A C Condenser Mounting Diesel Engine ACCUMULATOR REMOVAL 1 Disconnect the negative cable from the...

Page 1640: ...the fixed orifice tube using a needle nose pliers INSTALLATION 1 Install the fixed orifice tube 2 Connect the quick connect fittings at the con denser 3 Evacuate the A C system refer to Refrigerant Se...

Page 1641: ...p 8K Windshield Wiper and Washer Systems 3 Disconnect the vacuum hose Fig 24 4 Remove the reservoir attaching screws Fig 24 Remove the vacuum reservoir VACUUM RESERVOI J9424 34 Fig 24 Vacuum Reservoir...

Page 1642: ...gas engines or the diesel engine will not use an AIR pump Maintenance requirements for LDC and HDC emis sion systems differ because of different load and op erating conditions This section will cover...

Page 1643: ...eeds if adjustable Spark plug and gap The 5 9L HDC gas powered engine will have two labels One of the labels is located in front of the ra diator in the engine compartment Fig 2 and will contain vacuu...

Page 1644: ...G VEHICLE X X LITER PCR5 9T5FEY4 PTAPG SPARKPLUGS OXXX in GAP RC12YC NO ADJUSTMENTS NEEDED TEE CONNECTOR W ORIFICE EVAP CANISTER ROLLOVER VALVE W ORtFfCE f 2 5i PCV VALVE TO CLIMATE CONTROL VEHIGf SPE...

Page 1645: ...WHEN EQUIPPED ROLLOVER VALVE W ORIFICE CRANKCASE BREATHER TO BRAKE BOOSTER AIR PUMP INTAKE AAANIFOLD ORIFICE CHECK VALVE W ORIFICE J9325 34 ENGINE VACUUM SCHEMATIC 8 0L V 10 ENGINE ROLLOVER VALVE W O...

Page 1646: ...oal granules Fuel tank pressure vents into the EVAP canister Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold The EVAP canister purge solenoid allows t...

Page 1647: ...This dual function valve will relieve fuel tank pressure and also prevent fuel flow through the fuel tank vent hoses in the event of an accidental vehicle rollover The valve incorporates a pressure re...

Page 1648: ...ke mani fold vacuum Fig 9 Filtered air is routed into the crankcase through the air filter hose and crankcase breather filter This forces crankcase vapors through the PCV valve It is then drawn into a...

Page 1649: ...ssure to reduce 4 Turn engine off and remove PCV valve from cylinder head valve cover The valve should rattle when shaken Fig 15 Replace the PCV valve and retest the system if it does not operate as d...

Page 1650: ...horoughly drained More fre quent service may be necessary for vehicles operated extensively on short run stop and go or extended en gine idle service The filter must be replaced at correct intervals R...

Page 1651: ...TROL ORIFICE EXHAUST GAS INLET DOWNSTREAM ORIFICE J9425 20 Fig 21 Typical EGR Valve If the electrical connector to the E E T is dis connected or the electrical signal is lost the E G R valve will oper...

Page 1652: ...or driveability To be sure of proper op eration of the EGR system inspect all passages for blockage Check moving parts for binding Inspect the complete system for leaks Replace system com ponents or h...

Page 1653: ...inspect port slot type in throttle bore and associated passage in throttle body Use suitable sol vent to remove deposits and check for flow with light air pressure Normal operation should be restored...

Page 1654: ...lacement procedures OXYGEN 02S SENSOR For description operation diagnosis and removal installation procedures of the 02S sensor refer to Group 14 Fuel Systems INTAKE MANIFOLD AIR HEATER DIESEL ENGINE...

Page 1655: ...Check Valve 16 The system does not interfere with the ability of the EGR system to control nitrous oxide NOx emis sions 5 9L HDC ENGINE Air is drawn into the pump through a rubber tube that is connect...

Page 1656: ...flow through these valves in one direction only to wards the catalytic convertors Downstream air flow assists the oxidation process in the catalyst but does not interfere with EGR op eration AIR INJEC...

Page 1657: ...ition Possible Caust Correction EXCESSIVE 1ELT NOSE a Loose belt or defective auto belt tensioner a Refer to Group 7 Cooling b Seized pump b Replace pump EXClSSl i WJMP NOISE CHIRPING a Insufficient b...

Page 1658: ...Disconnect the air pump hose at the filter housing 4 The bottom front of the air filter housing is equipped with a rubber grommet Fig 1 A mounting stud is attached to the intake manifold Fig 1 and is...

Page 1659: ...filter housing 5 Position filter element into filter cover Latch the spring clips to seal cover to housing 6 Install the air inlet tube at air filter housing in let 7 Install and tighten clamp at air...

Page 1660: ...en the air inlet tube clamp at air filter housing inlet Fig 5 Remove this tube at air filter housing cover 2 The housing cover is equipped with four 4 spring clips Fig 5 and is hinged at the front wit...

Page 1661: ...he housing Fig 8 3 Remove the rubber cap Fig 8 4 Remove the mounting bracket strap bolt 5 Note the position of the tube fittings before re moving filter assembly from bracket Gently bend the strap and...

Page 1662: ...que 3 Connect vacuum hose to valve transducer as sembly 4 Clean upper and lower mating areas of intake manifold Fig 10 EGR Valve and Mounting Bolts 8 0L V 10 Engine 5 Install upper half of intake mani...

Page 1663: ...s to 23 N m 200 in lbs torque 8 Install vacuum lines to EGR valve 9 Install spark plug cable loom and plug cables to valve cover mounting stud 10 Install air filter housing EGR TUBE 8 9L V 10 ENGINE R...

Page 1664: ...solenoid Fig 15 3 Disconnect vacuum harness at solenoid Fig 15 Fig 15 Purge Solenoid 3 9U5 2U5 9L Engines Typical 4 Remove solenoid and its support bracket from intake manifold one bolt 5 2L 5 9L eng...

Page 1665: ...t or before draining the fuel tank OXYGEN 02S SENSOR For description operation diagnosis and removal installation procedures of the 02S sensor refer to Group 14 Fuel Systems POWERTRAIN CONTROL MODULE...

Page 1666: ...E 21 164 AFTERMARKET PAINT AND TRIM CODE DESCRIPTIONS 23 4 AIR AND TRANSMISSION TEMPERATURE SENSORS SENSOR RESISTANCE OHMS ENGINE COOLANT INTAKE 14 58 14 140 AIR BLEED PROCEDURE 14 119 AIR CLEANER ENG...

Page 1667: ...BEARING 2 25 AXLE SHAFT OIL SEAL 2 35 AXLE SHAFT REMOVAL INSTALLATION 3 29 AXLE SHAFT SEAL AND BEARING SERVICE 3 11 AXLE SHAFT CARDAN U JOINT 2 26 AXLE SPECIFICATIONS 9 1 4 INCH 3 24 AXLE SPECIFICATIO...

Page 1668: ...SC 5 47 BREAK IN PERIOD 0 16 0 21 BREATHER FILTER CRANKCASE 25 9 BUCKLE SEAT BELT 23 22 BULB APPLICATION 8L 10 BULB CARGO LAMP 8L 4 BULB FRONT SIDE MARKER LAMP 8L 4 BULB HEADLAMP 8L 4 BULB LICENSE PLA...

Page 1669: ...37 14 87 CIRCUIT TESTS VOLTAGE DROP METHOD STARTER FEED 8 11 CIRCUIT TESTS STARTER CONTROL 8 12 CIRCUIT VOLTAGE BATTERY OPEN 8 5 CIRCUIT VOLTAGE TEST BATTERY OPEN 8 5 CIRCUITS ELECTRICAL 24 15 CIRCUI...

Page 1670: ...AIR 14 48 CONTROL IAC MOTOR PIN 60 PCM OUTPUT IDLE AIR 14 48 CONTROL INFORMATION LABEL TYPICAL VEHICLE EMISSION 25 3 CONTROL INFORMATION VECI LABEL VEHICLE EMISSION 25 2 CONTROL MODULE ACM AIRBAG 8M 2...

Page 1671: ...3 37 DESCRIPTION AND OPERATION 7 58 DESCRIPTION AND OPERATION SYSTEM 13 5 DESCRIPTION 5 8 DESCRIPTION COMPONENT BRAKES 5 15 DESCRIPTION COMPONENT HEATING AND AIR CONDITIONING 24 4 DESCRIPTION OVERHEA...

Page 1672: ...SASSEMBLY AND OVERHAUL ADAPTER 21 407 DISASSEMBLY AND OVERHAUL MASTER CYLINDER 5 11 DISASSEMBLY AND OVERHAUL TRANSMISSION 21 8 21 53 DISASSEMBLY DIFFERENTIAL FRONT SUSPENSION AND AXLE 2 35 DISASSEMBLY...

Page 1673: ...NGINE SPEED SENSOR DIESEL 8H 16 ENGINE ENGINE VACUUM SCHEMATIC 5 9L V 8 HDC 25 4 ENGINE ENGINE VACUUM SCHEMATIC 8 0L V 10 25 4 ENGINE EVAP CANISTER PURGE SOLENOID 3 9L 5 2L 5 9L 25 23 ENGINE EVAP CANI...

Page 1674: ...EMS 25 6 25 23 FILLER TUBE CAP FUEL TANK FUEL SYSTEM 14 27 FILLER TUBE NO LEAD FUEL TANK 14 27 FILTER AIR INJECTION PUMP AIR 25 20 FILTER BYPASS VALVE OIL 9 163 FILTER ENGINE OIL 0 17 0 22 FILTER FUEL...

Page 1675: ...WN SOLENOID RELAY 14 19 14 133 FUEL SHUTDOWN SOLENOID RELAY TEST 14 101 FUEL SHUTDOWN SOLENOID TEST 14 100 FUEL SUPPLY RESTRICTIONS 14 100 FUEL SYSTEM AIR IN 14 97 FUEL SYSTEM OPERATION DIESEL 14 20 F...

Page 1676: ...ERATOR SPECIFICATIONS BATTERY STARTER GENERATOR SERVICE 8B 10 GENERATOR SPECIFICATIONS BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICSA 8 21 GENERATOR TEST PROCEDURES 8 15 GLASS DOOR 23 16 GLASS RUN LOW...

Page 1677: ...104 14 140 IFS FRONT SUSPENSION COMPONENTS 2 48 IFS SUSPENSION ALIGNMENT AND ADJUSTMENTS 2 9 IFS SUSPENSION AND STEERING SYSTEM DIAGNOSIS 2 10 IFS SUSPENSION PRE ALIGNMENT INSPECTION 2 7 IGNITION CAB...

Page 1678: ...NSOR RESISTANCE OHMS ENGINE COOLANT 14 58 14 140 INTAKE HEATER INTAKE MANIFOLD COVER AIR 11 16 INTAKE MANIFOLD AIR HEATER 14 17 14 137 INTAKE MANIFOLD AIR HEATER RELAY TEST 14 106 INTAKE MANIFOLD AIR...

Page 1679: ...23 18 LOCK HYDROSTATIC 9 4 LOCK MOTOR AND LATCH ASSEMBLY REPLACEMENT 8P 3 LOCK MOTOR STALL TEST 8P 2 LOCK SERVICE 32RH 36RH 37RH PARK 21 162 LOCK SERVICE 42RH 46RH 47RH GOVERNOR AND PARK 21 162 LOCKOU...

Page 1680: ...N CONTROL 14 65 14 107 MODULE TEST 8 0L V 10 ENGINE IGNITION CONTROL 8D 14 MODULE 8 0L V 10 ENGINE IGNITION CONTROL 8D 7 8D 32 MODULE ALL GAS POWERED ENGINES FUEL PUMP 14 3 MODULE DIESEL ENGINE FUEL T...

Page 1681: ...6RH 37RH EXTENSION HOUSING BUSHING 21 160 OUTPUT SHAFT OVERHAUL PLANETARY GEAR TRAIN 21 237 OUTPUT SPEED CONTROL PCM PINS 33 AND 53 PCM 14 43 14 91 OUTPUT SPEED CONTROL PCM PINS 53 AND 33 PCM 14 47 14...

Page 1682: ...87 PIN 20 PCM OUTPUT GENERATOR FIELD PCM 14 39 14 88 PIN 21 PCM INPUT INTAKE MANIFOLD AIR TEMPERATURE SENSOR PCM 14 39 14 88 PIN 22 PCM INPUT THROTTLE POSITION SENSOR PCM 14 40 14 89 PIN 23 PCM INPUT...

Page 1683: ...G BALL 19 19 POWER STEERING GEAR SPECIFICATIONS 19 33 POWER STEERING HOSE 19 11 POWER STEERING PUMP 19 11 POWER STEERING PUMP INITIAL OPERATION 19 16 POWER STEERING SYSTEM DIAGNOSIS 19 2 19 4 19 5 19...

Page 1684: ...117 REAR SERVO AND BAND OVERHAUL 21 198 21 231 21 279 21 316 REAR SPEAKERS 8F 13 REAR SPEED SENSOR HARNESS INSTALLATION 5 44 REAR SPEED SENSOR HARNESS REMOVAL 5 44 REAR SPEED SENSOR INSTALLATION 5 43...

Page 1685: ...ENGINE IGNITION COIL 8D 14 8D 40 RESISTOR BLOWER MOTOR 24 26 RESTRICTIONS FUEL SUPPLY 14 100 RETAINER CRANKSHAFT REAR SEAL 9 117 RETAINER INSPECTION AND OVERHAUL OVERRUNNING CLUTCH LOW REVERSE DRUM O...

Page 1686: ...9L V 6 OR 5 2 5 9L V 8 ENGINES CRANKSHAFT POSITION 8D 11 SENSOR TEST 8 0L V 10 ENGINE CAMSHAFT POSITION 8D 11 SENSOR TEST 8 0L V 10 ENGINE CRANKSHAFT POSITION 8D 12 SENSOR THROTTLE POSITION 14 138 SE...

Page 1687: ...IC TRANSMISSION PRESSURE TEST 21 423 SPECIFICATIONS 4X2 AND 4X4 ALIGNMENT 2 49 SPECIFICATIONS 9 1 4 INCH AXLE 3 24 SPECIFICATIONS ALIGNMENT 2 49 SPECIFICATIONS AUTOMATIC TRANSMISSION GENERAL 21 421 SP...

Page 1688: ...ON SHAFT 21 185 21 232 21 264 21 316 SUPPORT OVERHAUL OVERRUNNING CLUTCH LOW REVERSE DRUM REAR 21 181 SUPPORT PLATE INSTALLATION BRAKE 5 69 SUPPORT PLATE REMOVAL BRAKE 5 68 SURFACE TOUCH UP PAINTED 23...

Page 1689: ...14 27 TANK FUEL FILTER IN 14 16 14 122 TANK FUEL 14 15 14 134 TANK MODULE FUEL 14 134 TANK MODULE DIESEL ENGINE FUEL 14 12 TANK PRESSURE RELIEF ROLLOVER VALVE FUEL 14 27 14 78 TANKS FUEL 14 25 14 78...

Page 1690: ...K 14 61 THROTTLE CABLE ACCELERATOR PEDAL 14 21 14 72 THROTTLE CABLE ASSEMBLY SERVO 8H 13 THROTTLE CABLE 14 22 THROTTLE CABLE REPLACEMENT 21 156 THROTTLE LINKAGE ADJUSTMENT DIESEL ENGINE 14 23 THROTTLE...

Page 1691: ...TUBES LINES HOSES AND CLAMPS FUEL 14 8 14 78 TUBES LINES HOSES AND CLAMPS LOW PRESSURE TYPE FUEL 14 17 TUBING AND FITTINGS HANDLING 24 3 TURBOCHARGER 5 9L DIESEL ENGINE 11 2 TURBOCHARGER 11 17 TURBOCH...

Page 1692: ...TIFICATION LABEL lntro 1 VEHICLE SPEED CONTROL SWITCH TEST 8H 8 VEHICLE SPEED CONTROL SYSTEM ELECTRICAL TESTS 8H 6 VEHICLE SPEED CONTROL SYSTEM SCHEMATIC 8H 9 VEHICLE SPEED SENSOR FUEL SYSTEM 14 83 14...

Page 1693: ...23 31 WHEELS 22 6 WHEN KEYS ARE NOT AVAILABLE TOWING 0 14 WILL NOT SOUND HORNS 8G 1 WINCH SPARE TIRE 13 3 WIND NOISE 23 2 WINDOW DEMISTERS SIDE 24 1 WINDOW REAR 23 6 WINDOW REGULATOR DOOR GLASS 23 16...

Page 1694: ...low In some cases it may be helpful to send a copy of the service manual page marked with your comments What features do you find most useful What errors have you found Please include page number What...

Page 1695: ...Fold Here Place Stamp Here Chrysler Corporation Service Publications CIMS 424 81 55 25999 Lawrence Ave Center Line Ml 48015 Fold Here...

Page 1696: ...low In some cases it may be helpful to send a copy of the service manual page marked with your comments What features do you find most useful What errors have you found Please include page number What...

Page 1697: ...Fold Here Place Stamp Here Chrysler Corporation Service Publications CIMS 424 81 55 25999 Lawrence Ave Center Line Ml 48015 Fold Here...

Page 1698: ...low In some cases it may be helpful to send a copy of the service manual page marked with your comments What features do you find most useful What errors have you found Please include page number What...

Page 1699: ...Chrysler Corporation Service Publications CIMS 424 81 55 25999 Lawrence Ave Center Line Ml 48015...

Page 1700: ...low In some cases it may be helpful to send a copy of the service manual page marked with your comments What features do you find most useful What errors have you found Please include page number What...

Page 1701: ...Fold Here Place Stamp Here Chrysler Corporation Service Publications CIMS 424 81 55 25999 Lawrence Ave Center Line Ml 48015 Fold Here...

Page 1702: ...U S T O M E R S A T I S F A C T I O N A N D V E H I C L E Q U A L I T Y WE ENCOURAGE PROFESSIONALISM THROUGH TECHNICIAN CERTIFICATION 81 370 4108 C u s t o m e r O n e o S E R V I C E P U B L I C A T...

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