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Dodge 1997 Ram 1500, Owner'S Manual

The 1997 Dodge Ram 1500 Owner's Manual is a comprehensive guide for owners, providing detailed information about operating and maintaining their vehicle. This manual is available for free download at manualshive.com, where users can easily access this essential resource to ensure they get the best out of their Dodge Ram experience.

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CASE - NV271 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-447

CASE - NV271 - DIAGNOSIS AND

TESTING, TRANSFER . . . . . . . . . . . . . . . . . 21-448

CASE - NV271 - DISASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-450

CASE - NV271 - INSPECTION, TRANSFER . 21-459
CASE - NV271 - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-473

CASE - NV271 - OPERATION, TRANSFER

. 21-448

CASE - NV271 - REMOVAL, TRANSFER

. . 21-450

CASE - NV273 - ASSEMBLY, TRANSFER

. . 21-556

CASE - NV273 - CLEANING, TRANSFER

. . 21-554

CASE - NV273 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-542

CASE - NV273 - DIAGNOSIS AND

TESTING, TRANSFER . . . . . . . . . . . . . . . . . 21-543

CASE - NV273 - DISASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-544

CASE - NV273 - INSPECTION, TRANSFER . 21-554
CASE - NV273 - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-568

CASE - NV273 - OPERATION, TRANSFER

. 21-543

CASE - NV273 - REMOVAL, TRANSFER

. . 21-544

CASE BEARINGS - INSTALLATION,

DIFFERENTIAL . . . . . 3-106,3-134,3-161,3-48,3-75

CASE BEARINGS - REMOVAL,

DIFFERENTIAL . . . . . 3-105,3-134,3-161,3-48,3-75

CASE CONTROL MODULE -

DESCRIPTION, TRANSFER . . . . . . . . . . . . . 8E-16

CASE CONTROL MODULE - OPERATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16

CASE, NV241 GENII - TRANSFER

. . . . . . . 21-438

CASE, NV241/NV243 - TRANSFER

. . . . . . 21-439

CASE, NV243 - TRANSFER

. . . . . . 21-505,21-506

CASE, NV244 GENII - TRANSFER

. . . . . . . 21-535

CASE, NV271 - TRANSFER

. . . . . . . . . . . . 21-473

CASE NV271/NV273, SPECIAL TOOLS -

TRANSFER . . . . . . . . . . . . . . . . . . . 21-474,21-569

CASE, NV273 - TRANSFER

. . . . . . . . . . . . 21-568

CASE SKID PLATE - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26

CASE SKID PLATE - REMOVAL,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26

CASTER ADJUSTMENT - STANDARD

PROCEDURE, CAMBER . . . . . . . . . . . . . . . . . . 2-4

CASTER AND TOE ADJUSTMENT -

STANDARD PROCEDURE, CAMBER . . . . . . . . 2-4

CATALYTIC CONVERTER - DESCRIPTION

. . . 11-6

CATALYTIC CONVERTER - OPERATION

. . . . . 11-6

CATCH - INSTALLATION, LATCH STRIKER

/ SECONDARY . . . . . . . . . . . . . . . . . . . . . . . 23-48

CATCH - REMOVAL, LATCH STRIKER /

SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . 23-47

CAUTION - A/C SYSTEM

. . . . . . . . . . . . . . . 24-43

CAUTION, HALF SHAFT

. . . . . . . . . . . . . . . . . 3-20

CAUTION, INTERIOR

. . . . . . . . . . . . . . . . . . 23-62

CENTER - DESCRIPTION, ELECTRONIC

VEHICLE INFO . . . . . . . . . . . . . . . . . . . . . . . 8M-7

CENTER - DIAGNOSIS AND TESTING,

ELECTRONIC VEHICLE INFORMATION . . . . . 8M-8

CENTER - INSTALLATION, ELECTRONIC

VEHICLE INFO . . . . . . . . . . . . . . . . . . . . . . . 8M-9

CENTER & LEFT OUTBOARD -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-50

CENTER & LEFT OUTBOARD - REMOVAL . . 8O-48
CENTER - OPERATION, ELECTRONIC

VEHICLE INFO . . . . . . . . . . . . . . . . . . . . . . . 8M-7

CENTER - REMOVAL, ELECTRONIC

VEHICLE INFO . . . . . . . . . . . . . . . . . . . . . . . 8M-9

CENTER ANCHOR & RIGHT OUTBOARD -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-50

CENTER ANCHOR & RIGHT OUTBOARD -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-49

CENTER ARMREST / SEAT BACK -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-77

CENTER ARMREST / SEAT BACK -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23-76

CENTER BEARING - ADJUSTMENTS

. . . . . . . . 3-9

CENTER BEARING - INSTALLATION

. . . . . . . . 3-9

CENTER BEARING - REMOVAL

. . . . . . . . . . . . 3-9

CENTER BEZEL - INSTALLATION,

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 23-57

CENTER BEZEL - REMOVAL,

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 23-57

CENTER HIGH MOUNTED STOP LAMP -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8L-11

CENTER HIGH MOUNTED STOP LAMP -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11

CENTER HIGH MOUNTED STOP LAMP

UNIT - INSTALLATION . . . . . . . . . . . . . . . . . 8L-11

CENTER HIGH MOUNTED STOP LAMP

UNIT - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-11

CENTER PROGRAMMING - STANDARD

PROCEDURE, ELECTRONIC VEHICLE
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 8M-8

CENTER SEAT - INSTALLATION

. . . . . . . . . . 23-76

CENTER SEAT - REMOVAL

. . . . . . . . . . . . . 23-75

CENTER SEAT BACK HINGE -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-79

CENTER SEAT BACK HINGE - REMOVAL . . . 23-78
CENTER SEAT BACK INERTIA HINGE

COVER - INSTALLATION . . . . . . . . . . . . . . . 23-77

CENTER SEAT BACK INERTIA HINGE

COVER - REMOVAL . . . . . . . . . . . . . . . . . . . 23-77

CENTER SEAT BACK LID - INSTALLATION

. 23-79

CENTER SEAT BACK LID - REMOVAL

. . . . . 23-79

CENTER SEAT BELT - INSTALLATION,

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-31

CENTER SEAT BELT - REMOVAL, FRONT

. . 8O-30

CENTER SEAT BELT & RETRACTOR -

INSTALLATION, FRONT . . . . . . . . . . . . . . . . 8O-29

CENTER SEAT BELT & RETRACTOR -

INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8O-45

CENTER SEAT BELT & RETRACTOR -

REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . . 8O-29

CENTER SEAT BELT & RETRACTOR -

REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8O-44

CENTER SEAT CUSHION - INSTALLATION . . . 23-79
CENTER SEAT CUSHION - REMOVAL

. . . . . 23-79

CENTER SEAT CUSHION COVER -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-79

CENTER SEAT CUSHION COVER -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23-79

CENTERING - STANDARD PROCEDURE,

CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . 8O-19

CERTIFICATION LABEL - DESCRIPTION,

VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-11

CHAIN COVER(S) - INSTALLATION,

TIMING BELT . . . . . . . . . . . . . . . . . . . . 9-171,9-81

CHAIN COVER(S) - REMOVAL, TIMING

BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 9-170,9-81

CHAIN WEAR - STANDARD PROCEDURE,

MEASURING TIMING . . . . . . . . . . . . . . . . . . 9-167

CHAIN WEAR, STANDARD PROCEDURE -

MEASURING TIMING . . . . . . . . . . . . . . . . . . . 9-77

CHAIN/TENSIONER - DESCRIPTION,

TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-229

CHAIN/TENSIONER - OPERATION,

TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-229

CHANNEL - INSTALLATION, GLASS RUN

. . 23-22,

23-31

CHANNEL - REMOVAL, GLASS RUN

. 23-21,23-30

CHARGE - STANDARD PROCEDURE,

REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-47

CHARGE AIR COOLER AND PLUMBING -

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17

CHARGE AIR COOLER AND PLUMBING -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 11-16

CHARGE AIR COOLER AND PLUMBING -

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11-17

CHARGE AIR COOLER AND PLUMBING -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 11-17

CHARGE AIR COOLER AND PLUMBING -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

CHARGE AIR COOLER AND PLUMBING -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17

CHARGE AIR COOLER SYSTEM - LEAKS

- DIAGNOSIS AND TESTING . . . . . . . . . . . . 11-16

CHARGING - DESCRIPTION

. . . . . . . . . . . . . 8F-19

CHARGING - OPERATION

. . . . . . . . . . . . . . 8F-19

CHARGING - STANDARD PROCEDURE,

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-8

CHARGING SYSTEM - DIAGNOSIS AND

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19

CHARGING SYSTEM - SPECIFICATIONS,

TORQUE - GENERATOR . . . . . . . . . . . . . . . . 8F-20

CHART - SPECIFICATIONS, TORQUE

. . . . . . . . 5-8

CHART, SPECIFICATIONS - TORQUE

. . . . . . . 5-46

CHART, SPECIFICATIONS - TORQUE

. . . . . 19-19,

19-23,19-35,19-42

CHART, SPECIFICATIONS - TORQUE

. . 2-10,2-29,

2-42

CHART, SPECIFICATIONS - TORQUE

. . . . . . 22-13

CHARTS - DIAGNOSIS AND TESTING,

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 21-145

CHARTS - DIAGNOSIS AND TESTING,

SMOKE DIAGNOSIS . . . . . . . . . . . . . . . . . . . 9-236

CHECK - STANDARD PROCEDURE,

COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . 7-17

CHECK - STANDARD PROCEDURE, FLUID

LEVEL . . . . . . . . . . . . . . . . . . . . . . 21-202,21-366

CHECK - STANDARD PROCEDURE, OIL

PUMP VOLUME . . . . . . . . . . . . . . . . . . . . . 21-387

CHECK CABLE - INSTALLATION

. . . . . . . . . 23-15

CHECK CABLE - REMOVAL

. . . . . . . . . . . . . 23-15

CHECK GAUGES INDICATOR -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J-21

CHECK GAUGES INDICATOR -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J-21

CHECK VALVE - DESCRIPTION

. . . . . . . . . . . 8R-7

CHECK VALVE - INSTALLATION

. . . . . . . . . . 8R-8

CHECK VALVE - OPERATION

. . . . . . . . . . . . . 8R-8

CHECK VALVE - REMOVAL

. . . . . . . . . . . . . . 8R-8

CHILD RESTRAINT ANCHOR -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8O-15

CHILD RESTRAINT ANCHOR -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-18

CHILD RESTRAINT ANCHOR -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8O-17

CHILD RESTRAINT ANCHOR - REMOVAL

. . 8O-17

CHIME WARNING SYSTEM -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8B-1

CHIME WARNING SYSTEM - DIAGNOSIS

AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8B-3

CHIME WARNING SYSTEM - OPERATION . . . 8B-1
CIGAR LIGHTER OUTLET -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-97-2

CIGAR LIGHTER OUTLET - DIAGNOSIS

AND TESTING . . . . . . . . . . . . . . . . . . . . . 8W-97-2

CIGAR LIGHTER OUTLET - OPERATION

. 8W-97-2

CIRCUIT - DIAGNOSIS AND TESTING,

AMBIENT TEMPERATURE SENSOR . . . . . . 8M-10

CIRCUIT - OPERATION, FUEL DRAIN

. . . . . 14-67

CIRCUIT ACTUATION TEST MODE -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-1

CIRCUIT FUNCTIONS - DESCRIPTION

. . 8W-01-6

CIRCUIT INFORMATION - DESCRIPTION . 8W-01-5
CIRCUIT SENSE - DESCRIPTION,

IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10

CIRCUIT SENSE - OPERATION, IGNITION

. . 8E-11

CIRCUITS - OPERATION, NON-

MONITORED . . . . . . . . . . . . . . . . . . . . . . . . . 25-8

CLAMPS - DESCRIPTION, HOSE

. . . . . . . . . . . 7-3

CLAMPS - OPERATION, HOSE . . . . . . . . . . . . . 7-5
CLEANING/REVERSE FLUSHING -

STANDARD PROCEDURE, COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

CLEARANCE - STANDARD PROCEDURE,

CONNECTING ROD BEARING AND
CRANKSHAFT JOURNAL . . . . . . . . . . . . . . . 9-272

CLEARANCE - STANDARD PROCEDURE,

MAIN BEARING . . . . . . . . . . . . . . . . . . . . . . 9-274

CLEARANCE LAMP - INSTALLATION, CAB

. 8L-12

CLEARANCE LAMP - REMOVAL, CAB

. . . . . 8L-11

CLOCKSPRING - DESCRIPTION

. . . . . . . . . 8O-18

CLOCKSPRING - INSTALLATION

. . . . . . . . . 8O-21

CLOCKSPRING - OPERATION

. . . . . . . . . . . 8O-19

CLOCKSPRING - REMOVAL

. . . . . . . . . . . . 8O-20

CLOCKSPRING CENTERING - STANDARD

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8O-19

CLUSTER - ASSEMBLY, INSTRUMENT

. . . . 8J-15

CLUSTER - DESCRIPTION, INSTRUMENT

. . . 8J-2

CLUSTER - DIAGNOSIS AND TESTING,

INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8J-10

CLUSTER - DISASSEMBLY, INSTRUMENT

. . 8J-14

CLUSTER - INSTALLATION, INSTRUMENT

. 8J-16

CLUSTER - OPERATION, INSTRUMENT

. . . . . 8J-6

CLUSTER - REMOVAL, INSTRUMENT

. . . . . 8J-14

CLUSTER BEZEL - INSTALLATION . . . . . . . . 23-49
CLUSTER BEZEL - REMOVAL

. . . . . . . . . . . 23-49

CLUTCH - 5.9L DIESEL - DESCRIPTION,

FAN DRIVE VISCOUS . . . . . . . . . . . . . . . . . . . 7-52

CLUTCH - 5.9L DIESEL - OPERATION,

FAN DRIVE VISCOUS . . . . . . . . . . . . . . . . . . . 7-52

CLUTCH - ASSEMBLY, FRONT

. . . . . . . . . . 21-207

CLUTCH - ASSEMBLY, LOW/REVERSE

. . . 21-385

CLUTCH - ASSEMBLY, REAR

. . . . . . . . . . . 21-249

CLUTCH - CLEANING, LOW/REVERSE

. . . . 21-385

CLUTCH - CLEANING, REAR

. . . . . . . . . . . 21-248

CLUTCH - DESCRIPTION, FRONT

. . . . . . . 21-205

CLUTCH - DESCRIPTION, OVERDRIVE

. . . 21-217

6

INDEX

DR

Description

Group-Page

Description

Group-Page

Description

Group-Page

Summary of Contents for 1997 Ram 1500

Page 1: ... Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8T Navigation Telecommunication 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bumpers 14 Fuel System 19 Steering 21 Transmission and Transfer Case 22 Tires Wheels 23 Body 24 Heating Air Conditioning 25 Emissions Control Component and System Index Se...

Page 2: ...ing the vehicle Refer to the VIN decoding chart to determine the identification of a vehicle The VIN is also imprinted on the Body Code Plate Equipment Identification Plate Vehicle Safety Certification Label Frame rail To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the VIN The check digit is used by the manufactu...

Page 3: ...ION VECI DESCRIPTION All models have a Vehicle Emission Control Infor mation VECI Label DaimlerChrysler permanently attaches the label in the engine compartment Fig 2 The label cannot be removed without defacing label information and destroying label The label contains the vehicle s emission specifica tions and vacuum hose routings All hoses must be connected and routed according to the label The ...

Page 4: ...le Order Number DIGITS 13 14 AND 15 Transmission Codes DG4 4 speed Automatic 45RFE DG8 4 speed Automatic 48RE DDC 5 speed Manual NV3500 DDP 5 speed Manual NV4500 DEC 6 speed Manual NV5600 DEE 6 speed Manual Tremec T 56 DIGITS 16 17 AND 18 Car Line Shell DR1 1500 4 X 2 DR6 1500 4 X 4 DR2 2500 4 X 2 DR7 2500 4 X 4 DR3 3500 4 X 2 DR8 3500 4 X 4 DIGIT 19 Price Class L Low H Highline DIGITS 20 AND 21 B...

Page 5: ...iesel ETH 5 9 L 6 cyl Cummins Turbo Diesel High Output BODY CODE PLATE LINE 2 DIGIT 1 Open Space DIGITS 2 AND 3 Species Code Used for Manufacturing DIGIT 4 Open Space DIGIT 5 Market Code B International C Canada M Mexico U United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number VIN Refer to VEHICLE DATA VEHICLE INFORMA TION VEHICLE IDENTIFICATION NUMBER DESCRIPTION for p...

Page 6: ...c bolt strength classes are 9 8 and 10 9 The metric strength class identification number is imprinted on the head of the bolt The higher the class number the greater the bolt strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener Identification and Fastener Strength Charts Fig 5 and Fig 6 INTERNATIONAL SYMBOLS 1 High Beam 13 Rear Window Was...

Page 7: ...Fig 5 FASTENER IDENTIFICATION 6 INTRODUCTION DR FASTENER IDENTIFICATION Continued ...

Page 8: ...Fig 6 FASTENER STRENGTH DR INTRODUCTION 7 FASTENER IDENTIFICATION Continued ...

Page 9: ...SAE units or vise versa CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in lbs x 0 11298 Newton Meters N m N m x 8 851 in lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7376 ft lbs Inches Hg 60 F x 3 377 Kilopascals kPa kPa x 0 2961 Inches Hg psi x 6 895 Kilopascals kPa kPa x 0 145 psi Inches x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 ...

Page 10: ...Fig 7 METRIC CONVERSION CHART DR INTRODUCTION 9 METRIC SYSTEM Continued ...

Page 11: ...ON Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 8 Fig 8 TORQUE SPECIFICATIONS 10 INTRODUCTION DR ...

Page 12: ... year of vehicle manufacture Gross Vehicle Weight Rating GVWR The gross front and rear axle weight ratings GAWR s are based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number VIN Type of vehicle Type of rear wheels Bar code Month Day and Hour MDH of final assembly Paint and Trim codes Country of origin The label is located on the driver side door shut face...

Page 13: ......

Page 14: ...diesel fuel with 50 No 1 diesel fuel This will provide better protection from fuel gelling or wax plugging of the fuel filters Diesel fuel is seldom completely free of water To prevent fuel system trouble including fuel line freez ing in winter drain the accumulated water from the fuel water separator using the fuel water separator drain provided If you buy good quality fuel and fol low the cold w...

Page 15: ... API classification defines the lubricants usage Such as API GL 5 and SAE 75W 90 LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI All approved products have the NLGI symbol Fig 3 on the label At the bottom of the NLGI symbol is the usage and quality identification letters Wheel bearing lubricant is identified by the letter G Chassis lubricant is identified by th...

Page 16: ...system is designed around the coolant The coolant must accept heat from engine metal in the cylinder head area near the exhaust valves and engine block Then coolant carries the heat to the radiator where the tube fin radiator can transfer the heat to the air The use of aluminum cylinder blocks cylinder heads and water pumps requires special corrosion protection Mopart Antifreeze Coolant 5 Year 100...

Page 17: ...ne cooling DESCRIPTION TRANSFER CASE Recommended lubricant for the NV241 GENII NV271 NV243 NV244 GENII and NV273 transfer cases is Mopart ATF 4 Automatic Transmission Fluid DESCRIPTION AXLE NOTE DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality FRONT AXLE C205F Mopart Gear Lubricant 75W 90 9 1 4 AA Mopart Synthetic Gear Lubricant 75W 90 REAR AXLE 9 1 4 Mopart Synthe...

Page 18: ...omponents and transfer that heat to the transmission case FLUID CAPACITIES SPECIFICATIONS FLUID CAPACITIES DESCRIPTION SPECIFICATION FUEL TANK Short Box Lt Duty 98 L 26 gal Long Box Lt Duty 132 L 35 gal ENGINE OIL WITH FILTER 3 7L 4 7 L 5 0 qts 4 7L 5 6 L 6 0 qts 5 7L 6 6 L 7 0 qts 5 9L DIESEL 11 4 L 12 0 qts DESCRIPTION SPECIFICATION COOLING SYSTEM 3 7L 15 4 L 16 2 qts 4 7L 15 4 L 16 2 qts 5 7L 1...

Page 19: ...he driving conditions Where time and mileage are listed follow the interval that occurs first CAUTION Failure to perform the required mainte nance items may result in damage to the vehicle At Each Stop for Fuel Check the engine oil level about 5 minutes after a fully warmed engine is shut off Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level rea...

Page 20: ...engine oil and engine oil filter X X X X X Lubricate outer tie rod ends 2500 3500 4X4 models only X X Change rear axle fluid X Change front axle fluid 4X4 X Inspect brake linings X Inspect engine air cleaner filter replace if necessary X Miles 18 000 21 000 24 000 27 000 30 000 Kilometers 29 000 34 000 38 000 43 000 48 000 Change engine oil and engine oil filter X X X X X Lubricate outer tie rod e...

Page 21: ...X Change rear axle fluid X Change front axle fluid 4X4 X Inspect brake linings X X Inspect engine air cleaner filter replace if necessary X Replace spark plugs X Replace ignition cables X Inspect PCV valve replace as necessary X Drain and refill automatic tranmission fluid and change main sump filter 45RFE 545RFE only X Miles 63 000 66 000 69 000 72 000 75 000 Kilometers 101 000 106 000 110 000 11...

Page 22: ...ect PCV valve replace as necessary X Inspect auto tension drive belt and replace if required 3 7L 4 7L 5 7L X Drain and refill automatic tranmission fluid and change main sump and spin on cooler return filter if equipped 45RFE 545RFE only X Miles 93 000 96 000 99 000 100 000 102 000 Kilometers 149 000 154 000 158 000 160 000 163 000 Change engine oil and engine oil filter X X X X Lubricate outer t...

Page 23: ...efill automatic tranmission fluid and change main sump filter 45RFE 545RFE only X This maintenance is recommended by the manu facture to the owner but is not required to maintain the emissions warranty This maintenance is not required if previously replaced Inspection and service should also be performed anytime a malfunction is observed or suspected Retain all receipts Schedule A Miles 6 000 12 0...

Page 24: ... 000 78 000 84 000 90 000 96 000 100 000 Kilometers 115000 125 000 134 000 144 000 154 000 160 000 Months 72 78 84 90 96 Change engine oil and engine oil filter X X X X X Lubricate outer tie rod ends 2500 3500 4X4 models only X X X X X Check transfer case fluid level 4X4 X Flush and replace Power Steering Fluid X Inspect brake linings X X Replace engine air cleaner filter X Replace spark plugs X I...

Page 25: ...he required service for your vehicle First is Schedule B It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule Day or night temperatures are below 0 C 32 F Stop and go driving Extensive engine idling Driving in dusty conditions Short trips of less than 16 km 10 miles More than 50 of your driving is at sustained high speeds during hot w...

Page 26: ... data label for your engine type California LEV 235 hp Engines Only see engine data label for your engine type Schedule B Follow schedule B if you usually operate your vehicle under one or more of the following conditions Day or night temperatures are below 0 C 32 F Stop and go driving Extensive engine idling Driving in dusty conditions Short trips of less than 16 km 10 miles More than 50 of your ...

Page 27: ...ransfer case fluid level 4X4 X Drain and refill automatic transmission fluid Replace filter and adjust bands X Miles 41 250 45 000 48 750 52 500 56 250 Kilometers 66 000 72 000 78 000 84 000 90 000 Change engine oil and engine oil filter X XL X XL X Lubricate outer tie rod ends 2500 3500 4X4 models only X X Inspect drive belt replace as required X Inspect water pump weep hole for blockage X Replac...

Page 28: ...rain and refill automatic transmission fluid Replace filter and adjust bands X Miles 78 750 82 500 86 250 90 000 93 750 Kilometers 126 000 132 000 138 000 144 000 150 000 Change engine oil and engine oil filter X XL X XL X Lubricate outer tie rod ends 2500 3500 4X4 models only X X Inspect drive belt replace as required X Change rear axle fluid X Change front axle fluid 4X4 X Check transfer case fl...

Page 29: ...5 000 Kilometers 186 000 192 000 198 000 204 000 210 000 216 000 Change engine oil and engine oil filter X XL X XL X XL Lubricate outer tie rod ends 2500 3500 4X4 models only X X X Clean engine air filter canister X Adjust valve lash clearance X Inspect drive belts replace as required X Drain and refill transfer case fluid 4X4 X Inspect fan hub X Inspect damper X Inspect water pump weep hole for b...

Page 30: ...pect brake linings X Inspect and adjust parking brake if necessary X Inspect fan hub X Inspect damper X Inspect front wheel bearings X Miles 45 000 52 500 60 000 67 500 75 000 Kilometers 72 000 84 000 96 000 108 000 120 000 Months 36 42 48 54 60 Change engine oil and engine oil filter XL X XL X XL Lubricate outer tie rod ends 2500 3500 4X4 models only X X X X X Check transfer case fluid level X Fl...

Page 31: ...necessary X Drain and refill automatic transmission fluid Replace filter and adjust bands X Miles 112 500 120 000 127 500 135 000 142 500 150 000 Kilometers 181 000 193 000 205 000 217 000 229 000 241 000 Months 90 96 102 108 114 150 Change engine oil and engine oil filter X XL X XL X XL Lubricate outer tie rod ends 2500 3500 4X4 models only X X X X X X Flush and replace engine coolant if it has b...

Page 32: ...ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION When using another vehicle as a booster do not allow vehicles to touch Electrical systems can be damaged on either vehicle TO JUMP START A DISABLED VEHICLE 1 Raise hood on disabled vehicle and visually inspect engine compartment f...

Page 33: ... Fig 6 OR SECURE VEHICLE TO HOIST ING DEVICE WHEN THESE CONDITIONS EXIST FLOOR JACK When properly positioned a floor jack can be used to lift a vehicle Fig 7 Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails Fig 6 CAUTION Do not lift vehicle with a floor jack posi tioned under An axle tube A body side sill A steering linkage component A drive...

Page 34: ...lat bed device can also be used to transport a disabled vehicle Fig 10 Fig 7 Vehicle Lifting Locations Fig 8 FRONT LIFT PAD LOCATION 1 BODY MOUNT BRACKET 2 FRONT LIFT PAD 3 TRANSMISSION CROSSMEMBER BRACKET 4 FRAME RAIL Fig 9 REAR LIFT PAD LOCATION 1 FRAME RAIL 2 REAR LIFT PAD 3 LEAF SPRING MOUNTING BRACKET 4 BOX MOUNTING BRACKET Fig 10 Tow Vehicles With Approved Equipment 1 SLING TYPE 2 WHEEL LIFT...

Page 35: ...quate ground clearance at the oppo site end of the vehicle especially when towing over rough terrain or steep rises in the road If necessary remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground to increase the ground clearance at the opposite end of the vehicle Install lug nuts on wheel attaching studs to retain brake drums or rotors RAMP ANGLE If a vehic...

Page 36: ... ure thane bushings should be tightened with the vehi cle at normal ride height It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued If springs are not at their normal ride position vehicle ride comfort could be affected and premature bushing wear may occur Wheel alignment involves the correct positioning of the wheels in relation to the vehicle T...

Page 37: ...ing System Diagnosis Chart below for additional information 1 Inspect tires for size air pressure and tread wear 2 Inspect front wheel bearings for wear 3 Inspect front wheels for excessive radial or lat eral runout and balance 4 Inspect ball studs linkage pivot points and steering gear for looseness roughness or binding 5 Inspect suspension components for wear and noise 6 On 4x4 vehicles check su...

Page 38: ...om the ground at the centerline of the rear lower control arm bolt front tip Fig 2 4 Measure and record the height from the ground at the front spindle centerline Static Load Radius Fig 2 5 Subtract the first measurement from the sec ond measurement The difference between the two measurement should be 58 mm 2 3 inches 3 mm 0 12 inches 6 If value is greater than 61 mm 2 4 inches tighten the torsion...

Page 39: ...he vehicle at normal ride height Fig 3 STANDARD PROCEDURE TOE ADJUSTMENT 4X4 SUSPENSION HEIGHT MESUREMENT MUST BE PERFORMED BEFORE AN ALIGN MENT The wheel toe position adjustment is the final adjustment 1 Start the engine and turn wheels both ways before straightening the wheels Secure the steering wheel with the front wheels in the straight ahead position 2 Loosen the tie rod jam nuts NOTE Each f...

Page 40: ...raightening the wheels Secure the steering wheel with the front wheels in the straight ahead position 2 Loosen the tie rod jam nuts NOTE Each front wheel should be adjusted for one half of the total toe position specification This will ensure the steering wheel will be centered when the wheels are positioned straight ahead 3 Adjust the wheel toe position by turning the inner tie rod as necessary F...

Page 41: ...alignment specifications are in degrees SPECIFICATIONS DESCRIP TION SPECIFICATION VEHICLE 1500 WHEEL BASE CASTER 4 0 Min 75 Max CAMBER 50 TOTAL TOE IN 10 4X2 120 5 in 4 0 0 10 4X2 140 5 in 4 2 0 10 4X2 160 5 in 4 4 0 10 VEHICLE 1500 WHEEL BASE CASTER 4 0 Min 75 Min CAMBER 50 TOTAL TOE IN 10 4X4 120 5 in 4 2 0 10 4X4 140 5 in 4 4 0 10 4X4 160 5 in 4 6 0 10 MAX RT LT DIF FERENCE 4X2 1500 40 50 0 06 ...

Page 42: ...SPECIAL TOOLS WHEEL ALIGNMENT 8876 CAMBER CASTER ADJUSTMENT TOOL DR WHEEL ALIGNMENT 2 7 WHEEL ALIGNMENT Continued ...

Page 43: ...18 KNUCKLE DESCRIPTION 18 OPERATION 18 REMOVAL 18 INSTALLATION 19 LOWER BALL JOINT DIAGNOSIS AND TESTING LOWER BALL JOINT 19 REMOVAL 19 INSTALLATION 20 LOWER CONTROL ARM REMOVAL REMOVAL 4X4 LD 21 REMOVAL 4X2 21 INSTALLATION INSTALLATION 4X4 LD 21 INSTALLATION 4X2 22 SPRING REMOVAL 22 INSTALLATION 23 SHOCK DIAGNOSIS AND TESTING SHOCK 24 REMOVAL REMOVAL 4X2 24 REMOVAL 4X4 24 INSTALLATION INSTALLATIO...

Page 44: ...ie Rod Ends Hub Bearing Rack Pinion Ball Joints NOTE Components attached with a nut must be torqued to specification NOTE Suspension components with rubber ure thane bushings should be tightened with the vehi cle at normal ride height It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued If springs are not at their normal ride position vehicle ride...

Page 45: ...rs Rebound travel is lim ited by the shock absorber SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Shock Absorber Upper Nut 4X4 54 40 Shock Absorber Lower Bolt 4X4 135 100 Shock Absorber Upper Nut 4X2 54 40 Shock Absorber Lower Bolt 4X2 28 21 Fig 2 FRONT SUSPENSION 4X4 LD ONLY 1 STABILIZER BAR 2 UPPER CONTROL ARM 3 STEERING KNUCKLE 4 ROTOR 5 OUTER TIE ROD END 6 SHO...

Page 46: ...s LD 132 97 Upper Suspension Arm Frame Nuts HD 4X2 only 170 125 Upper Suspension Arm Ball Joint Nut 1500 series only 54 Then an additional 90 40 Then an additional 90 Stabilizer Bar Frame Bolt 61 45 Stabilizer Link Lower Control Arm Nut 102 75 Stabilizer Link Stabilizer Bar Nut 38 27 Hub Bearing Bolts LD 163 120 Hub Bearing Bolts HD 4X2 176 130 Tie Rod End Nut 61 Then an additional 90 45 Then an a...

Page 47: ...T 8682 TORSION BAR LOADER UNLOADER 8686 TORSION BAR BUSHING REMOVAL INSTALL 8835 RECEIVER DRIVER BALLJOINT 8698 BALL JOINT PRESS C 4212F 2WD LOWER CONTROL ARM BUSHING REMOVAL INSTALL 8836 2 12 FRONT INDEPENDENT FRONT SUSPENSION DR FRONT INDEPENDENT FRONT SUSPENSION Continued ...

Page 48: ...Secure the cross member in a vise NOTE Extreme pressure lubrication must be used on the threaded portions of the tool This will increase the longevity of the tool and insure proper operation during the removal and installation pro cess 3 Install special tools 8838 threaded rod 8835 1 8835 4 and 8835 3 as shown in the graphic below Fig 5 4 Press out the bushing REMOVAL LOWER CONTROL ARM BUSHINGS 2W...

Page 49: ...rly orient the bushing voids in the correct position to within 10 The correct position places the long narrow void out board of the bushing and the short wide void inboard of the bushing Fig 8 Fig 5 TORSION BAR CROSS MEMBER BUSHING REMOVAL 1 8838 2 8835 1 3 8835 4 4 8835 3 Fig 6 LARGE LOWER CONTROL ARM BUSHING REMOVAL 1 8836 4 SPACER 2 8836 5 DRIVER 3 8839 THREADED ROD 4 8836 2 RECEIVER Fig 7 SMAL...

Page 50: ...LIGNMENT STANDARD PROCEDURE INSTALLATION TORSION BAR CROSS MEMBER BUSHING NOTE Extreme pressure lubrication must be used on the threaded portions of the tool This will increase the longevity of the tool and insure proper operation during the removal and installation pro cess 1 Install the new bushing into the cross member using special tools 8835 2 8835 4 and 8835 3 with the bearing and the thread...

Page 51: ...ON 3 Reset the vehicle ride height Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE 4 Perform a wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE HUB BEARING REMOVAL REMOVAL 4X4 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the brake caliper and rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS REMOVAL 4 Remove the ABS wheel speed ...

Page 52: ...S REMOVAL 4 Remove the ABS wheel speed sensor if equipped Refer to 5 BRAKES ELECTRICAL FRONT WHEEL SPEED SENSOR REMOVAL Fig 15 5 Remove the three hub bearing mounting bolts from the steering knuckle Fig 15 6 Slide the hub bearing out of the steering knuckle Fig 15 7 Remove the brake dust shield Fig 15 INSTALLATION INSTALLATION 4X4 1 Install the brake dust shield Fig 16 2 Install the hub bearing in...

Page 53: ...is a single casting with legs machined for the upper and lower ball joints The knuckle also has machined mounting locations for the front brake calipers and hub bearing OPERATION The steering knuckle pivot between the upper and lower ball joint Steering linkage attached to the knuckle allows the vehicle to be steered REMOVAL 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Re...

Page 54: ...TIRES WHEELS WHEELS STANDARD PROCE DURE 10 Remove the support and lower the vehicle 11 Perform a wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE LOWER BALL JOINT DIAGNOSIS AND TESTING LOWER BALL JOINT NOTE If the ball joint is equipped with a lubrication fitting grease the joint then road test the vehicle before performing test 1 Raise the front of the vehicle Place safet...

Page 55: ...nt flange using a chisel and hammer LD only 4 Replace the snap ring HD 4X2 only 5 Remove the support for the halfshaft and install into position If Equipped 6 Install the steering knuckle Refer to 2 SUS PENSION FRONT KNUCKLE INSTALLATION 7 Install the tie rod end into the steering knuckle Refer to 19 STEERING LINKAGE TIE ROD END INSTALLATION 8 Install and tighten the halfshaft nut to 251 N m 185 f...

Page 56: ...will hold the spring in place until the lower suspension arm is separated from the steer ing knuckle 7 Remove the stabilizer link Refer to 2 SUS PENSION FRONT STABILIZER LINK REMOVAL 8 Remove the lower ball joint nut at the steering knuckle 9 Install Ball Joint Remover tool 8677 on the lower ball joint and separate the ball joint from the knuckle NOTE Do not allow the upper control arm and steerin...

Page 57: ...ower ball joint and tighten to 52 N m 38 ft lbs on 1500 series only an additional 90 turn is required or 135 N m 100 ft lbs HD 4X2 only 9 Support the lower control arm at the outboard side of the lower control arm to support vehicle weight 10 Remove the spring compressor tool 11 Install the shock absorber Refer to 2 SUS PENSION FRONT SHOCK INSTALLATION 12 Install the stabilizer link Refer to 2 SUS...

Page 58: ...hock hole in the frame 3 Tighten the tool nut to compress the coil spring 4 Remove the support from the upper control arm and steering knuckle 5 Position the lower ball joint into the steering knuckle 6 Install the retaining nut on the lower ball joint and tighten to 52 N m 38 ft lbs on 1500 series only an additional 90 turn is required or 135 N m 100 ft lbs HD 4X2 only 7 Remove the spring compres...

Page 59: ...he vehicle 2 Remove the tire and wheel assembly 3 Support the lower control arm outboard end 4 Remove the upper shock nut and with the insu lator and retainer Fig 27 5 Remove the lower shock bolt Fig 27 6 Remove the shock INSTALLATION INSTALLATION 4X2 NOTE Upper shock nut must be replaced or use Mopar Lock N Seal or LoctiteT 242 on existing nut 1 Install the lower retainer and grommet on the shock...

Page 60: ... bushings on the stabi lizer bar using a mixture of soapy water or equiva lent in order to slide the bushing over the bar with ease Do not cut the new bushing for installa tion 2 Position the stabilizer bar on the frame cross member brackets and install the bracket and bolts finger tight Fig 29 NOTE Check the alignment of the bar to ensure there is no interference with the either frame rail or cha...

Page 61: ...NOT interchangeable The bars are identified and stamped R or L for right or left The bars do not have a front or rear end and can be installed with either end facing forward 1 Raise and support the vehicle with the front suspension hanging 2 Remove the transfer case skid plate Refer to 13 FRAME BUMPERS FRAME TRANSFER CASE SKID PLATE REMOVAL NOTE Count and record the number of turns for installatio...

Page 62: ...pped with a lubrication fitting grease the joint then road test the vehicle before performing test 1 Raise the front of the vehicle Place safety floor stands under both lower control arms as far outboard as possible Lower the vehicle to allow the stands to support some or all of the vehicle weight 2 Remove the front tires 3 Mount a dial indicator solidly to the frame and then zero the dial indicat...

Page 63: ... bolts and tighten to 132 N m 97 ft lbs LD or 170 N m 125 ft lbs HD 4X2 only 2 Insert the ball joint in steering knuckle and tighten the upper ball joint nut to 54 N m 40 ft lbs on 1500 series only an additional 90 turn is required 3 Install the wheel and tire assembly Refer to 22 TIRES WHEELS WHEELS STANDARD PROCE DURE 4 Remove the support and lower vehicle 5 Perform a wheel alignment Refer to 2 ...

Page 64: ... 37 REMOVAL RIGHT 37 INSTALLATION INSTALLATION LEFT 37 INSTALLATION RIGHT 37 LOWER SUSPENSION ARM REMOVAL 38 INSTALLATION 38 SHOCK DIAGNOSIS AND TESTING SHOCK 38 REMOVAL 38 INSTALLATION 38 SPRING REMOVAL 39 INSTALLATION 39 STABILIZER BAR REMOVAL 39 INSTALLATION 40 FRONT LINK COIL SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Shock Absorber Upper Nut 54 40 Shock Ab...

Page 65: ...orque of 263 Tie Rod End Nut 75 55 NOTE Suspension components with rubber urethane bushings should be tightened with the vehicle at nor mal ride height It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued If springs are not at their normal ride position vehicle ride comfort could be affected and pre mature bushing wear may occur SPECIAL TOOLS 9 1 ...

Page 66: ...re from the frame and steering knuckle if equipped 7 Back off the hub bearing mounting bolts 1 4 inch each Fig 3 Then tap the bolts with a hammer to loosen the hub bearing from the steering knuckle 8 Remove the hub bearing mounting bolts and remove the hub bearing 9 Remove the rotor assembly Fig 4 brake shield and spacer from the steering knuckle RECEIVER CUP 6761 BALLJOINT RECIEVER INSTALLER KIT ...

Page 67: ...aring flange Fig 7 4 Apply a liberal quantity of anti seize compound to the splines of the front drive shaft 5 Insert the two rearmost top and bottom rotor hub bolts in the steering knuckle Insert the bolts through the back side of the knuckle so they extend out the front face as shown Fig 4 Rotor Hub Bearing Assembly 1 ROTOR AND HUB 2 UNIT BEARING ASSEMBLY 3 SEAL Fig 5 ROTOR AND HUB BEARING 1 HUB...

Page 68: ...ing 12 Tighten to a final torque of 356 N m 263 ft lbs 13 Align the axle nut to the next forward cotter pin hole and install a new cotter pin in the axle nut 14 Install the brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION 15 Install the sensor wire to the steering knuckle and frame and if equipped Connect the wheel speed sensor wire under the hood 16 Install th...

Page 69: ... indicator This will be the first reading Fig 12 5 Set the dial indicator back to zero 6 Set up a jackstand and use a long prybar to lift the knuckle assembly Fig 13 pry upwards on the flat part of the steering knuckle next to the ball joint stud and nut Fig 14 using the jackstand as lever age Record the reading on the dial indicator This will be the second reading 7 Add the two reading together f...

Page 70: ...th C4212 F as shown to install lower ball stud Fig 17 Fig 14 PRYING LOCATION 1 PRY BAR 2 UPPER BALL JOINT 3 AXLE YOKE 4 GRESE SEAL 5 STEERING KNUCKLE Fig 15 LOWER SNAP RING Fig 16 LOWER BALL JOINT REMOVAL 1 SPECIAL TOOL C4212 F 2 SPECIAL TOOL 8975 2 3 KNUCKLE 4 SPECIAL TOOL 8975 4 Fig 17 LOWER BALL JOINT INSTALLATION 1 SPECIAL TOOL C4212 F 2 SPECIAL TOOL 8975 1 3 BALL JOINT 4 KNUCKLE 5 SPECIAL TOO...

Page 71: ... and pushing out on the bottom of the tire Record the reading on the dial indicator This will be the second reading Fig 18 7 Add the two reading together for a total upper ball joint movement If this reading is above 1 52 mm 0 060 in then replacement of the upper ball joint is necessary Refer to 2 SUSPENSION FRONT UP PER BALL JOINT REMOVAL REMOVAL 1 Position special tool 6761 RECEIVER and 8445 3 D...

Page 72: ... bracket Fig 21 3 Remove the nut and bolt at the frame rail and remove the upper suspension arm REMOVAL RIGHT 1 Raise and support the vehicle 2 Disconnect the exhaust system at the mani folds 3 Disconnect the rubber exhaust mounts at the muffler 4 Support the transmission 5 Remove the transmission cross member 6 Lower the exhaust system down in order to gain access to the removal of the upper bolt...

Page 73: ...by the hydraulic valving and may be intermit tent This condition is not repairable and the shock absorber must be replaced The shock absorbers are not refillable or adjust able If a malfunction occurs the shock absorber must be replaced To test a shock absorber hold it in an upright position and force the piston in and out of the cylinder four or five times The action throughout each stroke should...

Page 74: ...e rail bracket 4 Install the upper suspension arm 5 Install the front propeller shaft to the axle 4x4 model 6 Install drag link to pitman arm and tighten nut to specifications Install new cotter pin 7 Remove the supports and lower the vehicle 8 Tighten the following suspension components to specifications Link to stabilizer bar nut Lower shock bolt Track bar bolt at axle shaft tube bracket Upper s...

Page 75: ... Ensure the bar is centered with equal spacing on both sides 2 Tighten the clamp bolts to 61 N m 45 ft lbs 3 Install links to the axle bracket and tighten nut to 71 N m 52 ft lbs 4 Install links retainers grommets and nuts to the stabilizer bar Hold the link shaft with a wrench and tighten the nuts to 37 N m 27 ft lbs 5 Remove the supports and lower the vehicle Fig 25 Stabilizer Link 1 PULLER 2 LI...

Page 76: ...ition vehicle ride comfort could be affected and premature bush ing wear may occur DIAGNOSIS AND TESTING SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo nents These noises can usually be stopped by tight ening the attaching nuts If the noise persists inspect for damaged and worn bushings a...

Page 77: ...r 1 Tighten to specification 2 Worn bushings 2 Replace shock 3 Leaking shock 3 Replace shock SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Shock Absorber Lower Nut 135 100 Shock Absorber Upper Nut 135 100 Spring Clamp U Bolts Nuts 149 110 Spring Front Rear Bolt Nut LD 163 120 Spring Front Rear Bolt Nut HD 230 170 Spring Spring Rear Shackle Nuts 163 120 Spring Spri...

Page 78: ...ghten the bolts to 61 N m 45 ft lbs HD AUXILIARY SPRING BUMPERS 3500 REMOVAL 1 Remove the nut securing the auxiliary spring bumper to the bracket Fig 2 2 Remove the auxiliary spring bumper INSTALLATION 1 Install the auxiliary spring bumper 2 Install the nut securing the auxiliary spring bumper to the bracket Fig 2 Tighten the nut to 25 N m 34 ft lbs SHOCK REMOVAL 1 Raise vehicle and support the ax...

Page 79: ...Position spring on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube 2 Align the front of the spring with the bolt hole in the front bracket Install the eye pivot bolt and nut 3 Align the rear of the spring into the shackle and install the bolt and nut 4 Tighten the spring front and rear eye pivot bolt snug do not torque 5 Install the spring clamp bolts plat...

Page 80: ...tall a new spring tip liner onto the leaf 2 Firmly seat the spring tip liner onto the leaf A C Clamp can be used to compress the adjacent leaves together Fig 8 which will seat the liner retaining pin into the hole NOTE THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINT ING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING 3 Apply a small amount of lubricant...

Page 81: ...ER TO CLOSE THE SPRING CLINCH CLIP DAMAGE TO THE ISOLATOR MAY RESULT 7 Use an appropriate pry bar to bend open the spring clinch clip If necessary remove the existing spring clinch clip isolators 8 Repeat procedure for the other side of the vehi cle 9 Iinstall the tire wheel assemblies 10 Lower the vehicle Fig 9 CLINCH CLIP ISOLATOR 1 SPRING CLINCH CLIP ISOLATOR 2 C CLAMP Fig 10 CLINCH CLIP REASSE...

Page 82: ...NIVERSAL JOINTS DISASSEMBLY DISASSEMBLY WITH SNAP RINGS 10 DISASSEMBLY WITH INJECTED RINGS 11 ASSEMBLY ASSEMBLY WITH SNAP RINGS 12 ASSEMBLY WITH INJECTED RINGS 13 DOUBLE CARDAN UNIVERSAL JOINTS DISASSEMBLY 16 ASSEMBLY 17 PROPELLER SHAFT DIAGNOSIS AND TESTING PROPELLER SHAFT VIBRATION Out of round tires or wheels that are out of bal ance will cause a low frequency vibration Driveline vibration can ...

Page 83: ...t 12 Inspect and repair as necessary Universal Joint Noise 1 Loose U joint clamp screws 1 Install new clamps and screws and tighten to proper torque 2 Lack of lubrication 2 Replace as U joints as necessary PROPELLER SHAFT BALANCE If propeller shaft is suspected of being out of bal ance use the following procedure NOTE Indexing propeller shaft 180 relative to the yoke may eliminate some vibrations ...

Page 84: ...f runout is not within specifications verify runout of the transmission transfer case and axle are within specifications Correct as necessary and mea sure propeller shaft runout again 8 Replace propeller shaft if the runout still exceeds the limits RUNOUT SPECIFICATIONS Front of Shaft 0 030 in 0 76 mm Center of Shaft 0 015 in 0 38 mm Rear of Shaft 0 030 in 0 76 mm note Measure front rear runout ap...

Page 85: ...lange Input Angle B 8 Subtract smaller figure from larger C minus A to obtain Transmission Transfer Case Output Operating Angle 9 Subtract smaller figure from larger C minus B to obtain axle Input Operating Angle Refer to rules and example in Fig 7 for addi tional information RULES Good cancellation of U joint operating angles should be within 1 degree Operating angles should be less than 3 degree...

Page 86: ... UNIVERSAL JOINT ANGLE EXAMPLE 1 4 9 ANGLE C 2 3 2 ANGLE B 3 INPUT YOKE 4 3 0 ANGLE A 5 OUTPUT YOKE Fig 8 UNIVERSAL JOINT ANGLE 1 YOKES MUST BE IN SAME PLANE DR PROPELLER SHAFT 3 5 PROPELLER SHAFT Continued ...

Page 87: ...9 22 SPECIAL TOOLS PROPELLER SHAFT LD FRONT REMOVAL 1 With vehicle in neutral position vehicle on hoist 2 Remove exhaust crossover pipe 3 Mark a line across the axle companion flange propeller shaft flange yoke and transfer case Fig 9 for installation reference INCLINOMETER 7663 Bearing Splitter 1130 INSTALLER 6052 Fig 9 COMPANION FLANGE 1 COMPANION FLANGE 2 PROPELLER SHAFT 3 FLANGE YOKE 4 REFEREN...

Page 88: ... crossover pipe 3 Mark a line across axle transfer case compan ion flange and propeller shaft flange yokes for instal lation reference 4 Remove axle transfer case companion flange bolts Fig 11 5 Remove propeller shaft INSTALLATION 1 Install propeller shaft with all reference marks aligned 2 Install transfer case companion flange bolts and tighten to 88 N m 65 ft lbs 3 Install new axle companion fl...

Page 89: ...output shaft 2 Align and install center bearing on crossmem ber if equipped and tighten nuts to 54 N m 40 ft lbs 3 Align reference marks on propeller shaft and pinion flange or pinon yoke 4 Install new bolts and tighten to Fig 14 Companion flange bolts 15 N m 85 ft lbs Fig 15 Yoke clamp bolts 29 N m 22 ft lbs NOTE Companion flange bolts incorporate a Loc titeT patch new bolts should be used If bol...

Page 90: ...Clean shaft splines and apply a coat of multi purpose grease 4 Align master splines and slide front and rear half shafts together Reposition slip yoke boot and install new clamp 5 Install propeller shaft in vehicle ADJUSTMENTS CENTER BEARING Launch shudder is a vibration that occurs at first acceleration from a stop Shudder vibration usually peaks at the engines highest torque output Shudder is a ...

Page 91: ... bearing cap and press 1 the lower cap through the yoke Fig 18 NOTE If the bearing cap will not pull out of the yoke by hand after pressing tap the yoke ear near the bearing cap to dislodge the cap 6 Pull bearing cap of the yoke 7 Turn yoke over in the press and straighten the cross 1 Press the cross until the remaining bearing cap 2 can be removed Fig 19 CAUTION If cross or bearing cap are not st...

Page 92: ...s remaining U joint bearing cap out of shaft yoke 7 Remove flange 1 with U joint out of shaft yoke 2 Fig 23 8 Position U joint press 2 with receiver 1 on flange Fig 24 9 Press U joint bearing caps 1 out of flange 2 Fig 25 10 Remove bearing cap on the outside of the flange Fig 20 PRESS ON YOKE 1 PRESS 2 RECEIVER Fig 21 BEARING OUT OF YOKE 1 BEARING CAPS 2 YOKE Fig 22 PRESS REMAINING BEARING 1 PRESS...

Page 93: ...flange ASSEMBLY ASSEMBLY WITH SNAP RINGS 1 Apply EP N L G I Grade 1 or 2 grease to inside of yoke bores Fig 24 PRESS ON FLANGE 1 RECEIVER 2 PRESS Fig 25 BEARING OUT OF FLANGE 1 BEARINGS 2 FLANGE Fig 26 REMAINING BEARING 1 RECEIVER 2 PRESS Fig 27 CROSS IN YOKE 1 CROSS 2 YOKE 3 12 PROPELLER SHAFT DR SINGLE CARDAN UNIVERSAL JOINTS Continued ...

Page 94: ...ng strike the yoke with a soft hammer to seat the needle bearings 6 Add grease to lube fitting if equipped 7 Install propeller shaft ASSEMBLY WITH INJECTED RINGS NOTE Replacement joint has internal snap rings 1 Place joint in flange with one bearing cap 2 Position press 3 with receiver 1 on flange and bearing cap 2 Fig 29 Fig 28 BEARING AND CROSS 1 BEARING CAP 2 CROSS Fig 29 PRESS ON FLANGE 1 RECE...

Page 95: ...g cap 1 and flange Fig 32 6 Press bearing cap until snap ring groove is through the flange 7 Install snap ring 1 on bearing cap 2 Fig 33 Fig 31 SNAP RING 1 BEARING 2 SNAP RING Fig 32 REMAINING BEARING 1 BEARING 2 RECEIVER 3 PRESS Fig 33 SNAP RING 1 SNAP RING 2 BEARING Fig 34 FLANGE WITH U JOINT 1 FLANGE 2 YOKE 3 14 PROPELLER SHAFT DR SINGLE CARDAN UNIVERSAL JOINTS Continued ...

Page 96: ...sition press 2 with receiver 3 on remain ing bearing cap 1 and yoke Fig 37 13 Press remaining bearing cap until snap ring groove is through the yoke 14 Install snap ring 2 on bearing cap 1 Fig 38 Fig 35 PRESS ON YOKE 1 RECEIVER 2 PRESS 3 BEARING Fig 36 SNAP RING 1 BEARING 2 SNAP RING Fig 37 REMAINING BEARING 1 BEARING 2 PRESS 3 RECEIVER Fig 38 SNAP RING 1 BEARING 2 SNAP RING DR PROPELLER SHAFT 3 1...

Page 97: ...et on the press with an inside diameter large enough to receive the bearing cap under the link yoke 7 Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap 8 Press one bearing cap from outboard side of the link yoke enough to grasp the cap with vise jaws Fig 40 9 Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bear...

Page 98: ...assem bled 1 Apply EP N L G I Grade 1 or 2 grease to inside of yoke bores 2 Fit cross into the propeller shaft yoke Fig 43 3 Place bearing cap over the trunnion and align cap with the yoke bore Fig 44 Keep needle bear ings upright in the bearing cap 4 Press bearing cap into yoke bore enough to clear snap ring groove and install snap ring Fig 45 Fig 42 REMOVE CENTERING KIT Fig 43 INSTALL CROSS IN Y...

Page 99: ...all centering kit assembly inside the link yoke Fig 48 NOTE Verify spring is properly positioned 8 Place two bearing caps on opposite trunnions of the remaining cross Fit open trunnions into the link yoke bores and bearing caps into the centering kit Fig 49 Fig 46 PRESS IN BEARING CAP Fig 47 INSTALL LINK YOKE Fig 48 INSTALL CENTERING KIT Fig 49 INSTALL REMAINING CROSS 3 18 PROPELLER SHAFT DR DOUBL...

Page 100: ...o the grooves Fig 51 11 Flexing the joint beyond center the joint should snap over center in both directions if correctly assembled Fig 52 12 Install propeller shaft Fig 50 PRESS IN BEARING CAP Fig 51 SEAT SNAP RINGS IN GROOVE Fig 52 CHECK ASSEMBLY DR PROPELLER SHAFT 3 19 DOUBLE CARDAN UNIVERSAL JOINTS Continued ...

Page 101: ... the joint Noise could also be caused by another component of the vehicle com ing in contact with the half shafts CLUNKING NOISE DURING ACCELERATION This noise may be a damaged or worn C V joint A torn boot or loose missing clamp on the inner outer joint which has allowed the grease to be lost will damage the C V joint SHUDDER VIBRATION DURING ACCELERATION This could be a worn damaged inner tripod...

Page 102: ...ng 5 Install upper ball joint into the knuckle 6 Install upper ball joint nut and tighten to spec ification 7 Install lower shock absorber bolt and tighten to specification 8 Install brake rotor and caliper 9 Install half shaft hub nut and tighten to 251 N m 185 ft lbs SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Half Shaft Nut 251 185 SPECIAL TOOLS Fig 2 STEERING KNUCKLE 1 S...

Page 103: ...ing cage 3 and housing with dabs of paint Fig 6 8 Clamp C V joint in a vertical position in a soft jawed vise 9 Press down one side of the bearing cage 3 to gain access to the ball at the opposite side NOTE If joint is tight use a hammer and brass drift to loosen the bearing hub Do not contact the bear ing cage with the drift Fig 4 BOOT CLAMP LOCATIONS 1 C V HOUSING 2 CLAMP 3 HALF SHAFT 4 CLAMP 5 ...

Page 104: ...e joint boot to the C V joint components before assem bling them 3 Align the inner race cage and housing accord ing to the alignment reference marks 4 Insert the inner race into the cage Fig 10 and rotate race into the cage 5 Rotate the inner race hub in the cage Fig 11 6 Insert cage into the housing Fig 12 Rotate the cage 90 into the housing so the large bearing hub counterbore is facing outwards...

Page 105: ...erify the span ring has engaged 12 Position the boot on the joint in it s original position NOTE Verify boot is not twisted and remove any excess air 13 Secure both boot clamps Fig 15 with Clamp Installer C 4975A Place tool on clamp bridge and tighten tool until jaws of the tool are closed Fig 12 BEARING CAGE AND HOUSING 1 OUTER RACE 2 BEARING CAGE WINDOW 3 CV JOINT HOUSING Fig 13 BALL BEARING 1 C...

Page 106: ...omponents for exces sive wear and damage Replace the tripod as a unit only if necessary INSTALLATION 1 Clean all C V joint components and shaft 2 Slide new boot down the half shaft 3 Install tripod and tripod snap ring on the half shaft Fig 19 4 Pack grease supplied with the joint boot into the housing and boot 5 Coat tripod with supplied grease 6 Install new bushing Fig 20 onto the housing 7 Inse...

Page 107: ... the shaft This measure ment should be 260 mm 10 25 in NOTE If measurement is not correct allow more or less air into the boot 10 Secure both boot clamps with Clamp Installer C 4975A Place tool on clamp bridge and tighten tool until the jaws of the tool are closed Fig 20 HOUSING BUSHING 1 BUSHING 2 HOUSING Fig 21 INNER C V BOOT 1 CLAMP 2 BOOT 3 CLAMP 4 SHAFT 5 HOUSING 3 26 HALF SHAFT DR CV JOINT I...

Page 108: ... can be checked by turning the vehicle The side gears are loaded dur ing turns They usually do not cause noise during straight ahead driving when the gears are unloaded A worn pinion mate shaft can also cause a snapping or a knocking noise BEARING NOISE The axle shaft differential and pinion bearings can all produce noise when worn or damaged Bearing noise can be either a whining or a growling sou...

Page 109: ...t the helper to shift the transmission into gear and lis ten for the noise A mechanics stethoscope is helpful in isolating the source of a noise DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1 Wheel loose 1 Tighten loose nuts 2 Faulty brinelled wheel bearing 2 Replace bearing Axle Shaft Noise 1 Misaligned axle tube 1 Inspect axle tube alignment Correct as necessary 2 Bent or sp...

Page 110: ...tity 2 Improper grade of lubricant 2 Replace scored gears Fill differential with the correct fluid type and quantity 3 Excessive spinning of one wheel tire 3 Replace scored gears Inspect all gears pinion bores and shaft for damage Service as necessary Loss Of Lubricant 1 Lubricant level too high 1 Drain lubricant to the correct level 2 Worn axle shaft seals 2 Replace seals 3 Cracked differential h...

Page 111: ...antity 2 Improper ring gear and pinion adjustment 2 Check ring gear and pinion contact pattern 3 Unmatched ring gear and pinion 3 Replace gears with a matched ring gear and pinion 4 Worn teeth on ring gear and or pinion 4 Replace ring gear and pinion 5 Loose pinion bearings 5 Adjust pinion bearing pre load 6 Loose differential bearings 6 Adjust differential bearing pre load 7 Mis aligned or sprung...

Page 112: ...e from the vehicle INSTALLATION 1 Raise axle into position 2 Install axle mounting bolts and tighten nuts to 95 N m 70 ft lbs 3 Install suspension crossmember and bolts Tighten crossmember nuts to 102 N m 75 ft lbs 4 Install front propeller shaft with reference marks aligned Fig 5 and tighten bolts to 115 N m 85 ft lbs 5 Install exhaust crossover 6 Install axle half shafts Fig 1 SUSPENSION CROSSME...

Page 113: ...of the original and replacement pinion Add or subtract this number from the original depth shim oil slinger to compensate for the difference in the depth variances The numbers represent thou sands of an inch deviation from the standard If the number is negative add that value to the required thickness of the depth shims If the number is posi tive subtract that value from the thickness of the depth...

Page 114: ...ith a Pinion Gauge Set Pinion Block 8177 Arbor Discs 8541 and Dial Indicator C 3339 Fig 7 1 Assemble Pinion Height Block 6739 Pinion Block 8177 and rear pinion bearing onto Screw 6741 Fig 7 2 Insert assembled height gauge components rear bearing and screw into the housing through the pinion bearing cups Fig 8 3 Install front pinion bearing and Cone Nut 6740 onto the screw Tighten cone nut until To...

Page 115: ...The proper shim thick ness can be determined using slip fit Dummy Bear ings 8398 in place of the differential side bearings and a Dial Indicator C 3339 Before measuring differ ential bearing preload and gear backlash measure pinion gear depth and prepare pinion for installation Pinion gear depth is essential to establishing gear backlash and tooth contact patterns After measuring shim thickness to...

Page 116: ...int shims between both dummy bearings and the housing Fig 12 6 Install the marked bearing caps in their correct positions Install and snug the bolts 7 Using a dead blow hammer to seat the differ ential dummy bearings to each side of the differential housing Fig 13 and Fig 14 8 Install Pilot Stud C 3288 B in cover bolt hole below ring gear Fig 12 DUMMY SHIM 1 DUMMY SHIM 2 DIFFERENTIAL HOUSING 3 DIF...

Page 117: ...ential case dummy bearings and dummy shims from the housing 16 Install the pinion gear in the housing Install the companion flange and establish the correct pinion rotating torque 17 Install differential case and Dummy Bearings in the housing with a single dummy shim on the ring gear side of the axle and tighten retaining cap bolts 18 Position the dial indicator plunger on a flat surface between t...

Page 118: ...d ring gear downward while not allowing the pinion gear to rotate Dial indicator reading should be between 0 12 mm 0 005 in and 0 20 mm 0 008 in If backlash is not within specifi cations transfer the necessary amount of shim thick ness from one side of the differential housing to the other Fig 19 36 Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight lo...

Page 119: ...se to pinion gear Fig 24 Increase backlash by moving the ring away from the pinion gear Pinion gear set too low Fig 25 Increase pinion gear height by increasing the pinion depth shim thickness Fig 20 CORRECT CONTACT PATTERN Fig 21 INCORRECT BACKLASH 1 COAST SIDE TOE 2 DRIVE SIDE HEEL Fig 22 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE HEEL Fig 23 INCORRECT BACKLASH 1 DRIVE SIDE HEEL 2 COAST SI...

Page 120: ...r 205 mm 8 0 in Ring Gear Backlash 0 12 0 20 mm 0 005 0 008 in Ring Gear Runout 0 12 mm 0 005 in Pinion Bearing Preload New Bearings 2 0 2 8 N m 18 25 in lbs Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Mounting Nuts 95 70 Differential Fill Hole Plug 34 25 Differential Cover Bolts 22 15 Bearing Cap Bolts 61 45 Ring Gear Bolts 108...

Page 121: ...PULLER C 293 PA PLUG C 293 3 ADAPTER C 293 42 ADAPTER C 293 48 PILOTS C 3288 B DIAL INDICATOR C 3339 INSTALLER C 3716 A INSTALLER C 3718 HANDLE C 4171 PULLER C 452 3 40 FRONT AXLE C205F DR FRONT AXLE C205F Continued ...

Page 122: ...MOVER C 4660 A SPREADER W 129 B INSTALLER 5063 INSTALLER 6448 HOLDER 6719A PINION DEPTH SET 6775 DUMMY SHIM 8107 ADAPTER PLATES 8142A PINION BLOCK 8177 DR FRONT AXLE C205F 3 41 FRONT AXLE C205F Continued ...

Page 123: ...REMOVER 8240A DUMMY BEARING 8398 REMOVER 8401 INSTALLER 8692 INSTALLER 8693 INSTALLER 8694 INSTALLER 8695 REMOVER 8831 3 42 FRONT AXLE C205F DR FRONT AXLE C205F Continued ...

Page 124: ...te if equipped 3 Clean axle seal area 4 Remove axle shaft O ring 5 Remove axle shaft 6 Remove axle shaft seal with a small pry bar INSTALLATION 1 Clean axle shaft bore clean 2 Install a new axle shaft seal with Installer 8694 and Handle C 4171 Fig 28 3 Lubricate seal lip with gear lubricant 4 Insert axle shaft through seal bearing and engage it into side gear splines Push firmly on the axle shaft ...

Page 125: ...p ring 6 Install axle shaft O ring 7 Install skid plate if necessary 8 Install half shaft PINION SEAL REMOVAL 1 Remove both half shafts 2 Remove front propeller shaft 3 Rotate pinion gear three or four times and ver ify pinion rotates smoothly 4 Record pinion rotating torque with an inch pound torque wrench for installation reference Fig 32 5 Position Holder 6719 against the companion flange and i...

Page 126: ...rease pin ion bearing rotating torque and never exceed spec ified preload torque Failure to heed caution may result in damage 6 Record pinion rotating torque using an inch pound torque wrench The rotating torque should be equal to the reading recorded during removal plus an additional 0 56 N m 5 in lbs Fig 36 7 If rotating torque is low tighten the pinion nut in 6 8 N m 5 ft lbs increments until t...

Page 127: ... housing and zero the indicator 7 Spread the housing to remove the differential case from the housing Fig 38 Measure the distance with the dial indicator CAUTION Never spread over 0 50 mm 0 020 in If the housing is over spread it could be distorted or damaged 8 Remove dial indicator 9 While holding the differential case in position remove bearing cap bolts and caps 10 Remove differential from the ...

Page 128: ...side gears and thrust washers into the differentail case 3 Rotate pinion mate gears and thrust washers into the differentail case 4 Install pinion gear mate shaft 5 Align hole in pinion gear mate shaft with hole in the differential case 6 Install roll pin 3 in the differential case with a punch 1 and hammer Fig 41 Peen edge of roll pin hole in differential case in two places 180 apart 7 Install ri...

Page 129: ...using Tap differential case to ensure bearings cups are seated in the housing 6 Install bearing caps to their original locations and loosely install cap bolts 7 Remove housing spreader 8 Tighten the bearing cap bolts to 61 N m 45 ft lbs 9 Install axle shafts 10 Apply a bead of orange Mopar Axle RTV seal ant or equivalent to the housing cover CAUTION If cover is not installed within 3 to 5 min utes...

Page 130: ... 45 9 Install bolts into two of the threaded holes in the companion flange 180 apart 10 Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes Tighten the bolts so that the Holder 6719 is held to the flange 11 Remove the pinion nut 12 Remove the companion flange with Remover C 452 Fig 46 13 Remove pinion from differential housing 14...

Page 131: ...2 Fig 50 20 Remove depth shims from the pinion shaft and record thickness of shims Fig 46 COMPANION FLANGE REMOVER 1 COMPANION FLANGE 2 PULLER TOOL Fig 47 FRONT PINION BEARING CUP 1 HOUSING 2 REMOVER 3 HANDLE Fig 48 REAR PINION BEARING CUP 1 HOUSING 2 REMOVER 3 HANDLE Fig 49 COLLAPSIBLE SPACER 1 COLLAPSIBLE SPACER 2 REAR PINION BEARING 3 PINION DEPTH SHIM 3 50 FRONT AXLE C205F DR PINION GEAR RING ...

Page 132: ...th Installer 8692 and Driver Handle C 4171 Fig 51 3 Install front pinion bearing cup with Installer 8693 and Handle C 4171 4 Lubricate front pinion bearing and install bear ing in the housing 5 Apply a light coating of gear lubricant on the lip of pinion seal 6 Install pinion seal with Installer 8695 and Handle C 4171 Fig 52 Fig 50 REAR PINION BEARING 1 PULLER 2 VISE 3 ADAPTERS 4 DRIVE PINION GEAR...

Page 133: ...t in 6 8 N m 5 ft lbs increments until desired rotating torque is achieved Measure rotating torque frequently to avoid over crushing the collapsible spacer Fig 57 The pinion rotating torque should be Original Bearings 1 to 2 5 N m 10 to 20 in lbs New Bearings 2 0 to 2 8 N m 18 to 25 in lbs CAUTION Never loosen pinion nut to decrease pin ion bearing rotating torque and never exceed spec ified prelo...

Page 134: ...e the ring gear bolts Failure to heed caution may result in damage 18 Install differential in housing and verify gear mesh backlash and contact pattern Fig 56 PINION NUT 1 DIFFERENTIAL HOUSING 2 COMPANION FLANGE HOLDER 3 TORQUE WRENCH Fig 57 PINION ROTATING TORQUE 1 PINION COMPANION FLANGE 2 TORQUE WRENCH Fig 58 RING GEAR BOLTS 1 TORQUE WRENCH 2 BOLTS 3 RING GEAR 4 DIFFERENTIAL CASE DR FRONT AXLE ...

Page 135: ... can be checked by turning the vehicle The side gears are loaded dur ing turns They usually do not cause noise during straight ahead driving when the gears are unloaded A worn pinion mate shaft can also cause a snapping or a knocking noise BEARING NOISE The axle shaft differential and pinion bearings can all produce noise when worn or damaged Bearing noise can be either a whining or a growling sou...

Page 136: ...ear and lis ten for the noise A mechanics stethoscope is helpful in isolating the source of a noise DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1 Wheel loose 1 Tighten loose nuts 2 Faulty brinelled wheel bearing 2 Replace bearing Axle Shaft Noise 1 Misaligned axle tube 1 Inspect axle tube alignment Correct as necessary 2 Bent or sprung axle shaft 2 Inspect and correct as nece...

Page 137: ...y 2 Improper grade of lubricant 2 Replace scored gears Fill differential with the correct fluid type and quantity 3 Excessive spinning of one wheel tire 3 Replace scored gears Inspect all gears pinion bores and shaft for damage Service as necessary Loss Of Lubricant 1 Lubricant level too high 1 Drain lubricant to the correct level 2 Worn axle shaft seals 2 Replace seals 3 Cracked differential hous...

Page 138: ...g pre load 6 Loose differential bearings 6 Adjust differential bearing pre load 7 Mis aligned or sprung ring gear 7 Measure ring gear run out Replace components as necessary 8 Loose differential bearing cap bolts 8 Inspect differential components and replace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1...

Page 139: ...n the axle under the vehicle 4 Install springs retainer clip and bolts 5 Raise axle and align it with the spring pads 6 Position upper and lower suspension arms in the axle brackets Install bolts nuts and align the suspension alignment cams to the reference marks Do not tighten at this time Fig 2 SHOCK ABSORBER 1 SHOCK 2 SPRING 3 FLAG NUT 4 SHOCK BOLT Fig 3 TRACK BAR 1 TRACK BAR 2 BOLT 3 NUT Fig 4...

Page 140: ...DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing Take measurements with Pinion Gauge Set and Dial Indi cator C 3339 Fig 6 1 Assemble Pinion Height Block 6739 Pinion Block 8878 and rear pinion bearing onto Screw 6741 Fig 6 2 Insert assembled height gauge components rear bearing and screw into the housing through pin ion be...

Page 141: ...e pinion gear until the gears make contact zero backlash If zero backlash cannot be obtained turn the pinion side adjuster until zero backlash is obtained 4 Holding the differential case toward the pinion gear turn bearing adjusters with Spanner Wrench 8883 until they make contact with the differential bearings cups 5 Back off the ring gear side adjuster 4 holes to obtain initial ring gear backlas...

Page 142: ...oduce low noise and long gear life Gears which are not positioned properly may be noisy and have shortened gear life 1 Wipe clean each tooth of the ring gear 2 Apply gear marking compound to all of the ring gear teeth 3 Verify bearing cap bolts are torque to specifica tion 4 Apply the brakes lightly to create a 14 N m 10 ft lbs pinion rotating torque 5 Rotate the pinion pinion yoke 4 full revoluti...

Page 143: ...n ion depth by decreasing the pinion depth shim thick ness Fig 14 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE HEEL Fig 15 INCORRECT BACKLASH 1 DRIVE SIDE HEEL 2 COAST SIDE HEEL Fig 16 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE TOE Fig 17 LOW PINION HEIGHT Fig 18 HIGH PINION HEIGHT 3 62 FRONT AXLE 9 1 4 AA DR FRONT AXLE 9 1 4 AA Continued ...

Page 144: ... in lbs Pinion Bearing Preload Differential Case Bearing Preload New Bearing 3 4 5 6 N m 30 50 in lbs Pinion Bearing Preload Differential Case Bearing Preload Original Bearing 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 32 24 Differential Cover Bolts 40 30 Bearing Cap Bolts 85 63 Ring Gear Bolts 140 103 Axle Nut 356 263 Pinion Shaft Lock Bolt 52 38 A...

Page 145: ...PULLER C 293 PA INSTALLER C 3095 A DIAL INDICATOR SET C 3339 HANDLE C 4171 CUP INSTALLER D 146 DIAL INDICATOR STUD L 4438 SPLITTER 1130 REMOVER EXTRACTOR 6310 3 64 FRONT AXLE 9 1 4 AA DR FRONT AXLE 9 1 4 AA Continued ...

Page 146: ...PINION DEPTH SET 6730 ARBOR DISCS 8289 RECEIVER 8498 PINION BLOCK 8878 ADAPTERS 8879 BEARING INSTALLER 8881 SEAL INSTALLER 8882 DR FRONT AXLE 9 1 4 AA 3 65 FRONT AXLE 9 1 4 AA Continued ...

Page 147: ...ADJUSTER WRENCH 8883 SEAL INSTALLER 8885 CUP INSTALLER 8886 PLUG 8888 PINION DRIVER 8976 FLANGE WRENCH 8979 3 66 FRONT AXLE 9 1 4 AA DR FRONT AXLE 9 1 4 AA Continued ...

Page 148: ...ve axle shaft cotter pin hub nut and washer Fig 19 4 Remove four hub bearing bolts Fig 20 from the back of the steering knuckle PINION INSTALLER 8982 FLANGE PULLER 8992 BRIDGE 938 Fig 19 AXLE NUT 1 AXLE NUT 2 AXLE 3 COTTER PIN Fig 20 HUB BEARING BOLTS 1 STUB SHAFT 2 BEARING BOLTS 3 AXLE SHAFT DR FRONT AXLE 9 1 4 AA 3 67 FRONT AXLE 9 1 4 AA Continued ...

Page 149: ... cap to be removed 3 Locate a socket with an outside diameter that is smaller than the bearing cap Place the socket driver against the opposite bearing cap 4 Position the yoke with the sockets in a vise Fig 23 5 Tighten the vise jaws to force the bearing cap into the larger socket receiver 6 Release the vise jaws Remove the sockets and bearing cap that was partially forced out of the yoke 7 Repeat...

Page 150: ...l side gears Fig 24 3 Install hub bearing in the knuckle 4 Install hub bearing bolts and tighten to 202 N m 149 ft lbs 5 Install ABS wheel speed sensor brake rotor and caliper 6 Install axle washer and nut Tighten axle nut to 179 N m 132 ft lbs 7 Rotate axle several 5 to 10 times to seat the wheel bearing 8 Tighten axle nut to final torque of 356 N m 263 ft lbs 9 Align nut to next cotter pin hole ...

Page 151: ...pand the turnbuckle until the seal bottom out in the housing 3 Install differential into the axle housing 4 Install axle shaft and hub bearings PINION SEAL REMOVAL 1 Mark the propeller shaft and pinion flange for installation reference 2 Remove propeller shaft 3 Remove hub bearings and axle shafts 4 Rotate pinion gear three or four times 5 Measure and record the torque necessary to rotate Fig 30 t...

Page 152: ...en pinion nut until pinion end play is taken up 6 Rotate pinion several times to seat bearings 7 Measure pinion rotating torque with an inch pound torque wrench and compare it to recorded measurement Tighten pinion nut in small incre ments until pinion rotating torque is 0 40 0 57 N m 3 5 in lbs greater than recorded measurement 8 Rotate pinion several times then verify pinion rotating torque agai...

Page 153: ... differential bearing adjusters Fig 35 with Spanner Wrench 8883 7 Remove differential case from the housing 8 Remove bearing cups and tag them left and right for installation reference DISASSEMBLY 1 Remove pinion shaft lock bolt 2 Remove pinion shaft Fig 36 Fig 34 ADJUSTERS AND LOCKS 1 ADJUSTER LOCK BOLT 2 ADJUSTER LOCK 3 ADJUSTER 4 BEARING CAP Fig 35 ADJUSTERS 1 BEARING CUP 2 ADJUSTER 3 BEARING C...

Page 154: ...ubricant 2 Install differential side gears and thrust wash ers Fig 39 3 Rotate the one pinion gear with thrust washer into the differential case Fig 40 Then rotate the other pinion gear with thrust washer into the differ ential case Fig 37 PINION GEAR 1 DIFFERENTIAL WINDOW 2 PINION GEAR 3 THRUST GEAR Fig 38 SIDE GEARS 1 SIDE GEAR 2 SIDE GEAR 3 PINION GEARS Fig 39 SIDE GEARS 1 DIFFERENTIAL WINDOW 2...

Page 155: ...Install ring gear side adjuster lock and bolt Do not tighten adjuster lock bolt at this time 9 Tighten pinion gear side adjuster firmly against the differential case bearing cup 10 Rotate the pinion several times to seat the dif ferential bearings 11 Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup 12 Tighten pinion gear side adjuster until it just makes conta...

Page 156: ...ail case into housing PINION GEAR RING GEAR REMOVAL NOTE The ring and pinion gears are service in a matched set Never replace the ring gear pinion gear without replacing the other matching gear 1 Mark pinion flange and propeller shaft for installation alignment 2 Disconnect propeller shaft from pinion flange and remove propeller shaft 3 Remove axle shafts 4 Remove differential from housing 5 Place...

Page 157: ... Puller 8992 Fig 47 10 Remove pinion gear from housing with Pinion Driver 8976 and a hammer Fig 48 NOTE Thread drive on shaft until it bottoms out Fig 45 RING GEAR 1 DIFFERENTIAL CASE 2 RING GEAR 3 HAMMER Fig 46 FLANGE WRENCH 1 PINION FLANGE 2 WRENCH Fig 47 PINION FLANGE PULLER 1 PINION FLANGE 2 PULLER Fig 48 PINION DRIVER 1 PINION SHAFT 2 PINION DRIVER 3 76 FRONT AXLE 9 1 4 AA DR PINION GEAR RING...

Page 158: ...ith a punch and hammer and discard CAUTION Do not reuse front pinion bearing cup 17 Remove rear pinion bearing cup from the housing with a punch and hammer if bearing is replaced INSTALLATION 1 Install front pinion bearing cup Fig 50 with Installer D 146 and Handle C 4171 2 Install rear pinion bearing cup Fig 51 with Installer 8886 and Handle C 4171 if bearing is replaced Fig 49 REAR PINION BEARIN...

Page 159: ...t pinion bearing onto the pinion shaft Draw the pinion shaft into the front bearing with Installer 8982 Fig 55 Fig 52 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fig 53 REAR PINION BEARING 1 PRESS 2 INSTALLER 3 PINION GEAR 4 REAR PINION BEARING Fig 54 COLAPSIBLE SPACER 1 COLAPSIBLE SPACER 2 PINION GEAR 3 REAR PINION BEARING Fig 55 PINION GEAR INSTALLER 1 INSTALLER 2 DIFFERENTIAL HOUSING 3 ...

Page 160: ...gain 16 Position the ring gear on differential case and start two new ring gear bolts 17 Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear 18 Torque ring gear bolts to 140 N m 103 ft lbs 19 Install differential in housing 20 Measure final rotating torque with an inch pound torque wrench The final pinion rotating torque plus differential case bearing pre...

Page 161: ...oise range If the noise stops or changes greatly check for Insufficient lubricant Incorrect ring gear backlash Gear damage Differential side gears and pinions can be checked by turning the vehicle They usually do not cause noise during straight ahead driving when the gears are unloaded The side gears are loaded during vehi cle turns A worn pinion shaft can also cause a snap ping or a knocking nois...

Page 162: ...U joints Loose spring mounts Loose pinion gear nut and yoke Excessive ring gear backlash Excessive side gear to case clearance The source of a snap or a clunk noise can be deter mined with the assistance of a helper Raise the vehi cle on a hoist with the wheels free to rotate Instruct the helper to shift the transmission into gear Listen for the noise a mechanics stethoscope is helpful in isolatin...

Page 163: ...ntity 2 Improper grade of lubricant 2 Replace scored gears Fill differential with the correct fluid type and quantity 3 Excessive spinning of one wheel tire 3 Replace scored gears Inspect all gears pinion bores and shaft for damage Service as necessary Loss Of Lubricant 1 Lubricant level too high 1 Drain lubricant to the correct level 2 Worn axle shaft seals 2 Replace seals 3 Cracked differential ...

Page 164: ... components and replace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Raise and support the vehicle 2 Position a lift under axle and secure axle to lift 3 Remove wheels and tires assemblies 4 Remove all brake components 5 Remove axle vent hose 6 Mark propeller shaft and companion flange for installation...

Page 165: ...nsate for the difference in the depth variances The numbers represent thou sands of an inch deviation from the standard If the number is negative add that value to the required thickness of the depth shims If the number is posi tive subtract that value from the thickness of the depth shim Pinion Gear Depth Variance Chart Note where Old and New Pinion Marking columns intersect Intersecting figure r...

Page 166: ...006 20 007 20 008 PINION DEPTH MEASUREMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing Take measurements with Pinion Gauge Set and Dial Indi cator C 3339 Fig 5 1 Assemble Pinion Height Block 6739 Pinion Block 8542 and rear pinion bearing onto Screw 6741 Fig 5 2 Insert assembled height gauge components rear bearing and screw into the housing through ...

Page 167: ... reading DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing preload and gear backlash The maximum ring gear backlash variation is 0 076 mm 0 003 in Mark the gears so the same teeth are meshed during all backlash measurements Maintain the torque while adjusting the bearing preload and ring gear backlash Excessive adjuster torque will introduce a h...

Page 168: ... range of backlash is 0 15 to 0 203 mm 0 006 to 0 008 in 8 Continue increasing the torque at the right side threaded adjuster until the specified backlash is obtained NOTE The left side threaded adjuster torque should have approximately 102 N m 75 ft lbs If the torque is considerably less the complete adjustment procedure must be repeated 9 Tighten the left side threaded adjuster until 102 N m 75 ...

Page 169: ...ear Fig 14 Increase backlash by moving the ring away from the pinion gear using the adjusters Pinion gear set too low Fig 15 Increase pinion gear height by increasing the pinion depth shim thickness Pinion gear set too high Fig 16 Decrease pin ion depth by decreasing the pinion depth shim thick ness Fig 11 INCORRECT BACKLASH 1 COAST SIDE TOE 2 DRIVE SIDE HEEL Fig 12 INCORRECT BACKLASH 1 DRIVE SIDE...

Page 170: ...ickness will determine required thickness of replacement thrust washer Fig 18 In some cases the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted The C lock is preventing the side gear from sliding on the axle shaft 5 If there is no side gear clearance remove the C lock from the axle shaft Use a micrometer to mea sure the thrust washer thickness Record th...

Page 171: ...g Preload New Bearings 1 7 4 N m 15 35 in lbs Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Differential Cover Bolts 41 30 Bearing Cap Bolts 136 100 Ring Gear Bolts 157 115 Pinion Nut Minimum 285 210 Adjuster Lock Screw 10 7 5 90 Backing Plate Bolts 65 48 Pinion Mate Shaft Lock Screw 11 8 Axle U Bolt Nuts 149 110 SPECIAL TOOLS PUL...

Page 172: ...TALLER C 3095 A DIAL INDICATOR SET C 3339 INSTALLER C 3718 INSTALLER C 4076 B WRENCH C 4164 HANDLE C 4171 INSTALLER C 4198 INSTALLER C 4213 REMOVER C 4307 DR REAR AXLE 9 1 4 3 91 REAR AXLE 9 1 4 Continued ...

Page 173: ...INSTALLER C 4345 TRAC LOK TOOLS C 4487 PULLER C 452 HANDLE C 4735 INSTALLER D 130 REMOVER 6310 HOLDER 6719A PINION GAUGE SET 6730 6774 6775 TRAC LOK TORQUE FIXTURE 6790 3 92 REAR AXLE 9 1 4 DR REAR AXLE 9 1 4 Continued ...

Page 174: ...nd drain lubricant 6 Rotate differential case so pinion mate shaft lock screw is accessible Remove lock screw and pin ion mate shaft from differential case Fig 20 FIXTURE 8136 TRAC LOK TOOLS 8139 ARBOR DISCS 8541 PINION BLOCK 8542 Fig 19 REAR ROTOR 1 ROTOR 2 CALIPER ADAPTER 3 CALIPER Fig 20 PINION MATE SHAFT LOCK SCREW 1 LOCK SCREW 2 PINION MATE SHAFT DR REAR AXLE 9 1 4 3 93 REAR AXLE 9 1 4 Contin...

Page 175: ...ighten lock screw to 11 N m 8 ft lbs 6 Install differential cover and fill with gear lubricant to the bottom of the fill plug hole 7 Install brake rotor caliper adapter and caliper 8 Install wheel and tire 9 Remove support and lower vehicle AXLE SHAFT SEALS REMOVAL 1 Remove axle shaft 2 Remove axle shaft seal Fig 23 from the axle tube with a small pry bar INSTALLATION 1 Wipe the axle tube bore cle...

Page 176: ...be the seal is installed to the correct depth 4 Install the axle shaft 5 Install differential cover and fill with gear lubricant to the bottom of the fill plug hole PINION SEAL REMOVAL 1 Mark universal joint companion flange and pinion shaft for installation reference 2 Remove propeller shaft from the companion flange 3 Remove the brake rotors to prevent any drag 4 Rotate companion flange three or...

Page 177: ...ightening torque 285 N m 210 ft lbs when installing the companion flange retaining nut at this point Dam age to collapsible spacer or bearings may result 8 Hold companion flange with Holder 6719 and tighten the pinion nut with a torque set to 285 N m 210 ft lbs Fig 27 Rotate pinion several revolu tions to ensure the bearing rollers are seated 9 Rotate pinion with an inch pound torque wrench Rotati...

Page 178: ...CAUTION If housing cover is not installed within 3 to 5 minutes the cover must be cleaned and new RTV applied Failure to heed caution may result in damage 2 Install cover and identification tag Tighten cover bolts in a criss cross pattern to 41 N m 30 ft lbs 3 Fill differential to specifications 4 Install fill plug DIFFERENTIAL REMOVAL 1 Remove filler plug from the differential cover 2 Remove diff...

Page 179: ...ndow 1 and remove gear and thrust washer 2 Rotate remaining pinion gear 3 with thrust washer 2 Fig 33 to the differential window 1 and remove gear and washer 3 Remove differential side gears 1 2 and thrust washers Fig 34 Fig 31 THREADED ADJUSTER TOOL 1 AXLE TUBE 2 BACKING PLATE 3 THREAD ADJUSTER WRENCH Fig 32 FRIST PINION GEAR 1 DIFFERNTIAL CASE WINDOW 2 PINION GEAR 3 THRUST WASHER Fig 33 SECOND P...

Page 180: ...readed adjusters A dab of grease can be used to keep the adjusters in position 2 Install differential assembly into the housing 3 Install differential bearing caps in their origi nal locations Fig 38 4 Install bearing cap bolts and tighten the upper bolts to 14 N m 10 ft lbs Tighten the lower bolts finger tight until the bolt head is seated 5 Perform the differential bearing preload and adjustment...

Page 181: ...lleville spring washers within the clutch packs The second is the separating forces gen erated by the side gears as torque is applied through the ring gear Fig 40 This design provides the differential action needed for turning corners and for driving straight ahead during periods of unequal traction When one wheel looses traction the clutch packs transfer additional torque to the wheel having the ...

Page 182: ...d read rotating torque Fig 41 6 If rotating torque is less than 41 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the unit should be serviced DISASSEMBLY 1 Clamp Holding Fixture 8136 in vise and set differential case on fixture Fig 42 2 Remove pinion gear mate shaft screw 3 Remove pinion gear mate shaft Fig 40 TRAC LOK LIMITED SLIP DIFFERENTIAL 1 CASE 2 RING GEAR 3 DRIVE PINION 4 PI...

Page 183: ...g 7 Tighten forcing screw to 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs Fig 45 8 With a feeler gauge remove thrust washers from behind the pinion gears Fig 46 9 Insert turning bar from tool kit into pinion mate shaft hole in the case Fig 47 Fig 43 ADAPTER DISC 1 LOWER SIDE GEAR 2 DIFFERENTIAL CASE 3 DISC Fig 44 THREAD ADAPTER DISC 1 SOCKET 2 SLOT IN DISC 3 SCREWDRIVER...

Page 184: ...correct order during removal ASSEMBLY Clean all components in cleaning solvent and dry components with compressed air Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one component in either pack is damaged Inspect side gears and pinions Replace any gear that is worn cracked chipped or damaged Inspect differential case and pinion shaft Replace if worn or damag...

Page 185: ...ining clips are in position and seated in case pockets 6 Install lubricated disc from Trac Lokt Tool Kit 8139 in lower side gear 7 Install upper side gear and clutch disc pack Fig 51 CAUTION Verify clutch pack retaining clips are in position and seated in case pockets 8 Hold assembly in position and install threaded disc from tool kit into top side gear 9 Install forcing screw from Trac Lokt Tool ...

Page 186: ...shaft into each pinion gear to ver ify alignment 14 Remove Forcing Screw Discs and Threaded Adapter 15 Install pinion gear mate shaft and align holes in shaft and case 16 Install pinion mate shaft screw 17 Lubricate all differential components with hypoid gear lubricant DIFFERENTIAL CASE BEARINGS REMOVAL 1 Remove differential case from axle housing 2 Remove differential bearings from the case with...

Page 187: ...tal jaw protectors 6 Remove ring gear bolts from the differential case 7 Drive ring gear off the differential case with a rawhide hammer Fig 54 8 Install bolts into two of the threaded holes in the companion flange 180 apart 9 Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes Tighten the bolts so the Holder 6719 is held to the ...

Page 188: ...Fig 57 16 Remove rear pinion bearing cup from housing Fig 58 with Remover C 4307 and Handle C 4171 17 Remove collapsible spacer from the pinion shaft Fig 59 Fig 56 PINION GEAR 1 RAWHIDE HAMMER Fig 57 FRONT PINION BEARING CUP 1 REMOVER 2 HANDLE Fig 58 REAR PINION BEARING CUP 1 DRIVER 2 HANDLE Fig 59 COLLAPSIBLE SPACER 1 COLLAPSIBLE SPACER 2 REAR PINION BEARING 3 PINION DEPTH SHIM DR REAR AXLE 9 1 4...

Page 189: ... gears or bearings are replaced Refer to Adjust ments for Pinion Gear Depth Setting 1 Apply Mopar Door Ease or equivalent stick lubricant to outside surface of the pinion bearing cups 2 Install rear pinion bearing cup Fig 62 with Installer C 4308 and Driver Handle C 4171 and ver ify cup is seated Fig 60 REAR PINION BEARING 1 PULLER 2 VISE 3 ADAPTERS 4 PINION SHAFT Fig 61 PINION DEPTH SHIM 1 PINION...

Page 190: ...dle C 4735 1 Fig 64 6 Install pinion depth shim Fig 65 on the pin ion gear shaft 7 Install rear bearing on the pinion Fig 66 with Installer C 3095 A and a press Fig 63 FRONT PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 64 PINION SEAL INSTALLER 1 HANDLE 2 INSTALLER 3 HOUSING Fig 65 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fig 66 REAR PINION BEARING 1 PRESS 2 INSTALLER 3 PINION GEAR 4 REAR...

Page 191: ...ever loosen pinion nut to decrease pin ion rotating torque and never exceed specified pre load torque If preload torque or rotating torque is exceeded a new collapsible spacer must be installed 15 Slowly tighten the nut in 6 8 N m 5 ft lbs increments until the desired rotating torque is achieved Measure pinion rotating torque frequently to avoid over crushing the collapsible spacer 16 Check pinion...

Page 192: ...olts and alternately tighten to 156 N m 115 ft lbs Fig 70 CAUTION Never reuse the ring gear bolts The bolts can fracture causing extensive damage 21 Install differential in housing and verify gear mesh backlash and contact pattern 22 Install axle shafts 23 Install differential cover and fill with gear lubricant 24 Install propeller shaft with reference marks aligned Fig 70 RING GEAR BOLTS 1 TORQUE...

Page 193: ...t ring gear backlash Gear damage Differential side gears and pinions can be checked by turning the vehicle The side gears are loaded dur ing turns They usually do not cause noise during straight ahead driving when the gears are unloaded A worn pinion shaft can also cause a snapping or a knocking noise BEARING NOISE The axle shaft differential and pinion bearings can all produce noise when worn or ...

Page 194: ...e ring gear backlash Excessive side gear to case clearance The source of a snap or a clunk noise can be deter mined with the assistance of a helper Raise the vehi cle on a hoist with the wheels free to rotate Instruct the helper to shift the transmission into gear and lis ten for the noise A mechanics stethoscope is helpful in isolating the source of a noise DIAGNOSTIC CHART Condition Possible Cau...

Page 195: ... and shaft for damage Service as necessary Loss Of Lubricant 1 Lubricant level too high 1 Drain lubricant to the correct level 2 Worn axle shaft seals 2 Replace seals 3 Cracked differential housing 3 Repair as necessary 4 Worn pinion seal 4 Replace seal 5 Worn scored yoke 5 Replace yoke and seal 6 Axle cover not properly sealed 6 Remove clean and re seal cover Axle Overheating 1 Lubricant level lo...

Page 196: ...nts as necessary 8 Loose differential bearing cap bolts 8 Inspect differential components and replace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Raise and support the vehicle 2 Position a lift under axle and secure lift to the axle 3 Remove wheels and tires assemblies 4 Remove all brake components 5 ...

Page 197: ... the housing through pin ion bearing cups Fig 4 3 Install front pinion bearing and Cone nut 6740 onto the screw Tighten cone nut until Torque To Rotate the screw is 1 7 2 26 N m 15 20 in lbs Fig 3 4 Place Arbor Disc 6732 on Arbor D 115 3 in posi tion in the housing side bearing cradles Fig 5 5 Install differential bearing caps on arbor discs and snug the bearing cap bolts Then cross tighten cap bo...

Page 198: ...acklash cannot be obtained turn the pinion side adjuster until zero backlash is obtained 4 Holding the differential case toward the pinion gear turn bearing adjusters with Spanner Wrench 8883 Fig 8 until they make contact with the differ ential bearings cups 5 Back off the ring gear side adjuster 4 holes to obtain initial ring gear backlash Fig 5 GAUGE TOOLS IN HOUSING 1 ARBOR DISC 2 PINION BLOCK ...

Page 199: ...s If measurement does vary inspect the gears for burrs the differential case flange and ring gear mounting GEAR TOOTH CONTACT PATTERN Gear tooth contact pattern is used to verify the cor rect running position of the ring and pinion gears This will produce low noise and long gear life Gears which are not positioned properly may be noisy and have shorten gear life 1 Wipe clean each tooth of the ring...

Page 200: ...low Fig 15 Increase the pinion gear height by increasing the pinion depth shim thickness Pinion gear is set too high Fig 16 Decrease the pinion depth by decreasing the pinion depth shim thickness Fig 12 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE HEEL Fig 13 INCORRECT BACKLASH 1 DRIVE SIDE HEEL 2 COAST SIDE HEEL Fig 14 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE TOE Fig 15 LOW PINION HEI...

Page 201: ...ing Preload Diff Case Bearing Preload New Bearings 3 4 5 6 N m 30 50 in lbs Pinion Bearing Preload Diff Case Bearing Preload Original Bearings 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 32 24 Differential Cover Bolts 40 30 Bearing Cap Bolts 165 122 Ring Gear Bolts 237 175 Axle Flange Bolts 129 95 Adjuster Lock Bolt 25 18 SPECIAL TOOLS PULLER C 293 P...

Page 202: ...IAL INDICATOR STUD L 4438 BEARING INSTALLER MD 998805 SPLITTER 1130 PINION DEPTH GAUGE 6730 ARBOR DISCS 6732 ADAPTERS 8879 ADJUSTER WRENCH 8883 DR REAR AXLE 10 1 2 AA 3 121 REAR AXLE 10 1 2 AA Continued ...

Page 203: ...PLUG 8888 SEAL INSTALLER 8896 GAUGE BLOCK 8899 SOCKET 8954 BEARING INSTALLER 8956 CUP INSTALLER 8959 3 122 REAR AXLE 10 1 2 AA DR REAR AXLE 10 1 2 AA Continued ...

Page 204: ...CUP INSTALLER 8960 CUP INSTALLER 8961 CUP INSTALLER 8962 SEAL INSTALLER 8963 PINION DRIVER 8977 FLANGE WRENCH 8979 DR REAR AXLE 10 1 2 AA 3 123 REAR AXLE 10 1 2 AA Continued ...

Page 205: ...Mopar Lock N Seal or LoctiteT 242 on cleaned existing bolts 1 Clean axle flange and hub 2 Install new axle shaft gasket 3 Slide axle shaft into the axle tube 4 Install axle shaft flange bolts and tighten to 129 N m 95 ft lbs PINION INSTALLER 8981 FLANGE PULLER 8992 BRIDGE 938 Fig 17 AXLE FLANGE BOLTS 1 AXLE FLANGE 2 FLANGE BOLT 3 124 REAR AXLE 10 1 2 AA DR REAR AXLE 10 1 2 AA Continued ...

Page 206: ... 4171 2 Install inner hub bearing cup with Installer 8962 and Handle C 4171 3 Pack bearings with the appropriate grease 4 Install rear bearing and install new grease seal with Installer 8963 and Handle C 4171 5 Slide hub on the axle tube and install front bearing into the hub 6 Install hub bearing nut with Socket 8954 and tighten to 30 N m 22 ft lbs while rotating the hub Fig 21 7 Back off nut abo...

Page 207: ...asher 6 Remove pinion flange with Pinion Flange Puller 8992 Fig 24 7 Remove pinion shaft seal with a pry tool or slide hammer mounted screw INSTALLATION 1 Install new pinion seal with Installer 8896 and Handle C 4171 Fig 25 2 Apply a light coat of teflon sealant to the pin ion flange splines 3 Lightly tap the pinion flange onto the pinion until a few threads are showing 4 Install flange washer and...

Page 208: ...ry DIFFERENTIAL REMOVAL 1 Remove lubricant fill hole plug from the differ ential housing cover 2 Remove differential housing cover and drain the lubricant from housing 3 Remove axle shafts 4 Remove adjuster lock bolts and adjuster locks Fig 27 5 Mark bearing caps left and right for installa tion reference 6 Remove bearing cap bolts and remove bearing caps 7 Loosen differential bearing adjusters Fi...

Page 209: ... to the differential window and remove the gear 4 Remove differential side gears and thrust washers Fig 32 Fig 28 BEARING ADJUSTERS 1 BEARING CUP 2 ADJUSTER 3 BEARING CUP 4 ADJUSTER Fig 29 PINION SHAFT 1 PINION GEAR 2 PINION SHAFT 3 RING GEAR 4 EXCITER RING Fig 30 FRIST PINION GEAR 1 DIFFERNTIAL CASE WINDOW 2 PINION GEAR 3 THRUST WASHER Fig 31 SECOND PINION GEAR 1 DIFFERENTIAL WINDOW 2 THRUST WASH...

Page 210: ... pinion gear and thrust washer Rotate the gears to align hole in the pinion gears with hole in the differential case 5 Slide pinion shaft into the case and through the pinion gears Tap the shaft to seat the pinion shaft snap ring into the case Fig 35 Fig 32 SIDE GEARS 1 SIDE GEAR 2 SIDE GEAR 3 PINION GEARS Fig 33 SIDE GEAR 1 DIFFERENTIAL WINDOW 2 SIDE GEAR Fig 34 PINION GEAR 1 DIFFERENTIAL WINDOW ...

Page 211: ...nion gear side adjuster firmly against the differential case bearing cup 10 Rotate the pinion several times to seat the dif ferential bearings 11 Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup 12 Tighten pinion gear side adjuster until it just makes contact with the bearing cup 13 Tighten pinion gear side adjuster an addi tional New Bearings 6 Adjuster Holes...

Page 212: ...osite pinion gears and the side gear These friction forces transfer the power to the opposite wheel Once the frictional forces are overcome differ entiation will occur The torque will be continually biased by the frictional forces to the high traction wheel DISASSEMBLY 1 Remove differential ring gear bolts 2 Remove differential case cover locating screws Fig 38 3 Remove differential case cover 4 R...

Page 213: ...inion gears teeth for chips and cracks Fig 42 2 Inspect pinion gears shafts and brake shoes for scratches flat spots or worn Fig 42 3 Inspect side gears teeth for chips and cracks Fig 43 4 Inspect pinion and side gear bores for scratches Fig 44 NOTE If any damage is found the differential must be replaced as an assembly Individual components can not be replaced separately Fig 41 PINION GEARS 1 PIN...

Page 214: ... the bores next to the brake shoes with the pinion shaft facing up 5 Install other side gear and thrust washer 6 Install other set of pinion gears into the brake shoes in the case 7 Install other set of brake shoes onto the pinion gears shafts Fig 46 8 Install differential cover and location screws 9 Install new ring gear bolts and tighten to 237 N m 175 ft lbs Fig 44 PINION SIDE GEAR BORE 1 PINIO...

Page 215: ...NION GEAR RING GEAR TONE RING REMOVAL NOTE The ring and pinion gears are service in a matched set Never replace the ring gear pinion gear without replacing the other matching gear 1 Mark pinion flange and propeller shaft for installation alignment 2 Disconnect propeller shaft from pinion flange and remove propeller shaft 3 Remove differential from axle housing Fig 47 DIFFERENTIAL CASE BEARING 1 BR...

Page 216: ...lts holding ring gear to differential case 7 Drive ring gear from differential case with a soft hammer Fig 50 8 Hold pinion flange with Flange Wrench 8979 Fig 51 and remove pinion flnage nut and washer Fig 49 EXCITER RING 1 DIFFERENTIAL CASE 2 RING GEAR 3 PUNCH 4 EXCITER RING Fig 50 RING GEAR 1 DIFFERENTIAL CASE 2 RING GEAR 3 HAMMER Fig 51 FLANGE WRENCH 1 PINION FLANGE 2 FLANGE WRENCH DR REAR AXLE...

Page 217: ...ng with Puller C 293 PA and Adapter Blocks 8879 Fig 54 15 Remove pinion depth shim from the pinion gear shaft and record thickness of the shims 16 Remove front pinion bearing cup from the housing with a punch and hammer and discard cup CAUTION Do not reuse front pinion bearing cup 17 Remove rear pinion bearing cup from the housing with a punch and hammer if bearing is going to be replaced Fig 52 P...

Page 218: ...on the pin ion gear shaft 4 Install rear pinion bearing Fig 58 with Installer MD 998805 and a press Fig 55 FRONT PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 56 REAR PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 57 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fig 58 REAR PINION BEARING 1 PRESS 2 INSTALLER 3 PINION GEAR 4 REAR PINION BEARING DR REAR AXLE 10 1 2 AA 3 137 PINION GEAR RING GEAR TO...

Page 219: ...old the pinion and lightly tap the pinion flange onto the pinion until a few threads are show ing 11 Install pinion flange washer and new pinion nut 12 Hold pinion flange with Flange Wrench 8979 Fig 62 and tighten pinion nut until pinion end play is taken up Fig 59 COLLAPSIBLE SPACER 1 COLAPSIBLE SPACER 2 PINION GEAR 3 REAR PINION BEARING Fig 60 PINION GEAR INSTALLER 1 INSTALLER 2 DIFFERENTIAL HOU...

Page 220: ...a hammer and brass punch Fig 65 Drive the ring down until it is seated against the ring gear CAUTION Do not damage exciter ring teeth during installation 21 Install differential into the housing 22 Verify ring gear backlash and gear contact pattern 23 Measure final rotating torque with an inch pound torque wrench The final pinion rotating torque plus differential case bearing preload is New Bearin...

Page 221: ...ct ring gear backlash Gear damage Differential side gears and pinions can be checked by turning the vehicle The side gears are loaded dur ing turns They usually do not cause noise during straight ahead driving when the gears are unloaded A worn pinion shaft can also cause a snapping or a knocking noise BEARING NOISE The axle shaft differential and pinion bearings can all produce noise when worn or...

Page 222: ...e ring gear backlash Excessive side gear to case clearance The source of a snap or a clunk noise can be deter mined with the assistance of a helper Raise the vehi cle on a hoist with the wheels free to rotate Instruct the helper to shift the transmission into gear and lis ten for the noise A mechanics stethoscope is helpful in isolating the source of a noise DIAGNOSTIC CHART Condition Possible Cau...

Page 223: ... and shaft for damage Service as necessary Loss Of Lubricant 1 Lubricant level too high 1 Drain lubricant to the correct level 2 Worn axle shaft seals 2 Replace seals 3 Cracked differential housing 3 Repair as necessary 4 Worn pinion seal 4 Replace seal 5 Worn scored yoke 5 Replace yoke and seal 6 Axle cover not properly sealed 6 Remove clean and re seal cover Axle Overheating 1 Lubricant level lo...

Page 224: ...s necessary 8 Loose differential bearing cap bolts 8 Inspect differential components and replace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Raise and support the vehicle 2 Position a lifting device under axle and secure lift to the axle 3 Remove wheels and tires assemblies 4 Remove all brake componen...

Page 225: ...sing through pin ion bearing cups Fig 4 3 Install front pinion bearing and Cone nut 6740 onto the screw Tighten cone nut until Torque To Rotate the screw is 1 7 2 26 N m 15 20 in lbs Fig 3 4 Place Arbor Discs 8289 on Arbor D 115 3 in position in the housing side bearing cradles Fig 5 5 Install differential bearing caps on arbor discs and snug the bearing cap bolts Then cross tighten cap bolts to 2...

Page 226: ...acklash cannot be obtained turn the pinion side adjuster until zero backlash is obtained 4 Holding the differential case toward the pinion gear turn bearing adjusters with Spanner Wrench 8883 Fig 8 until they make contact with the differ ential bearings cups 5 Back off the ring gear side adjuster 4 holes to obtain initial ring gear backlash Fig 5 GAUGE TOOLS IN HOUSING 1 ARBOR DISC 2 PINION BLOCK ...

Page 227: ...oints If measurement does vary inspect the gears for burrs the differential case flange and ring gear mounting GEAR TOOTH CONTACT PATTERN Gear tooth contact pattern is used to verify the cor rect running position of the ring and pinion gears This will produce low noise and long gear life Gears which are not positioned properly may be noisy and have shorten gear life 1 Wipe clean each tooth of the ...

Page 228: ...low Fig 15 Increase pin ion gear height by increasing the pinion depth shim thickness Pinion gear is set too high Fig 16 Decrease pinion depth by decreasing the pinion depth shim thickness Fig 12 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE HEEL Fig 13 INCORRECT BACKLASH 1 DRIVE SIDE HEEL 2 COAST SIDE HEEL Fig 14 INCORRECT BACKLASH 1 DRIVE SIDE TOE 2 COAST SIDE TOE Fig 15 LOW PINION HEIGHT Fig...

Page 229: ... Differential Case Bearing Preload New Bearing 3 4 5 6 N m 30 50 in lbs Pinion Bearing Preload Differential Case Bearing Preload Original Bearing 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 32 24 Differential Cover Bolts 40 30 Bearing Cap Bolts 281 207 Ring Gear Bolts 237 175 Axle Flange Bolts 129 95 Adjuster Lock Bolt 25 18 SPECIAL TOOLS DIAL INDICA...

Page 230: ...DIAL INDICATOR STUD L 4438 SPLITTER 1130 PINION DEPTH GAUGE 6730 CUP INSTALLER 8153 ARBOR DISCS 8289 ADJUSTER WRENCH 8883 SEAL INSTALLER 8896 DR REAR AXLE 11 1 2 AA 3 149 REAR AXLE 11 1 2 AA Continued ...

Page 231: ...PINION BLOCK 8897 SOCKET 8954 CUP INSTALLER 8960 CUP INSTALLER 8961 SEAL INSTALLER 8963 PLUG 8964 3 150 REAR AXLE 11 1 2 AA DR REAR AXLE 11 1 2 AA Continued ...

Page 232: ...BEARING INSTALLER 8965 CUP INSTALLER 8968 PINION DRIVER 8977 FLANGE WRENCH 8979 PINION INSTALLER 8981 FLANGE PULLER 8992 DR REAR AXLE 11 1 2 AA 3 151 REAR AXLE 11 1 2 AA Continued ...

Page 233: ... axle shaft into the axle tube 4 Install axle shaft flange bolts and tighten to 129 N m 95 ft lbs AXLE BEARINGS REMOVAL 1 Remove axle shaft flange bolts and remove shaft 2 Remove retianer ring Fig 18 from the axle shaft tube 3 Remove hub bearing nut locking key Fig 19 BRIDGE 938 Fig 17 AXLE FLANGE BOLTS 1 AXLE FLANGE 2 FLANGE BOLT Fig 18 RETAINER RING 1 RETAINER RING 2 LOCKING KEY 3 BEARING NUT Fi...

Page 234: ...n to 30 N m 22 ft lbs while rotating the hub Fig 21 7 Back off nut about 30 and align next hub nut key slot with axle tube key slot and install locking key NOTE End play should be 0 025 0 25 mm 0 01 0 001 in 8 Install retainer ring with ring end in the key slot 9 Install new axle shaft gasket and install the axle shaft PINION SEAL REMOVAL 1 Remove axle shafts 2 Mark the propeller shaft and pinion ...

Page 235: ...nion several times to seat bearings 7 Measure pinion rotating torque with an inch pound torque wrench and compare it to recorded measurement Tighten pinion nut in small incre ments until pinion rotating torque is 0 40 0 57 N m 3 5 in lbs greater than recorded measurement 8 Rotate pinion several times then verify pinion rotating torque again 9 Install axle shafts 10 Install propeller shaft with ref...

Page 236: ...erential bearing adjusters Fig 28 with Spanner Wrench 8883 8 Remove differential case from the housing 9 Remove bearing cups and tag them left and right for installation reference DISASSEMBLY 1 Remove ring gear 2 Remove pinion shaft with a hammer and punch from the side with the hole in the pinion shaft Fig 29 Fig 27 ADJUSTER LOCKS 1 LOCK BOLT 2 ADJUSTER LOCK 3 ADJUSTER 4 BEARING CAP Fig 28 ADJUST...

Page 237: ...st washers are being used install them into their orignial locations 1 Lubricate all differential components with axle lubricant 2 Install differential side gears and thrust wash ers Fig 33 Fig 30 FIRST PINION GEAR 1 DIFFERENTIAL WINDOW 2 PINION GEAR 3 THRUST WASHER Fig 31 SECOND PINION GEAR 1 DIFFERENTIAL WINDOW 2 THRUST WASHER 3 PINION GEAR Fig 32 SIDE GEARS 1 SIDE GEAR 2 SIDE GEAR 3 PINION GEAR...

Page 238: ...e oil or lint free cloth CAUTION Do not use water steam kerosene or gasoline for cleaning 2 Lubricate differential case bearing 3 Install differential case with bearings cups into the housing NOTE A light coat of grease on the cups will hold them in place during installation 4 Install bearing caps and bolts Fig 36 Tighten the bearing cap bolts finger tight NOTE Do not torque bearing cap and bolts ...

Page 239: ...Adjustments for pro cedure 18 Install axle shaft gasket and install axle shafts 19 Install differential housing gasket and cover Tighten cover bolts to 40 N m 30 ft lbs 20 Fill axle with lubricant refer to Lubrication Maintenance for capacity and lubricant type 21 Install fill plug and tighten to 32 N m 24 ft lbs DIFFERENTIAL TRAC RITE DESCRIPTION The Trac Rite differential is a helical gear diffe...

Page 240: ... Remove remaining three pinion brake shoes Fig 38 LOCATION SCREWS 1 DIFFERENTIAL COVER 2 LOCATION SCREWS Fig 39 SIDE GEAR AND THRUST WASHER 1 SIDE GEAR 2 THRUST WASHER Fig 40 PINION BRAKE SHOES 1 BRAKE SHOES 2 PINION GEARS Fig 41 PINION GEARS 1 PINION GEARS 2 SIDE GEAR DR REAR AXLE 11 1 2 AA 3 159 DIFFERENTIAL TRAC RITE Continued ...

Page 241: ...ts and brake shoes for scratches flat spots or worn Fig 42 3 Inspect side gears teeth for chips and cracks Fig 43 4 Inspect pinion and side gear bores for scratches Fig 44 NOTE If any damage is found the differential must be replaced as an assembly Individual components can not be replaced separately Fig 42 PINION GEAR AND BRAKE SHOE 1 BRAKE SHOES 2 PINION GEAR 3 PINION SHAFT Fig 43 SIDE GEARS 1 T...

Page 242: ...gears into the brake shoes in the case 7 Install other set of brake shoes onto the pinion gears shafts Fig 46 8 Install differential cover and location screws 9 Install new ring gear bolts and tighten to 237 N m 175 ft lbs DIFFERENTIAL CASE BEARINGS REMOVAL 1 Remove differential case from the housing 2 Install Plug 8964 into the end of the case 3 Remove differental case bearings with Bearing Split...

Page 243: ...emove the exciter ring if it is not being replaced 5 Place differential case in a vise with soft metal jaw protectors 6 Remove bolts holding ring gear to differential case 7 Drive ring gear from differential case with a soft hammer Fig 50 8 Hold pinion flange with Flange Wrench 8979 Fig 51 and remove pinion flange nut 9 Remove pinion flange from pinion with Pinion Flange Puller 8992 Fig 52 Fig 47 ...

Page 244: ...ion bearing and discard bear ing CAUTION Do not reuse front pinion bearing cup 13 Remove collapsible spacer from the pinion shaft Fig 50 RING GEAR 1 DIFFERENTIAL CASE 2 RING GEAR 3 HAMMER Fig 51 FLANGE WRENCH 1 PINION FLANGE 2 FLANGE WRENCH Fig 52 PINION FLANGE PULLER 1 PINION FLANGE 2 PULLER Fig 53 PINION DRIVER 1 PINION SHAFT 2 PINION DRIVER DR REAR AXLE 11 1 2 AA 3 163 PINION GEAR RING GEAR TON...

Page 245: ...d hammer if bearing is going to be replaced INSTALLATION 1 Install new front pinion bearing cup Fig 55 with Installer 8960 and Handle C 4171 2 Install new rear pinion bearing cup Fig 56 with Installer 8968 and Handle C 4171 3 Install pinion depth shim Fig 57 on the pin ion gear shaft Fig 54 BEARING SPLITTER 1 PINION BEARING 2 SPLITTER Fig 55 FRONT PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 56 REA...

Page 246: ...er and new pinion nut 12 Hold pinion flange with Flange Wrench 8979 Fig 62 and tighten pinion nut until pinion end play is taken up 13 Rotate pinion several times to seat bearings 14 Measure pinion rotating torque with an inch pound torque wrench Fig 63 Tighten pinion nut in small increments until pinion rotating torque is New Pinion Bearings 1 7 2 8 N m 15 25 in lbs Original Pinion Bearings 1 1 2...

Page 247: ...lace exciter ring on the differential case 20 Install the exciter ring on the differential case evenly with a hammer and brass punch Fig 65 Drive the ring down until it is seated against the ring gear CAUTION Do not damage exciter ring teeth during installation Fig 62 FLANGE WRENCH 1 FLANGE WRENCH 2 PINION FLANGE Fig 63 PINION ROTATING TORQUE 1 PINION FLANGE 2 TORQUE WRENCH Fig 64 EXCITER RING 1 E...

Page 248: ...earing preload is New Bearings 3 4 5 6 N m 30 50 in lbs Original Bearings 2 8 5 1 N m 25 45 in lbs 23 Install axle shafts 24 Install the propeller shaft with the reference marks aligned 25 Install differential cover with gasket and tighten bolts to 40 N m 30 ft lbs 26 Fill differential with fluid and tighten fill plug to 32 N m 24 ft lbs DR REAR AXLE 11 1 2 AA 3 167 PINION GEAR RING GEAR TONE RING...

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Page 250: ...OSE 11 REMOVAL REAR TUBE HOSE ASSEMBLY 12 REMOVAL FRONT HOSE 12 INSTALLATION INSTALLATION REAR BRAKE HOSE 12 INSTALLATION REAR TUBE HOSE ASSEMBLY 13 INSTALLATION FRONT BRAKE HOSE 13 BRAKE PADS SHOES REMOVAL REMOVAL FRONT 13 REMOVAL REAR 14 INSTALLATION INSTALLATION FRONT 16 INSTALLATION REAR 16 DISC BRAKE CALIPERS DESCRIPTION 16 OPERATION 16 REMOVAL REMOVAL FRONT 17 REMOVAL REAR 17 DISASSEMBLY 18 ...

Page 251: ... 38 INSTALLATION RIGHT REAR CABLE 38 INSTALLATION LEFT REAR CABLE 39 SHOES REMOVAL 39 CLEANING REAR DRUM IN HAT BRAKE 39 INSPECTION REAR DRUM IN HAT BRAKE 39 INSTALLATION 40 ADJUSTMENTS ADJUSTMENT PARKING BRAKE SHOES 41 ADJUSTMENT WITH ADJUSTING TOOL 42 PEDAL REMOVAL 42 INSTALLATION 42 CABLE TENSIONER ADJUSTMENTS ADJUSTMENT 43 RELEASE HANDLE REMOVAL 44 INSTALLATION 44 BRAKES BASE DIAGNOSIS AND TES...

Page 252: ...rienced pump the pedal sev eral times If the pedal comes back up worn linings rotors drums or rear brakes out of adjustment are the most likely causes The proper course of action is to inspect and replace all worn component and make the proper adjustments SPONGY PEDAL A spongy pedal is most often caused by air in the system However thin brake drums or substandard brake lines and hoses can also cau...

Page 253: ...P WATER PUDDLES This condition is generally caused by water soaked lining If the lining is only wet it can be dried by driving with the brakes very lightly applied for a mile or two However if the lining is both soaked and dirt contaminated cleaning and or replacement will be necessary BRAKE LINING CONTAMINATION Brake lining contamination is mostly a product of leaking calipers or worn seals drivi...

Page 254: ...re should be in this order 1 Right rear 2 Left rear 3 Right front 4 Left front 4 Open up bleeder then have a helper press down the brake pedal Once the pedal is down close the bleeder Repeat bleeding until fluid stream is clear and free of bubbles Then move to the next wheel 5 Before moving the vehicle verify the pedal is firm and not mushy 6 Top off the brake fluid and install the reservoir cap S...

Page 255: ...to set steering wheel tilt and seat position to the most comfortable position The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals Change of pedal position is accomplished by means of a motor driven screw Operating the adjustable pedal switch activates the pedal drive motor Fig 3 The pedal drive motor turns a screw that cha...

Page 256: ...otor with the cables must be installed INSTALLATION NOTE Adjustable pedal cables are not serviceable If they need service the adjustable pedal motor with the cables must be installed 1 Install the adjustable pedal motor with the cables 2 Install the one mounting bolt for the adjustable pedal motor Fig 4 3 Clip the cable fasteners to the support 4 Reconnect the electrical connector 5 Reconnect the ...

Page 257: ...aliper Adapter Mounting Bolts Front LD 176 130 Caliper Adapter Mounting Bolts Front HD 339 250 Caliper Adapter Mounting Bolts Rear LD 135 100 Caliper Adapter Mounting Bolts Rear HD 197 145 Junction Block Bolts To Frame 10 7 5 Brake Pedal Assembly Bracket Nuts 28 21 Support Plate Mounting Bolts Nuts 64 47 Brake Line Fittings Master Cylinder 19 14 170 Brake Line Fittings Junction Block 19 14 170 Cal...

Page 258: ...e Hose Front Bolts To Frame 10 7 5 Brake Hose Front Fitting 19 14 250 Brake Hose Rear Fitting 19 14 250 Parking Brake Pedal Assembly 19 14 250 Rotor to Hub Bolt Rear 128 95 Hub Bearing Bolts LD 163 120 Hub Bearing Bolts HD 176 130 DR BRAKES BASE 5 9 HYDRAULIC MECHANICAL Continued ...

Page 259: ...aliper HD SRW 2x45 mm 1 77 in Rear Disc Brake Caliper HD DRW 2x51 mm 2 00 in Rear Disc Brake Rotor LD 350x22 mm 13 77 X 86 in Rear Disc Brake Rotor HD 353x30 mm 13 89 X 1 18 in Brake Booster Type Gasoline Engines LD Vacuum Dual Diaphragm Brake Booster Type Gasoline Engines HD SRW Vacuum Dual Diaphragm Brake Booster Type Diesel Engines HD DRW Hydroboost BRAKE LINES STANDARD PROCEDURE STANDARD PROCE...

Page 260: ...ighten the tool bar on the tube 5 Install the correct size adaptor on the flaring tool yoke screw 6 Lubricate the adaptor 7 Align the adaptor and yoke screw over the tube Fig 6 8 Turn the yoke screw in until the adaptor is squarely seated on the tool bar REMOVAL REMOVAL REAR BRAKE HOSE 1 Install prop rod on the brake pedal to keep pressure on the brake system 2 Raise and support the vehicle 3 Remo...

Page 261: ...curing the brake hose to the frame and remove the wheel speed sensor wire from the brake hose Fig 10 7 Remove the hose INSTALLATION INSTALLATION REAR BRAKE HOSE 1 Install the hose 2 Install the mounting bolt for the brake hose at the axle Fig 8 3 Install the two brake lines at the bottom of the hose located at the axle Fig 8 4 Install the vent tube Fig 8 5 Install the brake hose clip at the top of...

Page 262: ...ehicle 6 Remove the prop rod from the brake pedal 7 Bleed the brake system Refer to 5 BRAKES STANDARD PROCEDURE BRAKE PADS SHOES REMOVAL REMOVAL FRONT 1 Raise and support vehicle 2 Remove the wheel and tire assemblies 3 Compress the caliper 4 Remove the caliper Refer to 5 BRAKES HY DRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 5 Remove the caliper by tilting the top up and off the caliper adapter...

Page 263: ...ose to support caliper assembly 5 Remove the caliper Refer to 5 BRAKES HY DRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL and then tilt the top up and off the cal iper adapter Fig 18 or Fig 19 6 Remove inboard brake shoe from the caliper adapter Fig 20 Fig 14 Inboard Brake Shoe 1 INBOARD SHOE 2 CALIPER ADAPTER Fig 15 Outboard Brake Shoe 1 OUTBOARD SHOE 2 CALIPER ADAPTER Fig 16 Top Anti Rattle Sprin...

Page 264: ...KE CALIPER REAR 1 CALIPER ADAPTER 2 CALIPER ADAPTER MOUNTING BOLTS 3 CALIPER SLIDE BOLTS 4 BRAKE HOSE 5 CABLE 6 CALIPER 7 ROTOR 8 ANTI RATTLE CLIPS Fig 19 ROTOR PADS CALIPER DUAL REAR WHEELS 1 Rotor 2 Brake Shoes 3 Disc Brake Caliper Fig 20 Inboard Brake Shoe 1 INBOARD SHOE 2 CALIPER ADAPTER Fig 21 Outboard Brake Shoe 1 OUTBOARD SHOE 2 CALIPER ADAPTER DR BRAKES BASE 5 15 BRAKE PADS SHOES Continued...

Page 265: ...shoe in adapter 6 Tilt the bottom of the caliper over rotor and under adapter Then push the top of the caliper down onto the adapter 7 Install caliper Refer to 5 BRAKES HY DRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION Refer to 5 BRAKES HYDRAU LIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION 8 Install wheel and tire assemblies and lower vehicle Refer to 22 TIRES WHEELS WHEELS STANDARD PROCEDUR...

Page 266: ... by the amount of seal deflection Generally the amount is just enough to maintain contact between the pis ton and inboard brake pad REMOVAL REMOVAL FRONT CAUTION Never allow the disc brake caliper to hang from the brake hose Damage to the brake hose will result Provide a suitable support to hang the caliper securely 1 Install prop rod on the brake pedal to keep pressure on the brake system 2 Raise...

Page 267: ...hose port Use only enough air pressure to ease the piston out CAUTION Do not blow the piston out of the bore with sustained air pressure This could result in a cracked piston Fig 26 DISC BRAKE CALIPER FRONT 1 STEERING KNUCKLE 2 DISC BRAKE CALIPER 3 CALIPER MOUNTING ADAPTER 4 DISC BRAKE ROTOR Fig 27 8 LUG ROTOR CALIPER ASSEMBLY 1 ROTOR 2 CALIPER ADAPTER 3 ANTI RATTLE CLIPS 4 BRAKE HOSE WITH BANJO B...

Page 268: ...N Do not scratch piston bore while remov ing the seals 10 Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the caliper Fig 33 11 Remove caliper bleed screw INSPECTION The piston is made from a phenolic resin plastic material and should be smooth and clean The piston must be replaced if cracked or scored Do not attempt to restore a scored piston surface by sa...

Page 269: ...op of piston 4 Stretch boot rearward to straighten boot folds then move boot forward until folds snap into place 5 Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle Fig 36 6 Seat dust boot in caliper Fig 37 with Handle C 4171 and Installer HD 56 mm caliper Installer C 4340 LD 54 mm caliper Installer C 3716 A 7 Install the second ...

Page 270: ...o 27 N m 245 in lbs CAUTION Verify brake hose is not twisted or kinked before tightening fitting bolt 5 Remove the prop rod from the vehicle 6 Bleed the base brake system Refer to 5 BRAKES STANDARD PROCEDURE OR Refer to 5 BRAKES STANDARD PROCEDURE 7 Install the wheel and tire assemblies Refer to 22 TIRES WHEELS WHEELS STANDARD PRO CEDURE 8 Remove the supports and lower the vehicle 9 Verify a firm ...

Page 271: ...3 Install the inboard and outboard pads Fig 39 4 Install the caliper mounting bolts 5 Install the tire and wheel assembly DISC BRAKE CALIPER ADAPTER MOUNT REMOVAL REAR 1 Remove wheel and tire assembly 2 Remove the disc brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 3 Remove the caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOV...

Page 272: ...eservoir and caps before checking fluid level If not cleaned dirt could enter the fluid The fluid fill level is indicated on the side of the master cylinder reservoir Fig 41 The correct fluid level is to the MAX indicator on the side of the reservoir If necessary add fluid to the proper level SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and S...

Page 273: ...nstall the brake lines into the junction block and tighten to 19 23 N m 170 200 in lbs Fig 43 3 Bleed the base brake system Refer to 5 BRAKES HYDRAULIC MECHANICAL STAN DARD PROCEDURE MASTER CYLINDER DESCRIPTION A two piece master cylinder is used on all models The cylinder body containing the primary and sec ondary pistons is made of aluminum The removable fluid reservoir is made of nylon reinforc...

Page 274: ...vacuum reserve as follows Release brake pedal Increase engine speed to 1500 rpm close the throttle and immediately turn off igni tion to stop engine 7 Wait a minimum of 90 seconds and try brake action again Booster should provide two or more vac uum assisted pedal applications If vacuum assist is not provided booster is faulty POWER BOOSTER VACUUM TEST 1 Connect vacuum gauge to booster check valve...

Page 275: ...port area to protect the vehicle from brake fluid damage 5 Remove the brake lines from the master cylin der Fig 47 6 Remove the mounting nuts from the master cylinder Fig 47 7 Remove the master cylinder NOTE Gently ease the master cylinder reservoir assembly away from the booster During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid exc...

Page 276: ... onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder 2 Install new mounting nuts and tighten to 25 N m 221 in lbs 3 Install the brake lines and tighten to 19 N m 170 in lbs 4 Reconnect the electrical connector for the low fluid level switch 5 Fill and bleed the base brake system Refer to 5 BRAKES STANDARD PROCEDURE INSTALLATION HYDROBOOST NO...

Page 277: ... EXTE RIOR BRAKE LAMP SWITCH REMOVAL 4 On vehicles equipped with adjustable ped als Disconnect the adjuster cable to the pedal Fig 51 5 Remove the steering column Refer to 19 STEERING COLUMN REMOVAL 6 Remove the brake booster Fig 52 Refer to 5 BRAKES HYDRAULIC MECHANICAL POWER BRAKE BOOSTER REMOVAL 7 Disconnect the electrical connectors 8 Remove the module mounting bolts 9 Disconnect the accelerat...

Page 278: ...atmospheric pressure to boost brake assist REMOVAL 1 Remove master cylinder Refer to 5 BRAKES HYDRAULIC MECHANICAL MASTER CYLINDER REMOVAL 2 Disconnect vacuum line at booster 3 Remove clip securing booster push rod to brake pedal Refer to 5 BRAKES HYDRAULIC MECHAN ICAL PEDAL REMOVAL Fig 53 4 Remove the nuts from the booster mounting studs Fig 53 5 Remove the booster and gasket from front cowl pane...

Page 279: ...imes to discharge the accumulator Then depress the brake pedal using 40 lbs of force and start the engine The brake pedal should fall and then push back against your foot This indicates the booster is operating properly ACCUMULATOR LEAKDOWN 1 Start the engine apply the brakes and turn the steering wheel from lock to lock This will ensure the accumulator is charged Turn off the engine and let the v...

Page 280: ...uel shutdown relay and crank the engine for several seconds Refer to Fuel System for relay location and WARNING 3 Check fluid level and add if necessary 4 Connect fuel shutdown relay and start the engine 5 Turn the steering wheel slowly from lock to lock twice 6 Stop the engine and discharge the accumulator by depressing the brake pedal 5 times 7 Start the engine and turn the steering wheel slowly...

Page 281: ...ER BRAKE BOOSTER STANDARD PROCEDURE ROTORS DIAGNOSIS AND TESTING DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary Light surface rust and scale can be removed with a lathe equipped with dual sanding discs The rotor surfaces can be restored by machining with a disc brake lathe if surface scoring and wear are light Replace the rotor for the following conditions Se...

Page 282: ...the caliper from the steering knuckle Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL and remove caliper adapter assembly Fig 58 NOTE Do not allow brake hose to support caliper adapter assembly 4 Remove the rotor from the hub bearing wheel studs Fig 59 or Fig 60 Fig 56 Checking Rotor Runout And Thickness Variation 1 DIAL INDICATOR Fig 57 Measuring Rotor Thickness 1 MICROMETER 2 ...

Page 283: ...Fig 62 INSTALLATION INSTALLATION FRONT 1 On models with all wheel antilock system ABS check condition of tone wheel on hub bearing If teeth on wheel are damaged hub bearing assembly will have to be replaced tone wheel is not serviced separately 2 Install the rotor onto the hub bearing wheel studs 3 Install the caliper adapter assembly Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INST...

Page 284: ...to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION Fig 64 6 Install the tire and wheel assembly Refer to 22 TIRES WHEELS WHEELS STANDARD PRO CEDURE 7 Lower the vehicle SUPPORT PLATE REMOVAL 1 Remove wheel and tire assembly 2 Remove the disc brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 3 Remove the caliper adapter Refer to 5 BRAKES HYDRAULIC MECHAN...

Page 285: ...brake the pedal is depressed This creates tension in the cable which pulls forward on the park brake lever The lever pushes the park brake shoes outward and into contact with the drum section of the rotor The contact of shoe to rotor parks the vehicle A torsion locking mechanism is used to hold the pedal in an applied position Parking brake release is accomplished by the hand release A parking bra...

Page 286: ...ount bracket Then pull the cable through the bracket 6 Disengage the park brake cable from behind the rotor assembly Fig 70 7 Compress cable tabs on each cable end fitting at the brake cable support plate 8 Remove the cables from the brake cable sup port plates REMOVAL RIGHT REAR CABLE 1 Raise and support the vehicle 2 Lockout the parking brake cable Fig 69 3 Loosen the brake cable at the equalize...

Page 287: ...sh each cable end through the brake cable support plate hole until the cable end fitting tabs lock into place NOTE Pull on the cable to ensure it is locked into place 2 Push the cable through the frame bracket 3 Lock the left cable end fitting tabs into the frame bracket hole 4 Install the rear cables into the tensioner rod behind the rear of the brake assembly 5 Install the cable to the intermedi...

Page 288: ...oes Fig 67 CLEANING REAR DRUM IN HAT BRAKE Clean the individual brake components including the support plate exterior with a water dampened cloth or with brake cleaner Do not use any other cleaning agents Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper INSPECTION REAR DRUM IN HAT BRAKE As a general rule riveted brake shoes should be replaced wh...

Page 289: ... light to moderate force on the parking brake foot pedal 1 Reassemble the rear park brake shoes Fig 67 or Fig 78 2 Install the axleshaft Fig 76 Refer to 3 DIF FERENTIAL DRIVELINE REAR AXLE 9 1 4 AXLE SHAFTS INSTALLATION or Refer to 3 DIFFERENTIAL DRIVELINE REAR AXLE 11 1 2 AA 10 1 2 AA AXLE SHAFTS INSTALLATION 3 Install the park brake cable to the lever behind the support plate 4 Unlock the park b...

Page 290: ... that reads in 64th of an inch accurately read the measurement of the inside diam eter of the park brake drum from the special tool Fig 80 7 Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C 3919 by 1 64 of an inch Reset Gauge Brake Shoe Special Tool C 3919 or the equivalent used so that the outside measurement jaws are set to the reduced measurement Fig ...

Page 291: ... brake assembly installed on the backing plate 1 Be sure parking brake lever is fully released 2 Raise vehicle so rear wheels can be rotated freely 3 Remove plug from each access hole in brake support plates 4 Loosen parking brake cable adjustment nut until there is slack in front cable 5 Insert adjusting tool through support plate access hole and engage tool in teeth of adjusting screw star wheel...

Page 292: ...brakes are in good condition and operating properly 5 Verify the park brake cables operate freely and are not binding or seized 6 Check the rear brake shoe adjustment with standard brake gauge Refer to 5 BRAKES PARK ING BRAKE SHOES ADJUSTMENTS 7 Install the rotors Refer to 5 BRAKES HY DRAULIC MECHANICAL ROTORS INSTALLA TION and verify that the rotors rotate freely without drag 8 Install the wheel ...

Page 293: ... out of the instru ment panel receptacle INSTALLATION 1 Position the park brake release handle to the instrument panel 2 Slide the handle and bracket assembly up into the instrument panel receptacle until both of the park brake release handle mounting bracket latches are engaged with the notches in the instrument panel receptacle 3 Lower the park brake release handle and reach under the driver sid...

Page 294: ...ponents ABS system major components include Controller Antilock Brakes CAB Hydraulic Control Unit HCU Wheel Speed Sensors WSS ABS Warning Light OPERATION Battery voltage is supplied to the CAB The CAB performs a system initialization procedure at start up A check of the ABS motor is performed at 15 miles per hour Initialization consists of a static and dynamic self check of system electrical compo...

Page 295: ...s plus use of the DRB scan tool The pro cedure involves performing a base brake bleeding followed by use of the scan tool to cycle and bleed the HCU pump and solenoids A second base brake bleed ing procedure is then required to remove any air remaining in the system 1 Perform base brake bleeding Refer to 5 BRAKES STANDARD PROCEDURE OR Refer to 5 BRAKES STANDARD PROCEDURE 2 Connect scan tool to the...

Page 296: ...equency to determine a deceleration rate that would indicate a possible wheel locking tendency The signal strength of any magnetic induction sen sor is directly affected by Magnetic field strength the stronger the mag netic field the stronger the signal Number of windings in the sensor more wind ings provide a stronger signal Exciter ring speed the faster the exciter ring tone wheel rotates the st...

Page 297: ... outputs circuits to verify the system is operating properly If the CAB senses a malfunction in the system it will set a DTC into memory and trig ger the warning lamp NOTE The MDS or DRB III scan tool is used to diagnose the RWAL system For test procedures refer to the Chassis Diagnostic Manual REMOVAL 1 Raise the vehicle on a hoist 2 Remove the brake line mounting nut and remove the brake line fr...

Page 298: ... both the red BRAKE and amber ABS warning indicators are illuminated the EVBP may not be functioning HCU HYDRAULIC CONTROL UNIT DESCRIPTION The HCU consists of a valve body pump motor low pressure accumulators inlet valves outlet valves and noise attenuators OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation The pump provides the fluid volume n...

Page 299: ...the rear brakes The RWAL components include RWAL Valve Controller Antilock brake CAB Rear Wheel Speed Sensor WSS OPERATION When the brakes are applied hydraulic fluid is routed from the master cylinder s secondary circuit to the RWAL valve From there hydraulic fluid is routed to the rear brakes The Controller Antilock Brake CAB contains an Electronic Variable Brake Propor tioning EVBP control algo...

Page 300: ...alve Fig 6 INSTALLATION 1 Install rwal valve and Tighten the nuts to 15 N m 11 ft lbs Fig 6 2 Install the brake lines to the rwal valve and tighten to 19 N m 170 in lbs Fig 6 3 Install the electrical harness connector to the rwal valve and secure the connector 4 Install the battery 5 Install the battery cables to the battery 6 Remove the prop rod on the brake pedal 7 Bleed ABS brake system Refer t...

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Page 302: ...dling and disposal of products contain ing asbestos Failure to follow these instructions may result in personal injury or death DIAGNOSIS AND TESTING Road test and inspect components to determine a clutch problem Road test the vehicle at normal speeds Shift the transmission through all gear ranges and observe clutch action If clutch chatters grabs slips or does not release properly remove and insp...

Page 303: ... with a dial indicator Common causes of runout are heat warpage improper machining incorrect bolt tightening improper seating on crankshaft flange shoulder foreign material on crankshaft flange Flywheel machining is not recommended The fly wheel clutch surface is machined to a unique contour and machining will negate this feature Minor fly wheel scoring can be cleaned up by hand with 180 grit emer...

Page 304: ...e of disc torn gouged or worn 1 Flywheel surface scored or nicked 1 Correct surface condition if possible Replace flywheel and disc as necessary 2 Clutch disc sticking or binding on transmission input shaft 2 Inspect components and correct replace as necessary Clutch disc facing burnt Flywheel and cover pressure plate surfaces heavily glazed 1 Frequent operation under high loads or hard accelerati...

Page 305: ...inder failure 7 Replace hydraulic linkage assembly Clutch pedal squeak 1 Pivot pin loose 1 Tighten pivot pin if possible Replace clutch pedal if necessary 2 Master cylinder bushing not lubricated 2 Lubricate master cylinder bushing 3 Pedal bushings worn out or cracked 3 Replace and lubricate bushings 4 Rough surface on front bearing retainer 4 Replace front bearing retainer Clutch master or slave ...

Page 306: ...si tion on flywheel with paint or scriber Fig 1 Also note location marks on the pressure next to the bolt holes The mark will be a L or a circle with an X in it 4 Insert clutch alignment tool through clutch disc and into pilot bushing to hold disc in place while removing bolts 5 Loosen pressure plate bolts evenly a few threads at a time and in a diagonal pattern to pre vent warping the plate 6 Rem...

Page 307: ... to release bearing slide surface of the transmis sion front bearing retainer Fig 4 CAUTION Do not over lubricate shaft splines This can result in grease contamination of the disc Fig 1 PRESSURE PLATE POSITION TYPICAL 1 FLYWHEEL 2 ALIGNMENT MARKS 3 PRESSURE PLATE Fig 2 CLUTCH DISC AND PRESSURE PLATE 1 FLYWHEEL 2 PRESSURE PLATE AND DISC 3 ALIGNMENT TOOL Fig 3 LUBRICATION POINTS 1 CLUTCH HOUSING 2 F...

Page 308: ...inch the clutch housing transmis sion adapter plate must be replaced On gas engines if housing bore runout exceeds 0 053 in the clutch housing must be replaced NOTE Offset dowels are available for gas engines to correct housing bore runout They are not avail able for diesel engines 1 Remove the clutch housing 2 Remove the clutch cover and disc 3 Replace one of the flywheel bolts with an appropriat...

Page 309: ...ck position and zero the dial indicator 3 Measure and record face runout readings at four points 90 apart Fig 11 Take measurement at least twice for accuracy 4 Subtract lowest reading from highest to deter mine total runout If low reading was minus 0 004 in and highest reading was plus 0 009 in the total runout is 0 013 inch NOTE Maximum acceptable face runout is 0 010 inch Fig 7 CLUTCH HOUSING BO...

Page 310: ...fer slave cylinder release fork and boot fork pivot stud and wire hose brackets to new hous ing 4 Install structural dust cover if removed Refer to 9 ENGINE ENGINE BLOCK STRUCTURAL COVER INSTALLATION 5 Align and install clutch housing on engine Fig 14 Tighten housing bolts across the top of the hous ing first and to the following torque values A bolts 1 4in diameter 4 5 N m 40 in lb A bolts 3 8in ...

Page 311: ...ide of the release lever has one end with a raised area This raised area goes toward the slave cylinder side of the transmission 5 Install clutch housing if removed 6 Install transmission and transfer case 7 Check clutch master cylinder fluid level FLYWHEEL DIAGNOSIS AND TESTING Check flywheel runout whenever misalignment is suspected Flywheel runout should not exceed 0 08 mm 0 003 in Measure runo...

Page 312: ...he flywheel Use a scriber for this pur pose 2 Remove the old gear by cutting most of the way through it at one point with an abrasive cut off wheel Then complete removal with a cold chisel or punch ASSEMBLY NOTE The ring gear is a shrink fit on the flywheel This means the gear must be expanded by heating in order to install it The method of heating and expanding the gear is extremely important Eve...

Page 313: ...ve plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange 5 Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud 6 Lower vehicle 7 Disconnect clutch pedal interlock switch wires Fig 19 8 Remove clutch master cylinder rod pin 9 Verify that cap on clutch master cylinder reser voir is tight This will avoid spillage during re...

Page 314: ...CRIPTION A clutch pedal position switch CPPS is mounted on the clutch master cylinder push rod Fig 20 The wiring harness connector is inside of the vehicle under the left side of the instrument panel NOTE Switch is serviced with clutch master cylin der OPERATION The clutch pedal position switch is used to prevent starter motor engagement unless the clutch pedal is depressed An input from this swit...

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Page 316: ...EL ENGINE 19 STANDARD PROCEDURE ADDING ADDITIONAL COOLANT 19 SPECIFICATIONS TORQUE 19 SPECIFICATIONS 20 SPECIAL TOOLS COOLING 20 ACCESSORY DRIVE 21 ENGINE 30 TRANSMISSION 67 COOLING DESCRIPTION DESCRIPTION COOLING SYSTEM FLOW 3 7L 4 7L 5 7L ENGINE The cooling system regulates engine operating tem perature It allows the engine to reach normal oper ating temperature as quickly as possible It also ma...

Page 317: ...oling System Flow 3 7L 4 7L 1 LH CYL HEAD 2 BLEED 3 THERMOSTAT LOCATION 4 RH CYL HEAD 5 RH BANK CYL BLOCK 6 LH BANK CYL BLOCK 7 COOLANT TEMP SENSOR 8 FROM HEATER CORE 9 TO HEATER CORE 7 2 COOLING DR COOLING Continued ...

Page 318: ...he 5 9L diesel engine are shown in Fig 3 DESCRIPTION HOSE CLAMPS The cooling system utilizes spring type hose clamps If a spring type clamp replacement is neces sary replace with the original Mopart equipment spring type clamp CAUTION A number or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only a original equipment clamp with matching number or lett...

Page 319: ...Fig 3 Cooling System Circulation 5 9L Diesel Engine 7 4 COOLING DR COOLING Continued ...

Page 320: ...oped in the electronically controlled viscous fan clutch circuit a Diagnostic Trouble Code DTC can be set If fan speed is not detected a DTC will be set Coolant temperature sensor circuit problems can set a DTC If the problem is sensed in a monitored circuit often enough to indicated an actual problem a DTC is stored The DTC will be stored in the ECM mem ory for eventual display to the service tec...

Page 321: ...he system again with pressure applied Drops Quickly Indicates that serious leakage is occurring Examine the system for external leakage If leaks are not visible inspect for internal leakage Large radiator leak holes should be repaired by a reputable radiator repair shop INTERNAL LEAKAGE INSPECTION Remove the engine oil pan drain plug and drain a small amount of engine oil If coolant is present in ...

Page 322: ... three times to approximately 3000 rpm while observing coolant If internal engine combustion gases are leaking into cooling system bubbles will appear in coolant If bub bles do not appear internal combustion gas leakage is not present DIAGNOSIS AND TESTING COOLING SYSTEM DIESEL ENGINE COOLING SYSTEM DIAGNOSIS DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS LOW 1 Vehicle ...

Page 323: ...oolant mixture incorrect 6 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE refill with correct mixture Refer to 7 COOLING STANDARD PROCEDURE 7 Thermostat stuck shut 7 Inspect and test thermostat Replace thermostat if necessary 8 Bug screen or winter front being used 8 Remove bug screen or winter front 9 Electronically controlled viscous fan drive not operating properly 9 Check viscous f...

Page 324: ...BOTTLE TEMPERATURE GAUGE MAY READ HIGH 1 Radiator cap defective 1 Replace radiator cap 2 Radiator neck surface damaged 2 Replace radiator HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING 1 Vacuum created in cooling system on engine cool down is not being relieved through coolant reservoir overflow system 1 Replace radiator cap check vent hose between radiator and reservoir bottle for blockage also ch...

Page 325: ...Y CHECKS ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the com plaint Abnormal loads on the cooling system such as the following may be the cause PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL WIND AT IDLE SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of no...

Page 326: ...associated with removing the radiator cap 5 Improper operation of internal heater doors or heater controls 5 Inspect heater and repair as necessary Refer to 24 HEATING AIR CONDITIONING DIAGNOSIS AND TESTING for procedures TEMPERATURE GAUGE READS HIGH OR THE COOLANT WARNING LAMP ILLUMINATES COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM THE COOLING SYSTEM 1 Trailer is being towed a steep hill is be...

Page 327: ...nt reserve overflow tank as the engine cools 5 9L 7 a Check condition of radiator cap and cap seals Refer to Radiator Cap in this Group Replace cap if necessary b Check condition of radiator filler neck If neck is bent or damaged replace radiator c Check condition of the hose from the radiator to the coolant tank It should fit tight at both ends without any kinks or tears Replace hose if necessary...

Page 328: ...een or cardboard 15 Thermostat partially or completely shut 15 Check thermostat operation and replace as necessary Refer to 7 COOLING ENGINE ENGINE COOLANT THERMOSTAT REMOVAL 16 Viscous fan drive not operating properly 16 Check fan drive operation and replace as necessary Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 17 Cylinder head gasket leaking 17 Check for cylinder head gasket le...

Page 329: ...rect coolant leaks Refer to 7 COOLING DIAGNOSIS AND TESTING 6 Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing a thermostat to open late 6 a Check for cylinder head gasket leaks Refer to 7 COOLING DIAGNOSIS AND TESTING b Check for coolant in the engine oil Inspect for white steam emitting from the exhaust system Repair as necessary 7 Water pump impeller loose on sh...

Page 330: ... if necessary b Hose between coolant reserve overflow tank and radiator is kinked Repair as necessary c Vent at coolant reserve overflow tank is plugged Clean vent and repair as necessary d Reserve overflow tank is internally blocked or plugged Check for blockage and repair as necessary NOISY VISCOUS FAN DRIVE 1 Fan blades loose 1 Replace fan blade assembly Refer to 7 COOLING ENGINE RADIATOR FAN R...

Page 331: ...M IS COMING FROM THE FRONT OF VEHICLE NEAR THE GRILL AREA WHEN WEATHER IS WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE GAUGE IS IN NORMAL RANGE 1 During wet weather moisture snow ice or rain condensation on the radiator will evaporate when the thermostat opens This opening allows heated water into the radiator When the moisture contacts the hot radiator steam may be em...

Page 332: ... gun Connect a water supply hose and air supply hose to the flushing gun CAUTION Internal radiator pressure must not exceed 138 kPa 20 psi as damage to radiator may result Allow the radiator to fill with water When the radiator is filled apply air in short blasts Allow the radiator to refill between blasts Continue this reverse flushing until clean water flows out through the rear of the radiator ...

Page 333: ... until thermostat opens upper radiator hose warm to touch 6 If necessary add a 50 50 water and antifreeze mixture to the coolant reserve overflow tank This is done to maintain coolant level between the MAX and MIN marks The level in the reserve overflow tank may drop below the MIN mark after three or four warm up and cool down cycles STANDARD PROCEDURE DRAINING COOLING SYSTEM 5 9L DIESEL ENGINE WA...

Page 334: ...0 distilled water to obtain a freeze point of 37 C 35 F If it loses color or becomes con taminated drain flush and replace with fresh prop erly mixed coolant solution CAUTION Do not use coolant additives that are claimed to improve engine cooling Do not remove the radiator cap to add coolant to the system When adding coolant to maintain the cor rect level do so only at the reserve overflow bottle ...

Page 335: ...ck Heater Diesel 55 41 Transmission Oil Cooler Diesel M8 24 18 M12 77 57 SPECIFICATIONS SPECIFICATIONS DESCRIPTION SPECIFICATION Metric Standard 3 7 4 7L 5 7L Engine 15 4L 16 2 qts to the middle of the cold fill range 5 9L Diesel Engine 28L 29 5 qts SPECIAL TOOLS COOLING Pliers Constant Pressure Hose Clamp 6094 3 8 Quick Connect Release Tool 6935 SPANNER WRENCH 6958 Cooling System Pressure Tester ...

Page 336: ...ensioner maintains correct belt tension at all times Due to use of this belt tensioner do not attempt to use a belt tension gauge on 3 7L or 4 7L engines OPERATION The automatic belt tensioner maintains belt ten sion by using internal spring pressure a pivoting arm and pulley to press against the drive belt REMOVAL On 3 7L and 4 7L engines the tensioner is equipped with an indexing tang on back of...

Page 337: ...ies If specified tension is not maintained belt slippage may cause engine overheating lack of power steering assist loss of air conditioning capac ity reduced generator output rate and greatly reduced belt life It is not necessary to adjust belt tension on the 5 7L engines This engines is equipped with an auto matic belt tensioner The tensioner maintains correct belt tension at all times Fig 3 Due...

Page 338: ...ER ASSEMBLY The automatic belt tensioner maintains correct belt tension using a coiled spring within the tensioner housing The spring applies pressure to the tensioner arm pressing the arm into the belt tensioning the belt REMOVAL WARNING BECAUSE OF HIGH SPRING PRES SURE DO NOT ATTEMPT TO DISASSEMBLE AUTO MATIC TENSIONER UNIT IS SERVICED AS AN ASSEMBLY 1 Remove accessory drive belt Refer to 7 COOL...

Page 339: ...SSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle Before replacing a belt to resolve a noise condition inspect all of the accessory drive pulleys for alignment glazing or excessive end play ACCESSORY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING One or more ribs has sep...

Page 340: ...e is broken 5 Replace belt BELT BROKEN Note Identify and correct problem before new belt is installed 1 Incorrect belt tension 1 Replace Inspect Replace tensioner if necessary 2 Tensile member damaged during belt installation 2 Replace belt 3 Severe misalignment 3 Align pulley s 4 Bracket pulley or bearing failure 4 Replace defective component and belt NOISE Objectionable squeal squeak or rumble i...

Page 341: ...k condition of all pulleys CAUTION When installing the serpentine accessory drive belt the belt MUST be routed correctly If not the engine may overheat due to the water pump rotating in the wrong direction Fig 7 2 Install new belt Fig 7 Route the belt around all pulleys except the idler pulley Rotate the ten sioner arm until it contacts it s stop position Route the belt around the idler and slowly...

Page 342: ...OSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING One or more ribs has separated from belt body 1 Foreign objects imbedded in pulley grooves 1 Remove foreign objects from pulley grooves Replace belt 2 Installation damage 2 Replace belt RIB OR BELT WEAR 1 Pulley misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust fr...

Page 343: ...tension 1 Inspect Replace tensioner if necessary 2 Bearing noise 2 Locate and repair 3 Belt misalignment 3 Align belt pulley s 4 Belt to pulley mismatch 4 Install correct belt 5 Driven component induced vibration 5 Locate defective driven component and repair TENSION SHEETING FABRIC FAILURE Woven fabric on outside circumference of belt has cracked or separated from body of belt 1 Tension sheeting ...

Page 344: ...sion has been relieved from belt 3 Remove belt from water pump pulley first 4 Remove belt from vehicle INSTALLATION CAUTION When installing the accessory drive belt the belt must be routed correctly If not engine may overheat due to water pump rotating in wrong direction Refer to Fig 10 or Fig 11 for correct engine belt routing The correct belt with correct length must be used 1 Position drive bel...

Page 345: ... DESCRIPTION 44 OPERATION 44 DIAGNOSIS AND TESTING THERMOSTAT 44 REMOVAL 45 INSTALLATION 45 ENGINE COOLANT THERMOSTAT 5 9L DIESEL DESCRIPTION 46 OPERATION 46 DIAGNOSIS AND TESTING THERMOSTAT 47 REMOVAL 47 INSTALLATION 47 ENGINE COOLANT THERMOSTAT 8 0L DESCRIPTION 48 OPERATION 48 DIAGNOSIS AND TESTING THERMOSTAT 48 REMOVAL 49 INSTALLATION 49 FAN DRIVE VISCOUS CLUTCH GAS ENGINES DESCRIPTION 50 OPERA...

Page 346: ...th a 68 anti freeze concentration which prevents freezing down to 67 7 C 90 F A higher percentage will freeze at a warmer temperature Also a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water Use of 100 percent ethylene glycol will cause for mation of additive deposits in the system as the cor rosion inhibitive addit...

Page 347: ...rotection COOLANT PERFORMANCE The required ethylene glycol antifreeze and water mixture depends upon climate and vehicle operating conditions The coolant performance of various mix tures follows Pure Water Water can absorb more heat than a mixture of water and ethylene glycol This is for pur pose of heat transfer only Water also freezes at a higher temperature and allows corrosion 100 percent Ethy...

Page 348: ...he container backward towards the engine to disengage the mounting pin locking features and lift the container away from the fan shroud Fig 1 INSTALLATION 1 Align the coolant container mounting pins into the slots on the fan shroud and push the container onto the fan shroud 2 Secure the container to the fan shroud with the bolt Tighten to 8 5N m 75 in lbs NOTE Ensure that the locking feature on th...

Page 349: ...s They are marked with the word REVERSE to designate their usage Installation of the wrong fan or viscous fan drive can result in engine overheating CLEANING Clean the fan blades using a mild soap and water Do not use an abrasive to clean the blades INSPECTION WARNING DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS CAUTION If fan blade assembly is replaced becau...

Page 350: ...ve the wir ing harness bracket from the upper radiator shroud CAUTION Do not remove the fan pulley bolts This pulley is under spring tension 8 The electronically controlled viscous fan drive fan blade assembly is attached threaded to the fan pulley shaft Fig 4 Remove the fan blade fan drive assembly from fan pulley by turning the mounting nut counterclockwise as viewed from front Threads on the vi...

Page 351: ...ION WARNING DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS An optional engine block heater is available with all models The heater is equipped with a power cord The cord is attached to an engine compartment com ponent with tie st...

Page 352: ...t and warm the engine 7 Check the block heater for leaks ENGINE BLOCK HEATER 5 9L DIESEL DESCRIPTION WARNING DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS An optional engine block heater is available on all models The heater is ...

Page 353: ...des into an engine water jacket The ECT sensor is a two wire Negative Thermal Coefficient NTC sensor Meaning as engine coolant temperature increases resistance voltage in the sensor decreases As temperature decreases resis tance voltage in the sensor increases OPERATION At key on the Powertrain Control Module PCM sends out a regulated 5 volt signal to the ECT sensor The PCM then monitors the signa...

Page 354: ...he sensor from the intake manifold 5 7L V 8 The Engine Coolant Temperature ECT sensor on the 5 7L engine is located under the air conditioning compressor Fig 12 It is installed into a water jacket at the front of the cylinder block Fig 13 WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV ING THE COOLANT TEMPERATURE SENSOR 1 Partially...

Page 355: ...V 10 engine is threaded into the thermostat housing Fig 15 WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV ING THE COOLANT TEMPERATURE SENSOR 1 Partially drain the cooling system 2 Disconnect the electrical connector from the sensor 3 Remove the sensor from the cylinder head Fig 12 ECT LOCATION 5 7L V 8 1 TOP OF AIR CONDITIONING CO...

Page 356: ...LING STANDARD PROCEDURE ENGINE COOLANT THERMOSTAT 5 7L DESCRIPTION CAUTION Do not operate an engine without a ther mostat except for servicing or testing The thermostat on the 5 7L gas powered engine is located behind the thermostat housing at the front of the intake manifold Fig 16 The thermostat is a wax pellet driven reverse pop pet choke type Coolant leakage into the pellet container will caus...

Page 357: ...s on 5 9L engine is installed on a gasket with an anti stick coating This will aid in gasket removal and clean up 1 Disconnect the negative battery cable 2 Drain the cooling system until the coolant level is below the thermostat Refer to 7 COOLING STANDARD PROCEDURE 3 Air Conditioned vehicles Remove the support bracket generator mounting bracket to intake mani fold located near the rear of the gen...

Page 358: ...housing to the intake manifold Note The word FRONT stamped on hous ing Fig 21 For adequate clearance this must be placed towards the front of the vehicle The housing is slightly angled forward after the installation to the intake manifold 5 Install the housing to intake manifold bolts Tighten the bolts to 23 N m 200 in lbs 6 Install the radiator upper hose to the thermo stat housing CAUTION When i...

Page 359: ...3 The same thermostat is used for winter and sum mer seasons An engine should not be operated with out a thermostat except for servicing or testing Operating without a thermostat causes other prob lems These are longer engine warmup time unreli able warmup performance increased exhaust emissions and crankcase condensation This conden sation can result in sludge formation OPERATION The wax pellet i...

Page 360: ...e lower radiator hose at the thermostat housing 6 Remove the thermostat housing mounting bolts thermostat housing and thermostat Fig 24 INSTALLATION 1 Clean the mating areas of the timing chain cover and the thermostat housing 2 Install the thermostat spring side down into the recessed machined groove on the timing chain cover Fig 24 3 Position the thermostat housing on the timing chain cover 4 In...

Page 361: ... engine should not be operated with out a thermostat except for servicing or testing Operating without a thermostat will cause overheat ing OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat When heated the pellet expands overcoming closing spring tension and water pump pressure to force the valve to open Fig 24 Thermostat and Thermostat Housing 3 7L 4 7L...

Page 362: ...RE 3 Place the thermostat into a container filled with water 4 Place the container on a hot plate or other suit able heating device 5 Place a commercially available radiator ther mometer into the water 6 Apply heat to the water while observing the thermostat and thermometer 7 The thermostat will begin to open at 85 5 89 4 C 186 193 F If the valve starts to move before this temperature is reached i...

Page 363: ...iner at the spring end of the thermostat When heated the pellet expands overcoming closing spring tension and water pump pressure to force the valve to open DIAGNOSIS AND TESTING THERMOSTAT ON BOARD DIAGNOSTICS All gasoline powered models are equipped with On Board Diagnostics for certain cooling system com ponents Refer to On Board Diagnostics OBD in the Diagnosis section of this group for additi...

Page 364: ...placement is necessary use only an original equipment clamp with a matching number or letter 4 Remove upper radiator hose clamp Remove upper radiator hose at thermostat housing 5 Disconnect the wiring connectors at both of the sensors located on thermostat housing 6 Remove six thermostat housing mounting bolts thermostat housing and thermostat INSTALLATION 1 Clean mating areas of intake manifold a...

Page 365: ...ling is necessary the fan will remain at a reduced rpm regardless of engine speed Only when sufficient heat is present will the vis cous fan drive engage This is when the air flowing through the radiator core causes a reaction to the bimetallic coil It then increases fan speed to provide the necessary additional engine cooling Once the engine has cooled the radiator discharge temperature will drop...

Page 366: ...ic and be sure that the air flow is blocked 5 Be sure that the air conditioner if equipped and blowe fan is turned off WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 6 Start the engine and operate at 2400 rpm Within ten minutes the air temperature indicated on the dia...

Page 367: ... a signal to the viscous fan clutch to increase or decrease the fan speed Fan speed is monitored by the ECM Fan speeds above or below a calibrated threshold will set a DTC Circuit concerns will also set fan clutch DTC s DIAGNOSIS AND TESTING ELECTRONICALLY CONTROLLED VISCOUS FAN DRIVE NOISE NOTE It is normal for fan noise to be louder roar ing when Fan duty cycle high This may occur when ambi ent ...

Page 368: ...n ically controlled viscous fan drive connector located at the lower fan shroud to battery ground Fig 35 7 Using the DRB III verify that DTC 0480 set 8 Start the engine 9 Go to the SENSOR screen and observe the fan speed 10 Run the engine at 2500 rpm NOTE It maybe take 15 minutes before fan speed increases 11 The fan speed should increase according to the table below 12 If fan speed does not incre...

Page 369: ... PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM THE COOL ANT CAN OCCUR 2 Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TE...

Page 370: ... radi ator mounting features alignment dowel and support bracket at the lower part of the radiator 3 Lower the radiator into position while guiding the alignment dowel into the vertical post bracket Position and seat the lower radiator support bracket onto the lower radiator closure tube 4 Install the upper radiator mounting bolts Tighten bolts to 10 N m 90 in lbs 5 Connect the lower radiator hose...

Page 371: ...cement is necessary use only an original equipment clamp with a matching number or letter 3 Remove air box and turbocharger inlet tube 4 Remove coolant tank hose washer bottle hose and the positive battery cable from the fastening clips located on top of the radiator 5 Remove hose clamps and hoses from radiator 6 Remove the power steering cooler mounting bolts and position the power steering coole...

Page 372: ...TAINER INSTALLATION 12 Position coolant recovery tank hose washer bottle hose and the positive battery cable into the clips located on the top of the radiator 13 Install air box and turbocharger inlet hose Tighten clamps to 4 N m 35 in lbs 14 Position heater controls to full heat position 15 Fill cooling system with coolant Refer to 7 COOLING STANDARD PROCEDURE 16 Operate engine until it reaches n...

Page 373: ...RESSURE CAP ARE A SAFETY PRECAUTION WHEN HOT PRESSURE BUILDS UP IN COOLING SYSTEM TO PREVENT SCALDING OR INJURY RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND OR UNDER PRESSURE Do not remove the radiator cap at any time except for the following purposes Check and adjust antifreeze freeze point Refill the system with new antifreeze Conducting service procedures Checking for vacuum leaks...

Page 374: ...with a completely sealed diaphragm spring and a rubber gasket This gasket is used to seal to radiator filler neck top surface Use of proper cap will allow coolant return to radiator WATER PUMP 3 7L 4 7L DESCRIPTION DESCRIPTION WATER PUMP A centrifugal water pump circulates coolant through the water jackets passages intake manifold radiator core cooling system hoses and heater core The pump is driv...

Page 375: ...le 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Remove fan viscous fan drive assembly from water pump Fig 45 Refer to 7 COOLING EN GINE FAN DRIVE VISCOUS CLUTCH REMOVAL Do not attempt to remove fan viscous fan drive assembly from vehicle at this time WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR ...

Page 376: ...Inspect the water pump assembly for cracks in the housing water leaks from shaft seal worn bearing or impeller rubbing either the pump body or timing chain case cover INSTALLATION The water pump on 3 7L 4 7L engine is bolted directly to the engine timing chain case cover 1 Clean the gasket mating surfaces 2 Using a new gasket position water pump and install the mounting bolts Fig 47 Tighten the wa...

Page 377: ...ary OPERATION The diesel engine water pump draws coolant from the radiator outlet and circulates it through engine heater core and back to radiator inlet The crank shaft pulley drives the water pump with a serpentine drive belt DIAGNOSIS AND TESTING WATER PUMP A quick test to determine if pump is working is to check if heater warms properly A defective water pump will not be able to circulate heat...

Page 378: ... Tighten moubting bolts to 24 N m 18 ft lbs 2 Install heater hoses 3 Install upper and lower radiator hoses 4 Install belt tensioner assembly 5 Install idler pulleys 6 Install A C compressor and alternator brace Tighten bolt and nuts to 28 N m 21 ft lbs 7 Install fan shroud assembly 8 Connect washer bottle wiring and hose 9 Install coolant fill bottle 10 Install fan clutch assembly 11 Install serp...

Page 379: ...S ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only an original equipment clamp with a matching number o...

Page 380: ...pass hose from the water pump while removing pump from vehicle Do not remove the clamp from the bypass hose 14 Discard the water pump to timing chain case cover o ring seal Fig 56 Fig 53 Water Pump Location Typical 1 WATER PUMP BYPASS HOSE 2 FAN BLADE ASSEMBLY 3 VISCOUS FAN DRIVE 4 WATER PUMP AND PULLEY Fig 54 Belt Tensioner 8 0L V 10 Engines 1 PULLEY BOLT 2 IDLER PULLEY 3 TENSIONER PULLEY 4 TENSI...

Page 381: ...e installed to pump before pump is installed to engine 2 Clean the o ring mating surfaces at rear of water pump and front of timing chain case cover 3 Apply a small amount of petroleum jelly to o ring Fig 56 This will help retain o ring to water pump 4 Install water pump to engine as follows Guide water pump fitting into bypass hose as pump is being installed Install water pump bolts Fig 55 Tighte...

Page 382: ...oler Fig 1 and Fig 2 OPERATION Transmission oil is routed through the cooler where heat is removed from the transmission oil before returning to the transmission Fig 1 Cooling Module 3 7L 4 7L 5 7L 1 TRANS OIL COOLER 2 LOCATING TABS 3 POWER STEERING OIL COOLER 4 POWER STEERING OIL COOLER MOUNTING BOLT 5 TRANS OIL COOLER OUTLET 6 TRANS OIL COOLER INLET 7 COOLER LINE CLIP 8 COOLER LINE CLIP 9 MOUNTI...

Page 383: ...erify proper installation and install the secondary latches 5 Connect the battery negative cable 6 Start the engine and check all fittings for leaks 7 Check the fluid level in the automatic trans mission Refer to the appropriate transmission sec tion Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 45RFE 545RFE FLUID STANDARD PROCEDURE or Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 46RE FLUID STAN DA...

Page 384: ... assembly towards the front of vehicle Cooler must be rotated and tilted into position while removing REMOVAL WATER TO OIL COOLER CAUTION If a leak should occur in the water to oil cooler mounted to the side of the engine block engine coolant may become mixed with transmis sion fluid Transmission fluid may also enter engine cooling system Both cooling system and transmis sion should be drained and...

Page 385: ...M TURBOCHARGER SYSTEM CHARGE AIR COOLER AND PLUMBING INSTALLATION 5 Start the engine and check all fittings for leaks 6 Check the fluid level in the automatic trans mission Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 47RE FLUID STANDARD PROCEDURE INSTALLATION WATER TO AIR COOLER 1 Position oil cooler on cylinder block 2 Install lower mounting bolt to cooler at the cyl inder block Torque bolt to ...

Page 386: ...option of choosing a street address point of interest trip itinerary and other features outlined in the oper ator s manual The audio system includes the following compo nents Antenna Power amplifier with premium speaker system only Radio noise suppression components Radio receiver Remote radio switches if equipped Speakers Certain functions and features of the audio system rely upon resources shar...

Page 387: ...EAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND...

Page 388: ...tape head 3 Clean head with Mopar Cassette Head Cleaner 4 Faulty tape deck 4 Exchange or replace radio if required NO COMPACT DISC OPERATION 1 Faulty CD 1 Insert known good CD and test operation 2 Foreign material on CD 2 Clean CD and test operation 3 Condensation on CD or optics 3 Allow temperature of vehicle interior to stabilize and test operation 4 Faulty CD player 4 Refer to appropriate Diagn...

Page 389: ...ls that are broadcast by local commercial radio stations in both the Amplitude Modulating AM and Frequency Modulating FM frequency ranges These electromagnetic radio fre quency signals induce small electrical modulations into the antenna as they move past the mast The antenna body transfers the weak electromagnetic radio waves induced into the rigid antenna mast into the center conductor of the fl...

Page 390: ...f an ohm resistance High or infinite resistance indicates a damaged or open antenna conductor If OK go to Test 3 If not OK isolate and test each of the individual antenna conductor components Replace only the faulty antenna conductor component TEST 3 Test 3 checks the condition of the vehicle body ground connection To begin this test proceed as fol lows 1 This test must be performed with the batte...

Page 391: ...door opening and seat grommet into place 3 Connect the antenna body and cable to the instrument panel cable 4 Install the right side kick panel 5 Insert the antenna body through the hole in the fender and install adapter 6 Install the antenna cap nut Tighten to 7 N m 65 in lbs 7 Install the antenna mast 8 Connect the battery negative cable ANTENNA NAVIGATION REMOVAL 1 Disconnect and isolate the ba...

Page 392: ...ay from the radio Fig 6 7 Remove antenna cable from instrument panel by pulling on retaining fasteners Fig 7 INSTALLATION 1 Install antenna cable to instrument panel by pressing retaining fasteners into position 2 Connect instrument panel antenna cable to antenna body and cable 3 Install radio Refer to 8 ELECTRICAL AU DIO RADIO INSTALLATION 4 Install the instrument panel lower right center bezel R...

Page 393: ...cessory positions The electronic digital clock function of the radio operates on fused battery current supplied through the IOD fuse regardless of the ignition switch position REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove center instrument panel bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL REMOVAL 3 Remove radio mounting screws Fig 8 4 Disconnect ele...

Page 394: ...ugs This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center elec trode to help reduce the production of electromag netic radiation that can result in radio noise OPERATION There are two common strategies that can be used to suppress Radio Frequency Interference RFI and ElectroMagnetic Interference EMI radio noise The first suppression str...

Page 395: ...ds Tighten to 12 N m 106 in lbs 3 Connect the battery negative cable REMOTE SWITCHES DESCRIPTION A remote radio control switch option is available on some models Two rocker type switches are mounted on the back instrument panel side of the steering wheel spokes Fig 14 The switch on the left spoke is the seek switch and has seek up seek down and preset station advance functions The switch on the ri...

Page 396: ...of the DRB IIIt refer to the appropriate Diagnostic Service Manual For complete circuit diagrams refer to the appro priate wiring information WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE ...

Page 397: ...K repair the open remote radio switch ground cir cuit as required REMOVAL WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIA...

Page 398: ...e DRB IIIt diagnostic tool For information on the use of the DRB IIIt refer to the appropriate Diagnostic Service Manual Refer to the appropriate wiring information WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WA...

Page 399: ...NEL CENTER SPEAKER 1 Disconnect and isolate the battery negative cable 2 Remove instrument panel top cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER REMOVAL 3 Remove speaker mounting screws Fig 18 4 Disconnect electrical harness connector and remove speaker INSTRUMENT PANEL END SPEAKER 1 Disconnect and isolate the battery negative cable 2 Remove instrument panel top cover Refer ...

Page 400: ...OVER INSTALLATION 3 Connect battery negative cable INSTRUMENT PANEL END SPEAKER 1 Connect electrical harness connector and install speaker 2 Install instrument panel top cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER INSTALLATION 3 Connect battery negative cable REAR CAB SIDE SPEAKER 1 Connect electrical harness connector and install speaker 2 Install B pillar lower trim Refer ...

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Page 402: ...e hard wired circuits are integral to several wire harnesses which are routed throughout the vehicle and retained by many different methods Refer to the appropriate wiring information The instrument cluster chime warning system cir cuitry and the integral chime tone generator cannot be adjusted or repaired If the instrument cluster or the chime tone generator are damaged or faulty the instrument c...

Page 403: ...oil pressure message inputs received from the diesel Engine Control Module ECM over the PCI data bus indicating that the engine is running and that the oil pressure is low to illuminate the check gauges indicator The chimes will continue to sound for five seconds until the engine oil pressure message indicates that the oil pressure is not low or until the engine speed mes sage indicates that the e...

Page 404: ... programming of the instrument cluster determines the priority of each chime request input that is received as well as the rate and duration of each chime that is to be gener ated The hard wired chime warning system inputs to the instrument cluster as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures However conventiona...

Page 405: ... Faulty seat belt switch 2 Check for continuity between the ground circuit cavity and the seat belt switch sense circuit of the driver seat belt switch There should be no continuity with the seat belt buckled Replace the faulty seat belt if required NO KEY IN IGNITION WARNING CHIME BUT OTHER CHIME FEATURES OK 1 Driver door ajar switch sense circuit open 1 Check for continuity between the driver do...

Page 406: ... of the instrument cluster connector and a good ground Repair the open ground circuits s if required 2 Instrument cluster fused B circuit s open 2 Check for battery voltage at the B circuits of the instrument cluster connector Repair the open fused B circuit s if required 3 Instrument cluster fused ignition switch output run start circuit open 3 With the ignition switch in the On position check fo...

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Page 408: ... 23 STANDARD PROCEDURE DRIVE LEARN 23 COMMUNICATION DESCRIPTION The DaimlerChrysler Programmable Communica tion Interface PCI data bus system is a single wire multiplex system used for vehicle communications on many DaimlerChrysler Corporation vehicles Multi plexing is a system that enables the transmission of several messages over a single channel or circuit All DaimlerChrysler vehicles use this ...

Page 409: ...s does not necessarily mean a zero bit It also depends upon pulse width If the width is short it stands for a zero bit If the width is long it stands for a one bit Similarly a high active state does not necessarily mean a one bit This too depends upon pulse width If the width is short it stands for a one bit If the width is long it stands for a zero bit In the case where there are successive zero ...

Page 410: ...harness connector to the CAB and push down on the release to secure the con nector 5 Install negative battery cable to the battery DATA LINK CONNECTOR DESCRIPTION DATA LINK CONNECTOR The Data Link Connector DLC is located at the lower edge of the instrument panel near the steering column OPERATION DATA LINK CONNECTOR The 16 way data link connector diagnostic scan tool connector links the Diagnosti...

Page 411: ...el filter The support bracket mounts to the block with four capscrews and vibration isolators A ground wire is fastened to the bracket The other end of the wire is fastened to the engine block 1 Record any Diagnostic Trouble Codes DTC s found in the ECM To avoid possible voltage spike damage to the ECM ignition key must be off and both negative battery cables must be disconnected before unplug gin...

Page 412: ...ted circuit board based module with a on board micro processor The front control module interfaces with other electronic modules in the vehicle via the Programmable Com munications Interface PCI data bus J1850 In order to obtain conclusive testing the Programmable Communications Interface PCI data bus network and all of the electronic modules that provide inputs to or receive outputs from the fron...

Page 413: ... module with an input indicating the surface temperature of the selected seat cushion The Low heat set point is about 36 C 96 8 F and the High heat set point is about 42 C 107 6 F If the seat cushion surface temperature input is below the temperature set point for the selected tem perature setting the heated seat module energizes an N channel Field Effect Transistor N FET within the module which e...

Page 414: ...e harness connector from the connector receptacle on the back of the heated seat module Depress the connector retaining tab and pull straight apart 4 Remove the heated seat module from under the front seat INSTALLATION 1 Position the heated seat module under the front seat 2 Connect the seat wire harness connector on the connector receptacle on the back of the heated seat module 3 Working under th...

Page 415: ...s from Battery voltage Engine coolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Camshaft position sensor signal The PCM monitors the crankshaft position sensor If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine it will shut down the fuel...

Page 416: ...n these inputs the following occurs Voltage is applied to the fuel injectors with the ASD relay via the PCM The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off The PCM monitors the O2S sensor input and adjusts air fuel ratio It also adjusts engine idle speed through the idle air control IAC motor The PCM adjusts ignition timing by ...

Page 417: ...nternal to the Pow ertrain Control Module PCM Sensor Return provides a low noise ground refer ence for all engine control system sensors Refer to Power Grounds for more information OPERATION OPERATION PCM The PCM operates the fuel system The PCM is a pre programmed triple microprocessor digital com puter It regulates ignition timing air fuel ratio emission control devices charging system certain t...

Page 418: ...Radiator cooling fan relay pulse width modu lated Speed control vacuum solenoid Speed control vent solenoid Tachometer if equipped Driven through J1850 circuits Transmission convertor clutch circuit Driven through J1850 circuits OPERATION 5 VOLT SUPPLIES Primary 5 volt supply supplies the required 5 volt power source to the Crankshaft Position CKP sensor supplies the required 5 volt power source t...

Page 419: ... to vehicle 2 Tighten bolts Refer to torque specifications 3 Check pin connectors in the PCM and the three 32 way connectors four 38 way connectors if equipped with NGC for corrosion or damage Also the pin heights in connectors should all be same Repair as necessary before installing connectors 4 Install three 32 way connectors four 38 way connectors if equipped with NGC 5 Install cover over elect...

Page 420: ...ing The rolling code algorithm ensures secu rity by preventing an override of the SKIS through the unauthorized substitution of the SKIM or the PCM ECM However the use of this strategy also means that replacement of either the SKIM or the PCM ECM units will require a system initialization procedure to restore system operation When the ignition switch is turned to the ON or START positions the SKIM...

Page 421: ...t scan tool and select THEFT ALARM SKIM then MISCELLANEOUS 3 Select PCM REPLACED GAS ENGINE or CUMMINS ECM REPLACED DIESEL ENGINE 4 Enter secured access mode by entering the vehicle four digit PIN 5 Select ENTER to update PCM ECM VIN NOTE If three attempts are made to enter secure access mode using an incorrect PIN secured access mode will be locked out for one hour To exit this lockout mode turn ...

Page 422: ...G SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove upper and lower covers shrouds from steering column 3 Disconnect the steering column wir...

Page 423: ... is achieved by normal PCI bus traffic being present and the ignition being in the RUN position Reduced Power Mode will be entered when the ignition has been powered off In this state the module will shut down power supplied to external devices and to electronic interface inputs and out puts From this state the module can enter either Sleep Mode or Full Power Mode To enter this mode the module mus...

Page 424: ... Ignition key switch is in the RUN position Foot Brake is applied A valid mode sensor signal is being sensed by the TCCM SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met the TCCM begins a shift timer with a maximum duration of 1 second per D channel transition If the shift timer expires before the TCCM recognizes to correct mode sensor code the shif...

Page 425: ...s process will be allowed to occur 5 times If the transfer case has reached a non NEUTRAL D channel during the shift re attempts the LED for the achieved gear posi tion is illuminated and the shift attempts are stopped To re attempt the desired shift the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested ag...

Page 426: ...raking is utilized under the following conditions Whenever the transfer case is in the 2WD AWD or 4L D channel position Whenever an invalid mode sensor code is present Static motor braking is achieved by applying 12V on both shift motor wires NOTE Static Shift Motor Braking is independent of ignition key position SHIFT ATTEMPT LIMIT To protect the transfer case system the TCCM will impose a limit ...

Page 427: ...t Shaft Speed Sensor Line Pressure Sensor Some examples of indirect inputs to the TCM are Engine Body Identification Manifold Pressure Target Idle Torque Reduction Confirmation Engine Coolant Temperature Ambient Battery Temperature DRBIIIt Scan Tool Communication Based on the information received from these var ious inputs the TCM determines the appropriate shift schedule and shift points dependin...

Page 428: ...tors display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value For example if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm then the TCM can determine that the gear ratio is 2 1 In direct drive 3rd gear the gear ratio changes to 1 1 The gear ratio changes as clutches are applied and released By monitoring the ...

Page 429: ...t Delayed 3 4 upshift Early 4 3 coastdown shift High speed 4 2 3 2 2 1 kickdown shifts are prevented Shifts at high throttle openings willl be early No EMCC Cold Oil temperature between 10 F and 36 F Shift schedule is the same as Super Cold except that the 2 3 upshifts are not delayed Warm Oil temperature between 40 F and 80 F Normal operation upshift kickdowns and coastdowns No EMCC Hot Oil tempe...

Page 430: ...t N D UD CVI while per forming a Neutral to Drive shift The 1st N D UD CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a period of time 3 Repeat Step 1 and Step 2 until the recorded 1st N D UD CVI value stabilizes NOTE It is important that this procedure be per formed when the transmission temperature is between 80 110 F 27 43 C If this procedure t...

Page 431: ...lowing steps to have the TCM learn the 2C shift volume NOTE The transmission oil temperature must be above 110 F 43 C 1 With a vehicle speed below 48 km h 30 MPH and the transmission in 3rd gear perform multiple 3 2 kickdowns 2 Repeat Step 1 until the 3 2 kickdowns become smooth and the 2C CVI becomes stable LEARN A SMOOTH MANUAL 2 1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT NOTE The tr...

Page 432: ... 17 OPERATION 17 REMOVAL 17 INSTALLATION 18 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on gasoline engine equipped mod els Diesel engine equipped vehicles utilize two 12 volt batteries connected in parallel All of the com ponents of the battery system are located within the engine compartment of the vehicle The battery sys tem for this vehicle cove...

Page 433: ...at are used in these systems must perform within specifications It is important that the battery starting and charging systems be thor oughly tested and inspected any time a battery needs to be charged or replaced The cause of abnormal bat tery discharge overcharging or early battery failure must be diagnosed and corrected before a battery is replaced and before a vehicle is returned to service Th...

Page 434: ...tions are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The battery has an incorrect size or rating for this vehicle 5 Refer to Battery System Specifications for the proper size and rating Replace an incorrect battery as required 6 The battery is faulty 6 Determine the batte...

Page 435: ...ng procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads 8 Slow driving or prolonged idling with high amperage draw systems in use 8 Advise the vehicle operator as required THE BATTERY WILL NOT ACCEPT A CHARGE 1 The battery is faulty...

Page 436: ...battery is the correct size and has the correct ratings for the vehicle 4 Clean the battery thermal guard with a sodium bicarbonate baking soda and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film 5 Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner and a sodium bicarbonate baking soda and warm water c...

Page 437: ...r rent in amperes the battery can deliver for thirty seconds at 18 C 0 F Terminal voltage must not fall below 7 2 volts during or after the thirty second discharge period The CCA required is generally higher as engine displacement increases depending also upon the starter current draw requirements Reserve Capacity The Reserve Capacity RC rating specifies the time in minutes it takes for bat tery t...

Page 438: ... positive and negative plates to prevent them from contacting or shorting against one another These dissimilar metal plates are submerged in a sulfuric acid and water solution called an electrolyte The factory installed battery has a built in test indicator hydrometer The color visible in the sight glass of the indicator will reveal the battery condi tion Refer to Standard Procedures for the prope...

Page 439: ...eely during battery charging A green color is visible in the sight glass of the battery built in test indicator Three hydrometer tests taken at one hour inter vals indicate no increase in the temperature cor rected specific gravity of the battery electrolyte Open circuit voltage of the battery is 12 65 volts or above WARNING NEVER EXCEED TWENTY AMPERES WHEN CHARGING A COLD 1 C 30 F OR LOWER BATTER...

Page 440: ...to bypass the polarity sensing circuitry 3 Battery chargers vary in the amount of voltage and current they provide The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table If the charging current is still not mea surable at the end of the charging time the battery is faulty and must be replaced If the charging cur rent is...

Page 441: ...t crank for a minimum of fifteen seconds with a fully charged battery the battery must be load tested Refer to Standard Procedures for the proper battery load test procedures Black or Dark Indicates 0 to 75 battery state of charge The battery is inadequately charged and must be charged until a green indication is visi ble in the sight glass 12 4 volts or more before the battery is tested further o...

Page 442: ...non ignition controlled circuits in proper working order Up to thirty five milliamperes are needed to enable the memory functions for the Powertrain Con trol Module PCM digital clock electronically tuned radio and other modules which may vary with the vehicle equipment A vehicle that has not been operated for approxi mately twenty days may discharge the battery to an inadequate level When a vehicl...

Page 443: ...rcuit breaker and cir cuit identification This will isolate each circuit and identify the circuit that is the source of the high am perage IOD If the amperage reading remains high after removing and replacing each fuse and circuit breaker disconnect the wire harness from the gener ator If the amperage reading now becomes very low or nonexistent refer to Charging System for the proper charging syst...

Page 444: ...acing 6 While viewing the battery test result press the CODE button and the tester will prompt you for the last 4 digits of the VIN Use the UP DOWN arrow buttons to scroll to the correct character then press ENTER to select and move to the next digit Then press the ENTER button to view the SERVICE CODE Pressing the CODE button a second time will return you to the test results BATTERY TEST RESULTS ...

Page 445: ...y in the battery tray This holddown is designed to prevent battery movement during the most extreme vehicle operation conditions Periodic removal and lubrica tion of the battery holddown hardware is recom mended to prevent hardware seizure at a later date CAUTION Never operate a vehicle without a battery holddown device properly installed Damage to the vehicle components and battery could result R...

Page 446: ...battery positive cable terminal clamp to terminal post connection and the battery positive cable VOLTAGE DROP TEST WARNING MODELS EQUIPPED WITH A DIESEL ENGINE HAVE AN AUTOMATIC SHUTDOWN ASD RELAY LOCATED IN THE POWER DISTRIBUTION CENTER PDC REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT...

Page 447: ...ig 14 Rotate and hold the ignition switch in the Start position Observe the voltmeter If the reading is above 0 2 volt clean and tighten the battery negative cable eyelet terminal connection to the engine block Repeat the test If the reading is still above 0 2 volt replace the faulty battery negative cable NOTE If the vehicle is equipped with two 12v bat teries step 4 must be performed twice once ...

Page 448: ... prevents battery movement during even the most extreme vehicle operation Unrestrained battery movement during vehicle operation could result in damage to the vehi cle the battery or both REMOVAL LEFT SIDE 1 Remove the battery from the battery tray Refer to 8 ELECTRICAL BATTERY SYSTEM BAT TERY REMOVAL 2 Remove the integrated power module Refer to 8 ELECTRICAL POWER DISTRIBUTION INTEL LIGENT POWER ...

Page 449: ...efer to 23 BODY EXTERIOR LF WHEELHOUSE SPLASH SHIELD INSTALLATION 7 Install the anti lock brake controller if equipped 8 Connect the wire harness retainers on the bat tery tray assembly 9 Install the integrated power module Refer to 8 ELECTRICAL POWER DISTRIBUTION INTELLI GENT POWER MODULE INSTALLATION 10 Install the battery Refer to 8 ELECTRI CAL BATTERY SYSTEM BATTERY INSTALLA TION RIGHT SIDE 1 ...

Page 450: ... connected in series with the second rotor field terminal and ground A battery temperature sensor located in the bat tery tray housing is used to sense battery tempera ture This temperature data along with data from monitored line voltage is used by the PCM ECM Diesel to vary the battery charging rate This is done by cycling the ground path to control the strength of the rotor magnetic field The P...

Page 451: ...both the fuseblock and Power Distribution Center PDC for tightness in receptacles They should be properly installed and tight Repair or replace as required 4 Inspect generator mounting bolts for tightness Replace or tighten bolts if required Refer to the Gen erator Removal Installation section of this group for torque specifications 5 Inspect generator drive belt condition and ten sion Tighten or ...

Page 452: ...ture sensor is located under the vehicle battery and is attached snapped into a mounting hole on battery tray Fig 1 1 Remove battery Refer to 8 Battery for proce dures 2 Pry sensor straight up from battery tray mounting hole to gain access to electrical connector Fig 1 3 Disconnect sensor from engine wire harness electrical connector INSTALLATION The battery temperature sensor is located under the...

Page 453: ... Disconnect negative battery cable at battery 2 Remove generator drive belt Refer to 7 Cool ing System for procedure 3 Unsnap plastic insulator cap from B output terminal Fig 2 4 Remove B terminal mounting nut at rear of generator Fig 2 Disconnect terminal from genera tor 5 Disconnect field wire connector at rear of gen erator Fig 2 by pushing on connector tab 6 Remove 1 rear vertical generator mo...

Page 454: ...l ing System for procedure 3 Unsnap plastic insulator cap from B output terminal 4 Remove B terminal mounting nut at rear of generator Fig 7 Disconnect terminal from genera tor 5 Disconnect field wire connector at rear of gen erator by pushing on connector tab 6 Remove upper mounting bracket bolt Fig 6 7 Remove lower mounting bracket bolt and nut Fig 6 8 Remove generator from vehicle Fig 4 GENERAT...

Page 455: ...orce a belt over a pulley rim using a screwdriver The synthetic fiber of the belt can be damaged CAUTION When installing a serpentine accessory drive belt the belt MUST be routed correctly The water pump may be rotating in the wrong direction if the belt is installed incorrectly causing the engine to overheat Refer to belt routing label in engine compartment or refer to Belt Schematics in 7 Coolin...

Page 456: ... to control the strength of the rotor magnetic field The EVR circuitry monitors system line voltage B and battery temperature refer to Battery Temperature Sensor for more information It then determines a target charging voltage If sensed battery voltage is 0 5 volts or lower than the target voltage the PCM grounds the field winding until sensed battery volt age is 0 5 volts above target voltage A ...

Page 457: ...e ammeter volt ohmmeter battery charger carbon pile rheostat load tester and 12 volt test lamp may be required Certain starting system components are monitored by the PCM and may produce a Diagnostic Trouble Code DTC Refer to Diagnostic Trouble Codes in Emission Control for a list of codes OPERATION The starting system components form two separate circuits A high amperage feed circuit that feeds t...

Page 458: ...lay coil is de energized This causes the relay contacts to open When the relay contacts open the starter solenoid plunger hold in coil is de energized When the solenoid plunger hold in coil is de ener gized the solenoid plunger return spring returns the plunger to its relaxed position This causes the con tact disc to open the starter feed circuit and the shift lever to disengage the overrunning cl...

Page 459: ...STRAINT SYS TEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT AND POSSIBLE PERSONAL INJURY Battery Visually inspect battery for indica tions of physical damage and loose or corroded cable connections Determine state of charge and cranking capacity of batte...

Page 460: ...ts and current amperage draw reads below specifications refer to Feed Circuit Test in this section c If voltage reads 12 5 volts or greater and starter motor does not turn refer to Control Cir cuit Testing in this section d If voltage reads 12 5 volts or greater and starter motor turns very slowly refer to Feed Cir cuit Test in this section NOTE A cold engine will increase starter current amperage...

Page 461: ... each battery 3 Connect voltmeter to measure between battery positive terminal post and starter solenoid battery terminal stud Fig 4 Rotate and hold ignition switch in Start position Observe voltmeter If read ing is above 0 2 volt clean and tighten battery cable connection at solenoid Repeat test If reading is still above 0 2 volt replace faulty positive battery cable Note Certain diesel equipped ...

Page 462: ...attery cable If resistance tests detect no feed circuit problems refer to Starter Motor in the Diagnosis and Testing CONTROL CIRCUIT TESTING The starter control circuit components should be tested in the order in which they are listed as fol lows Starter Relay Refer to Starter Relay Diag nosis and Testing Starter Solenoid Refer to Starter Motor Diagnosis and Testing Ignition Switch Refer to Igniti...

Page 463: ...AND TESTING STARTER MOTOR Correct starter motor operation can be confirmed by performing the following free running bench test This test can only be performed with starter motor removed from vehicle Refer to Specifications for starter motor specifications 1 Remove starter motor from vehicle Refer to Starter Motor Removal and Installation 2 Mount starter motor securely in a soft jawed bench vise Th...

Page 464: ...lts at transmission Pry support bracket slightly to gain access to lower starter mounting bolt 4 Remove 1 bolt and 1 nut if equipped with a manual transmission Fig 9 5 Remove 2 bolts if equipped with an automatic transmission Fig 10 6 Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing Always support starter motor during this process do not le...

Page 465: ...vehicle 3 Remove 3 starter mounting bolts Fig 12 4 Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing Always support starter motor during this process Do not let starter motor hang from wire har ness 5 Tilt nose downwards and lower starter motor far enough to access and remove nuts securing starter wiring harness to starter Fig 13 Do not let ...

Page 466: ... cooler tube bracket into position 6 Install and tighten 3 starter mounting bolts Refer to Torque Specifications 7 Lower vehicle 8 Connect both negative battery cables to both batteries STARTER MOTOR RELAY DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull in coil of the starter solenoid when ignition switch is turned to Start position The starte...

Page 467: ...s application Go to Step 3 3 The relay normally open terminal 87 is con nected to common feed terminal 30 in the energized position This terminal supplies battery voltage to starter solenoid field coils There should be continu ity between cavity for relay terminal 87 and starter solenoid terminal at all times If OK go to Step 4 If not OK repair open circuit to starter solenoid as required 4 The co...

Page 468: ...ion of relay terminals and PDC connector terminals for damage or corrosion Repair if necessary before installing relay 5 Check for pin height pin height should be the same for all terminals within the PDC connector Repair if necessary before installing relay INSTALLATION 1 Push down firmly on starter relay until termi nals are fully seated into PDC receptacle 2 Install PDC cover 3 Connect battery ...

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Page 470: ...se located in the fuse block for the control circuit OPERATION The rear window defogger system is turned on by a momentary switch located in the A C heater control on the instrument panel When the rear window defogger switch is pressed to the On position current is directed through the rear window defogger relay to the rear defogger grid lines The heated grid lines heat the rear glass to help clea...

Page 471: ...eating grid is still inoperative one or more of the following could be faulty Rear window switch in the A C heater control Rear window grid lines all grid lines would have to be broken or one of the feed wires discon nected for the entire system to be inoperative If setting the defogger switch to the On position produces a severe voltmeter deflection check for a short circuit between the rear wind...

Page 472: ...ves a bat tery current input from fuse 27 15 amp in the IPM through a fused B circuit at all times The coil ground terminal 87 receives a ground input from the A C heater control when the A C heater control electronically pulls the control circuit to ground The coil battery terminal 85 receives a battery current input from fuse 36 10 amp in the IPM through a fused B circuit only when the ignition ...

Page 473: ...y or damaged it must be replaced Refer to 24 HEATING AIR CONDI TIONING CONTROLS A C HEATER CONTROL REMOVAL REAR WINDOW DEFOGGER GRID STANDARD PROCEDURE GRID LINE AND TERMINAL REPAIR REAR WINDOW DEFOGGER GRID LINE REPAIR WARNING THE REPAIR KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER WHICH MAY CAUSE SKIN OR EYE IRRITATION AND CAN BE HARMFUL IF SWALLOWED USE WITH ADEQUATE VENTILATION DO NOT USE ...

Page 474: ... be extended onto the adjacent grid line s as well as the bus bar 3 Apply a thin layer of conductive epoxy to the area where the terminal s where fastened and to the adjacent grid line s NOTE To prevent the terminal s from moving while the epoxy is curing a wedge or clamp must be used 4 Apply a thin layer of conductive epoxy on the terminal s and properly orient the terminal s at the desired locat...

Page 475: ... if the ignition switch is turned to the Off position or it can be shut off manually by pressing the rear window defogger switch a second time OPERATION When the rear window defogger switch is in the On position an electric heater grid located behind the glass of each of the outside rear view mirrors is energized When energized each of these heater grids produce heat to help clear the outside rear...

Page 476: ...ack lighting bulb Heated Seat Module also referred to as the Seat Heat Interface Module SHIM this module con tains the solid state electronic control and diagnostic logic circuitry for the heated seat system One heated seat module is used per vehicle and is mounted under the drivers front seat cushion Fig 1 Refer to the Electronic Control Modules section of the service manual for additional heated...

Page 477: ...t or open in the heated seat ele ment circuit or a heated seat sensor value that is out of range DIAGNOSIS AND TESTING HEATED SEAT SYSTEM HEATED SEAT SYSTEM SELF DIAGNOSIS The heated seat system is capable of performing some self diagnostics The following table depicts the various monitored failures which will be reported to the vehicle operator or technician by flashing the individual heated seat...

Page 478: ... switch back lighting does not illuminate but the cluster illu mination lamps do illuminate with the headlamps or park lamps turned On refer to Diagnosis and Test ing the Heated Seat Switch in this section for the location of the heated seat switch diagnosis and test ing procedures If a single LED indicator lamp for one heated seat switch does not operate and the heated seat ele ments do heat refe...

Page 479: ...wrapping NOTE When checking heated seat elements for continuity be certain to move the heating element being checked Moving the element such as sitting in the seat will eliminate the possibility of an inter mittent open in the element which would only be evident if the element was in a certain position Failure to check the element in various positions could result in an incomplete test 1 Position ...

Page 480: ...ack probe the heated seat module wire har ness connector do not disconnect Check cavity 7 for passenger 8 for driver seat for a range in volt age from approx 1 72 3 0 volts It should be within this range If OK check the heated seat element If NOT OK check for the proper 5 volt supply to the heated seat sensor from the module Refer to Wiring for specific information If 5 volts is not being sup plie...

Page 481: ...t through a fused ignition switch output run circuit when the ignition switch is in the On position The ground side of each indicator lamp is controlled by the heated seat module This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indi cate heated seat system faults by flashing the indica tor lamps on and off One...

Page 482: ... switch with a known good unit and test the operation of the switch indicator lamps If OK discard the faulty heated seat switch If not OK Refer to 8 ELEC TRICAL ELECTRONIC CONTROL MODULES MEMORY HEATED SEAT MIRROR MODULE DIAGNOSIS AND TESTING REMOVAL 1 Disconnect and isolate the negative battery cable 2 Wait two minutes for the system reserve capac itor to discharge before beginning any airbag or ...

Page 483: ... seat cushion and back When the sen sor input to the module indicates the correct temper ature set point has been achieved the module de energizes the N FET which de energizes the heated seat elements The heated seat module will continue to cycle the N FET as needed to maintain the selected temperature set point If the heated seat module detects a heated seat sensor value input that is out of rang...

Page 484: ...t module retaining screws Due to the fact that the retaining screws are installed with the seat cushion pan removed a small right angle screwdriver will be required to access and remove the screws 3 Disconnect the seat wire harness connector from the connector receptacle on the back of the heated seat module Depress the connector retaining tab and pull straight apart 4 Remove the heated seat modul...

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Page 486: ...IVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY HORN DIAGNOSIS AND TESTING HORN The most reliable efficient and accurate means to diagnose the ho...

Page 487: ... means to diagnose the horn system requires the use of a DRBIIIt scan tool and the proper Diag nostic Procedures manual For complete circuit diagrams refer to the appro priate wiring information WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY...

Page 488: ... INSTALLATION 22 IGNITION CONTROL DESCRIPTION The ignition system is controlled by the Powertrain Control Module PCM on all engines 3 7L V 6 ENGINE The 3 7L V 6 engine uses a separate ignition coil for each cylinder The one piece coil bolts directly to the cylinder head Rubber boots seal the secondary terminal ends of the coils to the top of all 6 spark plugs A separate electrical connector is use...

Page 489: ...ark plug on the opposite cylinder bank A separate pri mary electrical connector is used for each coil Eight conventional spark plug cables are used with the 5 7L These cables connect a coil on one cylinder bank directly to a spark plug on the opposite cylin der bank The cables are placed and routed in a spe cial plastic loom to keep them separated This loom is clipped to the intake manifold To pre...

Page 490: ...12 9 105 Ignition Coil Mounting 3 7L V 6 Engine 8 70 Ignition Coil Mounting 4 7L V 8 Engine 8 70 Ignition Coil Mounting 5 7L V 8 Engine 12 9 105 20 Knock Sensor 3 7L V 6 Engine 20 15 176 Knock Sensor 4 7L V 8 Engine 20 15 176 Knock Sensor 5 7L V 8 Engine 20 15 176 Spark Plugs 3 7L V 6 Engine 27 20 Spark Plugs 4 7L V 8 Engine 27 20 Spark Plugs 5 7L V 8 Engine 18 3 13 2 Do not apply any sealant thre...

Page 491: ...ark plug coil number is displayed on each plug cable 1 6 2 3 4 7 and 5 8 These numbers can also be found on the top of the intake manifold to the right of the throttle body Fig 2 SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12 000 Ohms Per Foot SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 3 7L V 6 ZFR6F 11G NGK 1 1 0 042 in 4 7L V 8 RC12MCC4 1 0...

Page 492: ...PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated The relay is used to connect the oxygen sensor heater element ignition coil and fuel injectors to 12 volt power supply This input is used only to sense that the ASD relay is energized If the Powertrain Control Module PCM does not see 12 volts at this input when the ASD should be activated it will set a Di...

Page 493: ...hould not show continuity between relay terminals 87A and 30 8 Disconnect jumper wires 9 Replace the relay if it did not pass the continu ity and resistance tests If the relay passed the tests it operates properly Check the remainder of the ASD and fuel pump relay circuits Refer to 8 Wiring Dia grams REMOVAL The ASD relay is located in the Power Distribution Center PDC Fig 5 Refer to label on PDC ...

Page 494: ...al voltage to switch low to 0 volts 4 7L V 8 The CMP sensor on the 4 7L engine contains a hall effect device called a sync signal generator to gener ate a fuel sync signal This sync signal generator detects notches located on a tonewheel The tone wheel is located at the front of the camshaft for the right cylinder head Fig 7 As the tonewheel rotates the notches pass through the sync signal generat...

Page 495: ...nal voltage to switch low to 0 volts The CMP Fig 9 provides a signal to the Engine Control Module ECM at all times when the engine is running The ECM uses the CMP information pri marily on engine start up Once the engine is run ning the ECM uses the CMP as a backup sensor for engine speed The Crankshaft Position Sensor CKP is the primary engine speed indicator for the engine after the engine is ru...

Page 496: ...ing bolt Fig 11 4 Carefully twist sensor from cylinder head 5 Check condition of sensor o ring 5 7L V 8 The Camshaft Position Sensor CMP on the 5 7L V 8 engine is located on right side of timing chain cover below generator Fig 12 1 Disconnect electrical connector at CMP sensor 2 Remove sensor mounting bolt Fig 13 3 Carefully twist sensor from cylinder head 4 Check condition of sensor o ring Fig 10...

Page 497: ...amshaft Position Sensor CMP on the 4 7L V 8 engine is bolted to the front top of the right cyl inder head Fig 11 1 Clean out machined hole in cylinder head 2 Apply a small amount of engine oil to sensor o ring 3 Install sensor into cylinder head with a slight rocking action Do not twist sensor into position as damage to o ring may result CAUTION Before tightening sensor mounting bolt be sure senso...

Page 498: ...pletely flush to back of timing chain cover If sensor is not flush damage to sen sor mounting tang may result 4 Install mounting bolt and tighten Refer to Torque Specifications 5 Connect electrical connector to sensor IGNITION COIL DESCRIPTION 3 7L V 6 The 3 7L V 6 engine uses 6 dedicated and individ ually fired coil for each spark plug Fig 15 Each coil is mounted directly into the cylinder head a...

Page 499: ...Because of coil design spark plug cables second ary cables are not used with the 3 7L V 6 engine 4 7L V 8 Battery voltage is supplied to the 8 individual igni tion coils from the ASD relay The Powertrain Con trol Module PCM opens and closes each ignition coil ground circuit at a determined time for ignition coil operation Fig 17 IGNITION COIL LOCATION 4 7L V 8 1 IGNITION COIL 2 COIL ELECTRICAL CON...

Page 500: ...his is done to meet changing engine operating conditions The PCM adjusts ignition timing based on inputs it receives from The engine coolant temperature sensor The crankshaft position sensor engine speed The camshaft position sensor crankshaft posi tion The manifold absolute pressure MAP sensor The throttle position sensor Transmission gear selection REMOVAL 3 7L V 6 An individual ignition coil is...

Page 501: ...e specifications 5 Connect electrical connector to coil by snapping into position 6 If necessary install throttle body air tube 4 7L V 8 1 Using compressed air blow out any dirt or con taminants from around top of spark plug 2 Check condition of coil o ring and replace as necessary To aid in coil installation apply silicone to coil o ring 3 Position ignition coil into cylinder head opening and pus...

Page 502: ...Always use the specified torque when installing the knock sen sors REMOVAL 3 7L V 6 4 7L V 8 The 2 knock sensors are bolted into the cylinder block under the intake manifold Fig 20 or Fig 21 NOTE The left sensor is identified by an identifica tion tag LEFT It is also identified by a larger bolt head The Powertrain Control Module PCM must have and know the correct sensor left right posi tions Do no...

Page 503: ... Thoroughly clean knock sensor mounting hole 2 Install sensor into cylinder block NOTE Over or under tightening the sensor mount ing bolts will affect knock sensor performance pos sibly causing improper spark control Always use the specified torque when installing the knock sen sors The torque for the knock senor bolt is rela tively light for an 8mm bolt NOTE Note foam strip on bolt threads This f...

Page 504: ...al gasoline Fig 23 There will not be evidence of electrode burning Gap growth will not average more than approximately 0 025 mm 001 in per 3200 km 2000 miles of operation Spark plugs that have normal wear can usually be cleaned have the electrodes filed have the gap set and then be installed Some fuel refiners in several areas of the United States have introduced a manganese additive MMT for unlea...

Page 505: ...ped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap Under certain conditions severe detonation can also separate the insulator from the center electrode Fig 27 Spark plugs with this condition must be replaced PREIGNITION DAMAGE Preignition damage is usually caused by excessive combustion chamber temperature The center elec trode di...

Page 506: ...ace as necessary 5 Inspect spark plug condition Refer to Diagnos tics and Testing Spark Plug Conditions 4 7L V 8 Each individual spark plug is located under each ignition coil Each individual ignition coil must be removed to gain access to each spark plug Refer to Ignition Coil Removal Installation 1 Remove necessary air filter tubing at throttle body 2 Prior to removing ignition coil spray com pr...

Page 507: ...STALLATION 3 7L V 6 Special care should be taken when installing spark plugs into the cylinder head spark plug wells Be sure the plugs do not drop into the plug wells as elec trodes can be damaged Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator 1 Start the spark plug into the cylind...

Page 508: ...e compartment OPERATION The coil capacitor s help dampen the amount of conducted electrical noise to the camshaft position sensor crankshaft position sensor and throttle posi tion sensor This noise is generated on the 12V sup ply wire to the ignition coils and fuel injectors REMOVAL The coil capacitor is located in the right rear sec tion of the engine compartment It is attached with a mounting st...

Page 509: ... the spark plug and coil cables route the cables correctly and secure them in the proper retainers Failure to route the cables properly may cause the radio to reproduce ignition noise It could also cause cross ignition of the plugs or may short circuit the cables to ground When installing new cables make sure a positive connection is made A snap should be felt when a good connection is made 5 7L V...

Page 510: ...DICATOR DESCRIPTION 27 OPERATION 27 HIGH BEAM INDICATOR DESCRIPTION 28 OPERATION 28 LAMP OUT INDICATOR DESCRIPTION 29 OPERATION 29 LOW FUEL INDICATOR DESCRIPTION 30 OPERATION 30 MALFUNCTION INDICATOR LAMP MIL DESCRIPTION 31 OPERATION 31 ODOMETER DESCRIPTION 32 OPERATION 32 OIL PRESSURE GAUGE DESCRIPTION 33 OPERATION 33 SEATBELT INDICATOR DESCRIPTION 34 OPERATION 34 STANDARD PROCEDURE ENHANCED SEAT...

Page 511: ... indicators of the EMIC A black plastic odometer trip odometer switch button protrudes through dedicated holes in the cluster mask and the cluster lens located near the lower edge of the cluster just to the left of the tachometer The molded plastic EMIC lens hood and mask unit has four integral mounting tabs one each on the upper and lower outboard corners of the unit These mounting tabs are used ...

Page 512: ...mming that allows it to provide various audible alerts to the vehicle operator including chime tones and beep tones An electromechanical relay is also soldered onto the circuit board to pro duce audible clicks that emulate the sound of a con ventional turn signal or hazard warning flasher Refer to 8 ELECTRICAL CHIME BUZZER DESCRIPTION Brake Lamp Control The EMIC provides electronic brake lamp requ...

Page 513: ...eadlamps low and high beams turn signal lamps and the brake lamps excluding CHMSL Panel Lamps Dimming Control The EMIC provides a hard wired 12 volt Pulse Width Modulated PWM output that synchronizes the dimming level of all hard wired panel lamps dimmer controlled lamps with that of the cluster illumination lamps Parade Mode The EMIC provides a parade mode also known as funeral mode that allows a...

Page 514: ...ic Throttle Control ETC Indicator with 5 7L Gasoline Engine only Gear Selector Indicator with Automatic Transmission only High Beam Indicator Lamp Out Indicator Low Fuel Indicator Malfunction Indicator Lamp MIL Seatbelt Indicator Security Indicator with Sentry Key Immo bilizer Vehicle Theft Security Systems only Service Four Wheel Drive Indicator with Four Wheel Drive only Tow Haul Indicator with ...

Page 515: ...ems safety systems and many other convenience items The EMIC is installed in the instrument panel so that all of these monitors can be easily viewed by the vehicle operator when driving while still allow ing relative ease of access for service The micropro cessor based EMIC hardware and software uses various inputs to control the gauges and indicators visible on the face of the cluster Some of the...

Page 516: ...e IPM on a fused ignition switch output run start cir cuit This arrangement allows the EMIC to provide some features regardless of the ignition switch posi tion while other features will operate only with the ignition switch in the On or Start positions The EMIC circuitry is grounded through a ground circuit and take out of the instrument panel wire harness with an eyelet terminal connector that i...

Page 517: ...or is closed Otherwise both dis play units are active when the ignition switch is in the On or Start positions and inactive when the igni tion switch is in the Off or Accessory positions The illumination intensity of the VFD units is con trolled by the EMIC circuitry based upon an input from the headlamp switch and a dimming level input received from the headlamp dimmer switch The EMIC synchronize...

Page 518: ...hods However the EMIC circuitry and PCI bus message controlled indi cators are diagnosed using the EMIC self diagnostic actuator test Refer to 8 ELECTRICAL INSTRU MENT CLUSTER DIAGNOSIS AND TESTING Proper testing of the PCI data bus and the electronic message inputs to the EMIC that control an indicator requires the use of a DRBIIIt scan tool Refer to the appropriate diagnostic information Specifi...

Page 519: ...e Box Lamp Driver Radio Illumination Driver Right Door Lock Driver with Power Locks Right Door Unlock Driver with Power Locks Transfer Case Switch Illumination Driver with Four Wheel Drive Refer to the appropriate wiring information for additional details GROUNDS The EMIC receives and supplies a ground path to several switches and sensors through the following hard wired circuits Ground Illuminati...

Page 520: ... indicator the service four wheel drive indi cator the tow haul indicator the transmission over temp indicator the upshift indicator the security indicator or the gear selector indicator disconnect and isolate the battery negative cable After about five minutes reconnect the battery negative cable and turn the ignition switch to the On position The instrument cluster should automatically relearn t...

Page 521: ...t do not start the engine 4 Release the odometer trip odometer switch but ton 5 The instrument cluster will simultaneously illuminate all of the operational segments in both VFD units perform a bulb check of each operational LED indicator The VFD segments and LED indica tors remain illuminated as each gauge needle is swept to several calibration points and back If a VFD segment or an LED indicator...

Page 522: ...fer to the appropriate diagnostic information 64 Driver door lock switch input circuit open Refer to the appropriate diagnostic information 65 Driver door lock switch input circuit stuck Refer to the appropriate diagnostic information 66 All door lock output circuit shorted to ground or voltage Refer to the appropriate diagnostic information 67 All door unlock output circuit shorted to ground or v...

Page 523: ...EL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGA TIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT 1 Disconnect and isolate the battery negativ...

Page 524: ...the instru ment panel Refer to 8 ELECTRICAL INSTRU MENT CLUSTER REMOVAL 3 Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board Fig 6 4 Pull the bulb and bulb holder unit straight back to remove it from the bulb mounting hole in the cluster electronic circuit board CLUSTER LENS HOOD AND MASK 1 Disconnect and isolate the battery negative cable 2 Remove th...

Page 525: ...ttery negative cable CLUSTER LENS HOOD AND MASK 1 Position the cluster lens hood and mask unit over the face of the instrument cluster Fig 7 Be certain that the odometer trip odometer switch but ton is inserted through the proper clearance holes in the mask and the lens 2 From the back of the instrument cluster install and tighten the eight screws around the outer perim eter of the rear cover that...

Page 526: ...nsistor on the instrument cluster circuit board based upon clus ter programming and electronic messages received by the cluster from the Controller Antilock Brake CAB over the Programmable Communications Interface PCI data bus The ABS indicator Light Emitting Diode LED is completely controlled by the instru ment cluster logic circuit and that logic will only allow this indicator to operate when th...

Page 527: ...on switch is in any position except On or Start The LED only illuminates when it is provided a path to ground by the instrument cluster transistor The instrument cluster will turn on the airbag indicator for the following reasons Bulb Test Each time the ignition switch is turned to the On position the airbag indicator is illu minated for about six seconds The entire six second bulb test is a funct...

Page 528: ... about two sec onds as a bulb test Brake Lamp On Message Each time the cluster receives a lamp on message from the CAB the brake indicator will be illuminated The CAB can also send brake lamp on messages as feedback dur ing ABS diagnostic procedures The indicator remains illuminated until the cluster receives a lamp off message from the CAB or until the ignition switch is turned to the Off positio...

Page 529: ...body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster There should be continuity If not OK repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required INDICATOR REMAINS ILLUMINATED BRAKE SYSTEM CHECKS OK 1 Disconnect and isolate the battery negative cable Disconnect t...

Page 530: ...trol the cargo lamp indicator a DRBIIIt scan tool is required Refer to the appropriate diagnostic information CHECK GAUGES INDICATOR DESCRIPTION A check gauges indicator is standard equipment on all instrument clusters Fig 12 On vehicles equipped with a gasoline engine the check gauges indicator is located near the lower edge of the instru ment cluster between the tachometer and the speed ometer O...

Page 531: ... the LED and the cluster control circuitry On vehicles with a gasoline engine the PCM con tinually monitors the engine temperature oil pres sure and electrical system voltage then sends the proper messages to the instrument cluster On vehi cles with a diesel engine the ECM continually mon itors the engine temperature oil pressure and electrical system voltage then sends the proper mes sages to the...

Page 532: ...nstrument cluster electronic circuit board The door ajar indicator is serviced as a unit with the instru ment cluster OPERATION The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programmin...

Page 533: ...scale after the igni tion switch is turned to the Off position The instru ment cluster circuitry controls the gauge needle position and provides the following features Engine Temperature Message Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal about 54 C 130 F for gas oline engines or about 60 C 140 F for diesel...

Page 534: ...ument cluster OPERATION The Electronic Throttle Control ETC indicator gives an indication to the vehicle operator when the ETC system is faulty or inoperative The ETC indi cator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module PCM over the Pro grammable Communicati...

Page 535: ...e operator of the level of fuel in the fuel tank This gauge is controlled by the instrument cluster circuit board based upon cluster programming and elec tronic messages received by the cluster from the Powertrain Control Module PCM on vehicles equipped with a gasoline engine or from the Engine Control Module ECM on vehicles equipped with a diesel engine over the Programmable Communica tions Inter...

Page 536: ...ens located on the lower edge of the speedometer gauge dial face of the cluster overlay The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated The gear selector indicator displays the following characters from left to right P R N D 2 and 1 Fig 18 Respectively these characters rep resent the park reverse neutral drive second gear and first gear posit...

Page 537: ... control the gear selector indicator a DRBIIIt scan tool is required Refer to the appro priate diagnostic information HIGH BEAM INDICATOR DESCRIPTION A high beam indicator is standard equipment on all instrument clusters Fig 19 The high beam indi cator is located near the upper edge of the instru ment cluster between the tachometer and the speedometer The high beam indicator consists of a stencil ...

Page 538: ...r is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module FCM over the Programmable Communications Interface PCI data bus The lamp out indicator is completely controlled by the instru ment cluster logic circuit and that logic will only allow this indicator to operate when the instrument clust...

Page 539: ...eed is zero or for sixty con secutive seconds and the vehicle speed is greater than zero the fuel gauge needle is moved to the one eighth graduation or below on the gauge scale the low fuel indicator is illuminated and a single chime tone is sounded The low fuel indicator remains illu minated until the cluster receives messages from the PCM or ECM indicating that the percent tank full is greater t...

Page 540: ...luminated for about two seconds as a bulb test The entire two second bulb test is a function of the PCM or ECM MIL Lamp On Message Each time the clus ter receives a MIL lamp on message from the PCM or ECM the indicator will be illuminated The indi cator can be flashed on and off or illuminated solid as dictated by the PCM or ECM message For some DTC s if a problem does not recur the PCM or ECM wil...

Page 541: ... rolls over to zero The odometer has a Rental Car mode which will illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions During daylight hours exterior lamps are Off the VFD is illuminated at full brightness for clear visibil ity At night exterior lamps are On the VFD lighting level is adjusted with th...

Page 542: ...r pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left to right from L or Low to H or High for gasoline engines On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is speci fied or from 0 psi to 110 psi in all other markets An International Control and Display Symbol...

Page 543: ...on all instrument clusters Fig 25 The seatbelt indicator is located on the upper edge of the instrument clus ter between the tachometer and the speedometer The seatbelt indicator consists of a stencil like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay The dark outer layer of the overlay prevents the indicator from be...

Page 544: ...tch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods For fur ther diagnosis of the seatbelt indicator or the instru ment cluster circuitry that controls the LED Refer to 8 ELECTRICAL INSTRUMENT CLUSTER DIAGNOSIS AND TESTING STANDARD PROCEDURE ENHANCED SEATBELT REMINDER PROGRAMMING The seatbelt indicator also includes a programma ble enhance...

Page 545: ...uminated The indicator can be flashed on and off or illuminated solid as dic tated by the SKIM message The indicator remains illuminated solid or continues to flash until the clus ter receives a lamp off message from the SKIM or until the ignition switch is turned to the Off position whichever occurs first For more information on the SKIS and the security indicator control parameters Refer to 8 EL...

Page 546: ...the TCCM Actuator Test Each time the cluster is put through the actuator test the service 4WD indicator will be turned on then off again during the VFD por tion of the test to confirm the functionality of the VFD and the cluster control circuitry The TCCM continually monitors the electronic transfer case switch and circuits to determine the condition of the system The TCCM then sends the proper la...

Page 547: ...TION A tachometer is standard equipment on all instru ment clusters The tachometer is located to the left of the speedometer just to the left of center in the instrument cluster The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face that reads left to right from 0 to 7 for gasoline engines On v...

Page 548: ...he odometer trip odometer information when they are illuminated by the instrument cluster electronic circuit board The tow haul indicator is ser viced as a unit with the VFD in the instrument clus ter OPERATION The tow haul indicator gives an indication to the vehicle operator when the Off position of the tow haul switch has been selected disabling the electron ically controlled overdrive feature ...

Page 549: ...cator for the following reasons Bulb Test Each time the ignition switch is turned to the On position the transmission over tem perature indicator is illuminated for about two sec onds as a bulb test Trans Over Temp Lamp On Message Each time the cluster receives a trans over temp lamp on message from the PCM indicating that the transmis sion fluid temperature is 135 C 275 F or higher the indicator ...

Page 550: ...l flasher The turn signals and the turn signal indicators continue to flash on and off until the clus ter receives a turn signal off input from the multi function switch or until the ignition switch is turned to the Off position whichever occurs first Hazard Warning On Input Each time the cluster detects a hazard warning on input from the hazard warning switch circuitry of the multi function switc...

Page 551: ... will then remain off until the vehicle stops accelerating and is brought back into the range of indicator operation or until the transmission is shifted into another gear Actuator Test Each time the cluster is put through the actuator test the upshift indicator will be turned on then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circu...

Page 552: ...ngine indicator operation until after the engine intake manifold air heater has completed a pre heat or post heat cycle System Voltage High Message Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is greater than about 15 5 volts the gauge needle is moved to the graduation on the far right end of the gauge scale and the check ga...

Page 553: ...ature within the intake manifold is too cool for efficient and reliable engine starting the wait to start indica tor will be illuminated The indicator remains illumi nated until the cluster receives a wait to start lamp off message until the ECM detects that the engine is running or until the ignition switch is turned to the Off position whichever occurs first Actuator Test Each time the cluster i...

Page 554: ...message inputs to the instru ment cluster that control the washer fluid indicator a DRBIIIt scan tool is required Refer to the appro priate diagnostic information WATER IN FUEL INDICATOR DESCRIPTION A water in fuel indicator is only found in the instrument clusters for vehicles equipped with an optional diesel engine Fig 37 The water in fuel indicator is located near the lower edge of the instru m...

Page 555: ...ntinually monitors the water in fuel sensor to determine whether there is excessive water in the diesel fuel system The ECM then sends the proper water in fuel lamp on and lamp off messages to the instrument cluster For further diagnosis of the water in fuel indicator or the instrument cluster circuitry that controls the indicator Refer to 8 ELECTRICAL INSTRUMENT CLUSTER DIAGNO SIS AND TESTING For...

Page 556: ...L WITHOUT CARGO BOX 9 INSTALLATION INSTALLATION WITH CARGO BOX 9 INSTALLATION WITHOUT CARGO BOX 9 BRAKE LAMP SWITCH DESCRIPTION 9 OPERATION 9 DIAGNOSIS AND TESTING BRAKE LAMP SWITCH 10 REMOVAL 10 INSTALLATION 11 CENTER HIGH MOUNTED STOP LAMP REMOVAL 11 INSTALLATION 11 CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL 11 INSTALLATION 11 CAB CLEARANCE LAMP REMOVAL 11 INSTALLATION 12 FOG LAMP REMOVAL 12 INS...

Page 557: ... Front Control Module Front Fog Lamp Relay Hazard Switch Multi Function Switch Park Lamp Relay Trailer Tow Connectors Some of the interior and exterior lighting functions are governed by the front control module The head lamp dome and door ajar switchs provide signals to the instrument cluster The instrument cluster sends a J1850 message to the front control module to enable the necessary componen...

Page 558: ... High Beams are illuminated and the Low Beams and Fog Lamps if ON are extinguished If the headlamps were in the high beam configuration when power was removed from the headlamps the headlamps will return to their last state prior to being shut off DIAGNOSIS AND TESTING LAMPS LIGHTING EXTERIOR WARNING EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS PER SONAL INJURY CAN RESULT CAUTION ...

Page 559: ...orroded terminals or splices in circuit 2 Inspect and repair all connectors and splices Refer to Electrical Wiring Information HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Electrical Wiring Information 2 Poor lighting circuit ground 2 Test for voltage drop across ground circuits refer to Electrical Wiring Information 3...

Page 560: ...us Communication 3 Verify messages being transmitted by Instrument Cluster and received by FCM 4 Front Control Module Malfunction 4 Refer to appropriate ICM FCM diagnostics FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF 1 Loose or corroded battery cables 1 Clean and secure battery cable clamps and posts 2 Loose or worn generator ...

Page 561: ...ted from Instrument Cluster and received by FCM FOG LAMPS DO NOT ILLUMINATE 1 Blown fuse for fog lamp 1 Replace fuse Refer to Electrical Wiring Information 2 No ground at fog lamps 2 Repair circuit ground Refer to Electrical Wiring Information 3 Faulty fog lamp switch part of headlamp switch 3 Replace headlamp switch 4 Broken connector terminal or wire splice in fog lamp circuit 4 Repair connector...

Page 562: ...ion Table lists the lamp title on the left side of the column and trade number or part number on the right BULB APPLICATION TABLE LAMP BULB Backup w cargo box 3057 Backup w box off 1156 Center High Mounted Stop lamp 912 Fog lamp 9006LL Front Park Turn Signal 3157NA Head lamp 9007 License Plate 168 Tail Brake Turn Signal w cargo box 3057 LAMP BULB Tail Brake Turn Signal w box off 1157 Side Marker T...

Page 563: ... to perform several functions including that of the backup lamp switch The TRS is described in further detail elsewhere in this service information The backup lamp switch cannot be adjusted or repaired and if faulty or damaged the entire switch unit must be replaced OPERATION The backup lamp switch controls the flow of bat tery voltage to the backup lamp bulbs through an output on the back up lamp...

Page 564: ...rtighten the tail lamp lens screws or damage to the tail lamp lens may result 3 Install the four screws that secure the tail lamp lens to the tail lamp unit Tighten the screws securely 4 Reconnect the negative battery cable BRAKE LAMP SWITCH DESCRIPTION The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering col umn under the instrument panel CAUTION The swi...

Page 565: ... the brake lamps The brake lamp switch can only be adjusted once That is at the initial installation of the switch If the switch is not adjusted properly or has been removed a new switch must be installed and adjusted DIAGNOSIS AND TESTING BRAKE LAMP SWITCH The brake lamp switch can be tested with an ohm meter The ohmmeter is used to check continuity between the pin terminals Fig 4 SWITCH CIRCUIT ...

Page 566: ... press into place 2 Position the socket in the lamp 3 Turn the bulb socket 1 4 turn clockwise 4 Install the CHMSL Refer to Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR CENTER HIGH MOUNTED STOP LAMP UN INSTALLATION 5 Connect the battery negative cable CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove screws holding CHMSL to roof panel Fig 6 3 S...

Page 567: ...LATION 1 Position fog lamp in bumper 2 Install the bolts attaching the fog lamp to the bumper 3 Connect fog lamp harness connector 4 Connect the battery negative cable 5 Check for proper operation and beam align ment FOG LAMP RELAY DESCRIPTION The front fog lamp relay is located in the Power Distribution Center PDC in the engine compart Fig 7 Clearance Lamp 1 NUT 2 CAB ROOF 3 BULB SOCKET 4 CLEARAN...

Page 568: ...ound path through this cir cuit Coil Battery Terminal The coil battery ter minal 86 receives battery voltage at all times from a fuse in the PDC through a fused B circuit Normally Open Terminal The normally open terminal 87 is connected to the front fog lamps through a front fog lamp relay output circuit and provides battery voltage to the front fog lamps when ever the relay is energized Normally ...

Page 569: ...attery cable HEADLAMP SWITCH DESCRIPTION The multiplexed headlamp switch is located on the instrument panel The headlamp switch controls the parking lamps fog lamps and the headlamps A sep arate switch in the module controls the interior lamps and instrument cluster illumination This switch also contains a rheostat for controlling the illumination level of the cluster lamps OPERATION The multiplex...

Page 570: ...tru ment panel bezal and secure with screws Tighten the screws to 2 2 N m 20 in lbs 2 Reconnect the instrument panel wire harness connector for the headlamp switch 3 Position the left instrument panel bezal on to the instrument panel 4 Install the cluster bezel onto the instrument panel Fig 10 5 Connect the battery negative cable HEADLAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative ...

Page 571: ...d lamp lens to the floor Transfer measurement to the alignment screen with tape Use this line for up down adjustment reference 7 Measure distance from the centerline of the vehicle to the center of each headlamp being aligned Transfer measurements to screen with tape to each side of vehicle centerline Use these lines for left right adjustment reference VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT 1 ...

Page 572: ...amp unit and 1 4 turn to lock 3 Connect the battery negative cable LICENSE PLATE LAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Disconnect the harness connector 3 Remove the retaining clip Fig 13 4 Separate license plate lamp from vehicle INSTALLATION 1 Position license plate lamp on the bumper 2 Install the clip 3 Reconnect the harness connector 4 Connect the battery nega...

Page 573: ...ition OPERATION TURN SIGNAL SYSTEM The Instrument Cluster monitors the multiplexed multifunction switch In a turning event the Instru ment Cluster senses a change in the turn signal lever and illuminates the appropriate turn signal indicator At the same time the Instrument Cluster will send a J1850 message on the PCI bus to the Front Control Module FCM The FCM will respond by activating the approp...

Page 574: ...Shroud Removal 3 Disconnect the wire connector from the back of the multi function switch 4 Remove the screws retaining the multi function switch to the steering column adapter collar Fig 16 5 Remove the multi function switch 6 Remove the screws retaining the clock spring to the multifunction switch INSTALLATION WARNING BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS ARMED REFER...

Page 575: ...amps when the relay is de ener gized and battery current to the park lamps when ever the relay is energized Coil Ground Terminal The coil ground termi nal 85 is connected to a control output of the Front Control Module FCM through a park lamp relay control circuit The FCM controls park lamp opera tion by controlling a ground path through this cir cuit Coil Battery Terminal The coil battery ter min...

Page 576: ...EMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIRBAG SEAT BELT TENSIONER FRONT IMPACT SENSORS SIDE CURTAIN AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACI TOR TO DISCHARGE BEFORE PERFORMING FUR THER DIAGNOSIS OR SERVICE THIS IS THE O...

Page 577: ...OR TAIL LAMP UNIT INSTALLATION 4 Reconnect the negative battery cable INSTALLATION WITHOUT CARGO BOX 1 Install the tail lamp bulb into the tail lamp socket by pushing inward and rotating it clockwise NOTE Install the tail lamp lens with the clear por tion back up lens at the top of the housing Make sure that the gasket is correctly in place and not twisted or torn 2 Position the tail lamp lens and...

Page 578: ... the two screws that secure the tail lamp unit to the cargo box 4 Raise the tailgate 5 Reconnect the negative battery cable INSTALLATION WITHOUT CARGO BOX 1 Position the tail lamp unit onto the mounting bracket while routing the wire harness through the bracket 2 Install the two nuts that secure the tail lamp housing to the mounting bracket 3 Connect the tail lamp wire harness connector to the bod...

Page 579: ...amp housing 4 Push the turn signal bulb inward and rotate it counter clockwise 5 Remove the turn signal bulb from the tail lamp socket INSTALLATION INSTALLATION WITH CARGO BOX 1 Install the turn signal bulb into the lamp back plate 2 Install the lamp back plate onto the tail lamp unit 3 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION 4 Reconnec...

Page 580: ...nd isolate the battery negative cable 2 Disconnect the wire harness connector from the lamp 3 Remove lamp lens 4 Remove bulb 5 Remove screw attaching underhood lamp to the inner hood panel Fig 27 6 Separate underhood lamp from vehicle INSTALLATION 1 Install bulb 2 Install lamp lens 3 Position the underhood lamp on the hood inner panel 4 Install the attaching screw through the lamp and into the hoo...

Page 581: ...h will not turn the lamps off The instrument cluster monitors the door ajar switches When a door is open the instrument cluster grounds the low side drivers to turn on the lamp Upon closing all doors the instrument cluster ini tiates a 30 second timer If any of the doors are opened during the time out cycle the instrument cluster will reset the timer until all doors are closed The instrument clust...

Page 582: ... diag nostic tools and methods Refer to the Body section under Doors for the Removal and Installation proce dures GLOVE BOX LAMP SWITCH REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the glove box from the instrument panel Refer to 23 BODY INSTRUMENT PANEL GLOVE BOX REMOVAL for the procedures 3 Reach through the glove box opening and behind the glove box lamp and switch mount...

Page 583: ...the lamp switches or bulb holders is faulty or damaged the entire overhead console wire harness assembly must be replaced For service of the reading and courtesy lamp bulbs refer to the appropriate wiring information OPERATION All reading and courtesy lamps located in the over head console are activated by the door ajar switches via the instrument cluster When all of the doors are closed these lam...

Page 584: ...he inboard side of the vehicle to insert the two pivot tabs on the inboard edge of the reading and courtesy lamp lens into the two pivot holes in the overhead console hous ing 4 Pivot the lens back up into position and press upward firmly until the latch tab in the center of the outboard edge of the reading and courtesy lamp lens snaps back into the overhead console housing 5 Reconnect the battery...

Page 585: ......

Page 586: ... REMOVAL 11 INSTALLATION 11 UNIVERSAL TRANSMITTER DESCRIPTION 11 OPERATION 11 DIAGNOSIS AND TESTING UNIVERSAL TRANSMITTER 11 STANDARD PROCEDURE STANDARD PROCEDURE ERASING TRANSMITTER CODES 12 STANDARD PROCEDURE SETTING TRANSMITTER CODES 12 REMOVAL 12 OVERHEAD CONSOLE DESCRIPTION Two different overhead consoles are available on DR models The Electronic Vehicle Information Cen ter EVIC Fig 1 or Comp...

Page 587: ...bi ent temperature sensor refer to Ambient Tempera ture Sensor later in this section Following are general descriptions of the major components used in the overhead console Refer to Wiring Diagrams for complete circuit schematics OPERATION Refer to the vehicle Owner s Manual for specific operation of each overhead console and its systems DIAGNOSIS AND TESTING OVERHEAD CONSOLE If the problem with t...

Page 588: ...his group NOTE If the compass reading displays dashes and only CAL appears in the display demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle Refer to Compass Demagnetizing in the Standard Procedures section of this group STANDARD PROCEDURE STANDARD PROCEDURE READING COURTESY LAMP REPLACEMENT 1 Open hood disconnect and isolate the negative battery cable 2 R...

Page 589: ...magnetize or degauss the overhead console for ward mounting screw and the roof panel above the overhead console Equivalent units must be rated as continuous duty for 110 115 volts and 60 Hz They must also have a field strength of over 350 gauss at 7 millimeters 0 25 inch beyond the tip of the probe To demagnetize the roof panel and the overhead console forward mounting screw proceed as follows 1 B...

Page 590: ...mber Fig 4 2 Turn the ignition switch to the On position If the compass temperature data is not currently being displayed momentarily depress and release the C T push button to reach the compass temperature dis play 3 Depress the RESET push button and hold the button down until VAR XX appears in the display This takes about five seconds 4 Release the RESET push button VAR XX will remain in the dis...

Page 591: ... cause the CMTC to change to Compass Temperature display OPERATION The Compass Mini Trip Computer module in the overhead console has buttons used to select various functions The CMTC selector buttons will not oper ate until the ignition is in the RUN position When the ignition switch is first turned to the RUN position the CMTC display Returns to the last mode setting selected before the ignition ...

Page 592: ...ng VFD dimming level is received through the J1850 PCI data bus circuit The EVIC module uses its internal programming and all of its data inputs to calculate and display the requested data If the data displayed is incorrect perform the self diagnostic tests as described in this group If these tests prove inconclu sive the use of a DRB IIIt scan tool and the proper Diagnostic Procedures manual are ...

Page 593: ... programmable features To enter the EVIC programming mode and to view or change the selected programmable features options proceed as follows 1 Turn the ignition switch to the On position 2 Momentarily depress and release the Menu push button to step through the programmable fea tures list Each programmable feature and its cur rently selected option will appear on the EVIC display in the sequence ...

Page 594: ...LAY The options include Off 30 Sec 60 Sec and 90 Sec The default is 90 Sec When a time interval is selected the headlamps will remain on for that length of time when the head lamps are turned off after the ignition is turned off or if the Auto mode is selected on vehicles with the Auto Headlamps option When Off is selected the headlamp delay feature is disabled TRAIN REMOTE When this feature is se...

Page 595: ... sages to the EVIC CMTC over the PCI J1850 data bus The temperature function is supported by the ambient temperature sensor a wiring circuit the Front Control Module the Programmable Communi cations Interface PCI data bus and a portion of the Electronics module If any portion of the ambient temperature sensor circuit fails the Front Control Module will self diagnose the circuit For complete circui...

Page 596: ...security sys tems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz MHz frequency range for remote opera tion The universal transmitter is capable of operat ing systems using either rolling code or non rolling code technology The electronics module displays messages and a small house shaped icon with one two or three dots corresponding to the thr...

Page 597: ...DARD PROCEDURE SETTING TRANSMITTER CODES 1 Turn off the engine 2 Erase the codes by pressing the two outside buttons Release the buttons when the display con firms the operation about 20 seconds 3 Choose one of the three buttons to train Place the hand held transmitter within one inch of the uni versal transmitter and push the buttons on both transmitters 4 Release both buttons Your universal tran...

Page 598: ...DARD PROCEDURE RKE TRANSMITTER PROGRAMING 9 SPECIFICATIONS REMOTE KEYLESS ENTRY TRANSMITTER 9 POWER LOCKS DESCRIPTION POWER LOCKS The power lock system allows all of the doors to be locked or unlocked electrically by operating a switch on either front door trim panel The power lock sys tem receives non switched battery current through a fuse in the Integrated Power Module IPM so that the power loc...

Page 599: ... when the Unlock button is depressed The RKE system includes two transmitters when the vehicle is shipped from the factory but the system can retain the vehicle access codes of up to a total of four transmitters The transmitter codes are retained in the RKE module memory even if the battery is dis connected If an RKE transmitter is faulty or lost new transmitter vehicle access codes can be pro gra...

Page 600: ...mote Keyless Entry Module is capable of retaining the transmitter Vehicle Access Code s in its memory even after vehicle power has been interrupted DIAGNOSIS AND TESTING POWER LOCKS The most reliable efficient and accurate means to diagnose the power lock system requires the use of a DRBIIIt scan tool and the proper Diagnostic Procedures manual Following are tests that will help to diagnose the ha...

Page 601: ...5 UNLOCK 330 OHMS 5 REMOVAL The power lock switch on the driver side front door trim panel is integral to the driver door module Refer to 8 ELECTRICAL POWER LOCKS DOOR MODULE REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 3 Remove the switch from the trim panel bezel INSTALLATION 1 Insert switch to trim panel ...

Page 602: ...ws the instrument cluster to sense the switch position Based upon the power lock switch input the instrument cluster controls the bat tery and ground feed outputs to the individual power lock motors to lock or unlock the door latches The Light Emitting Diode LED in the DDM power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module IPM ...

Page 603: ...or power window operates in a normal manner but the Auto Down feature is inoperative replace the faulty DDM Refer to the appropriate wir ing information 1 Disconnect and isolate the battery negative cable Remove the DDM from the door trim panel Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles 2 Test the DDM switch continuity See the Driver Door Module Swit...

Page 604: ... side front door or all doors if this feature is enabled unlock the interior lighting is turned on and if the vehicle is so equipped the VTSS is dis armed The panic message will also cause the exte rior lamps including the headlights to flash and the horn to sound for about three minutes or until a second panic message is sent to the instrument clus ter A vehicle speed of about 25 7 kilometers per...

Page 605: ...ies from the RKE trans mitter 4 Replace the two batteries with new 3V lithium 2016 cell Install the batteries with the positive ter minal up Reference the SIDE UP on the inside of the bottom half of the transmitter case 5 Align the two RKE transmitter case halves with each other and squeeze them firmly and evenly together until they snap back into place Test trans mitter operation STANDARD PROCEDU...

Page 606: ...ool can provide confirmation that the PCI data bus is functional and that all of the electronic mod ules are sending and receiving the proper messages on the PCI data bus The following procedure can be used as long as one programmed transmitter is available NOTE When entering program mode using that programmed fob ALL currently programmed fobs will be erased and they will have to be repro grammed ...

Page 607: ...ther the automatic dimming feature is operational When the automatic day night mirror is turned on the mirror switch is lighted by an integral Light Emitting Diode LED The mirror will auto matically disable its self dimming feature whenever the vehicle is being driven in reverse OUTSIDE REAR VIEW MIRROR The heated mirrors include an electric heating grid behind the mirror glass in each outside mir...

Page 608: ...mirror The automatic day night mirror circuitry also mon itors the transmission using an input from the backup lamp circuit The mirror circuitry is pro grammed to automatically disable its self dimming feature whenever it senses that the transmission backup lamp circuit is energized The automatic day night mirror is a completely self contained unit and cannot be repaired If faulty or damaged the e...

Page 609: ... a finger pressed tightly against the sensor or cover the sensor completely with electrical tape 7 Shine a light into the rearward facing head lamp photocell sensor The mirror glass should darken If OK go to Step 8 If not OK replace the faulty automatic day night mirror unit 8 With the mirror glass darkened place the transmission gear selector lever in the Reverse posi tion The mirror should retur...

Page 610: ... lumbar support in the seat back The power lumbar support allows the user to inflate or deflate a bladder located in the lower seat back to achieve optimum comfort and support in the lower lumbar region of the spinal column The power lumbar support shares the battery feed circuit of the power seat system Following are general descriptions of the major components in the power seat system Refer to H...

Page 611: ...attery feed and ground path to the motor are reversed through the switch contacts This causes the adjuster motor to run in the opposite direction No power seat switch should be held applied in any direction after the adjuster has reached its travel limit The power seat adjuster motors each contain a self resetting circuit breaker to protect them from overload However consecutive or frequent resett...

Page 612: ...h Fig 3 on this model has an additional switch knob for adjusting the power lum bar support The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield Refer to the owner s manual in the vehi cle glove box for more information on the power seat switch functions and the seat adjusting procedures The individual switches in the power seat switch assembly ...

Page 613: ...ll the screws that secure the power seat switch to seat cushion side bezel 2 Connect the electrical connector 3 Install the seat cushion switch bezel on the seat Refer to the Body section of the service manual for the procedure 4 If equipped install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat 5 Connect the battery negativ...

Page 614: ... switch and the motor for shorts or opens If the circuits check OK replace the faulty power seat track adjuster assembly If the circuits are not OK repair the wire harness as required REMOVAL 1 Remove the appropriate seat from the vehicle Refer to 23 BODY SEATS SEAT REMOVAL 2 Remove the power seat switch from the seat Refer to the procedure in this section of the service manual 3 Remove four seat ...

Page 615: ...otor and gearbox operate the lumbar adjuster mechanism in the center of the seat back driving a nut up or down a fixed drive screw The action of this nut extends or con tracts the plastic lumbar support band The more this band is contracted the more outward pressure is applied against the center of the seat back padding providing additional lumbar support DIAGNOSIS AND TESTING LUMBAR MOTOR Actuate...

Page 616: ... will cause the motor to rotate in one direction Reversing current through the motor terminals will cause the motor to rotate in the opposite direction DIAGNOSIS AND TESTING POWER WINDOWS WIRING VOLTAGE TEST The following wiring test determines whether or not voltage is continuous through the body harness to the front switch 1 Remove the Driver Door Module Refer to 8 ELECTRICAL POWER LOCKS DOOR MO...

Page 617: ...e replaced For complete circuit dia grams refer to the appropriate wiring information 1 Check the fuse in the Integrated Power Module IPM and the circuit breaker located near the park brake pedal If OK go to Step 2 If not OK replace the faulty fuse or circuit breaker 2 Turn the ignition switch to the On position Check for battery voltage at the fuse in the Inte grated Power Module IPM If OK turn t...

Page 618: ... INSTALLATION FRONT PASSENGER 1 Insert switch to trim panel bezel 2 Install door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION 3 Connect battery negative cable REAR PASSENGER 1 Install switch to door trim panel 2 Install door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLATION 3 Connect battery negative cable DR POWER WINDOWS 8N 21 WINDOW SWITCH Continued ...

Page 619: ......

Page 620: ...LY 25 ASSEMBLY 26 INSTALLATION 28 FRONT CENTER SEAT BELT RETRACTOR REMOVAL 29 INSTALLATION 29 FRONT CENTER SEAT BELT REMOVAL 30 INSTALLATION 31 FRONT OUTBOARD SEAT BELT RETRACTOR REMOVAL REMOVAL STANDARD CAB 32 REMOVAL QUAD CAB 33 INSTALLATION INSTALLATION STANDARD CAB 35 INSTALLATION QUAD CAB 36 FRONT OUTBOARD SEAT BELT BUCKLE REMOVAL 37 INSTALLATION 38 PASSENGER AIRBAG DESCRIPTION 39 OPERATION 4...

Page 621: ...nd an end release buckle secured to the center seat cushion frame Rear Seat Belts All three rear seating posi tions are equipped with three point seat belt sys tems The outboard seating position belts employ a lower C pillar mounted inertia latch type emergency locking retractor a fixed position upper C pillar mounted turning loop and a fixed lower seat belt anchor secured to the lower C pillar Th...

Page 622: ...l Restraint Sys tem SRS and vehicles with this equipment can be readily identified by a molded identification trim but ton with the SRS AIRBAG logo located on the headliner above each B pillar Fig 2 The supplemental restraint system includes the following major components which are described in further detail elsewhere in this service information Airbag Control Module The Airbag Control Module ACM...

Page 623: ...front airbags Refer to 8 ELEC TRICAL ELECTRONIC CONTROL MODULES COMMUNICATION DESCRIPTION Hard wired circuitry connects the supplemental restraint system components to each other through the electrical system of the vehicle These hard wired circuits are integral to several wire harnesses which are routed throughout the vehicle and retained by many different methods These circuits may be con nected...

Page 624: ...apply only to a barrier impact at the given speed Actual times will vary somewhat depending upon the vehicle speed impact angle severity of the impact and the type of collision When the ACM monitors a problem in any of the supplemental restraint system circuits or compo nents including the seat belt tensioners it stores a fault code or Diagnostic Trouble Code DTC in its memory circuit and sends an...

Page 625: ... NEW FASTENER IS NEEDED REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG WARNING TO AVOID PERSONAL INJURY OR DEATH WHEN A STEERING COLUMN HAS AN AIR BAG UNIT ATTACHED NEVER PLACE THE COL UMN ON THE FLOOR OR ANY OTHER SURFACE WITH THE STEERING WHEEL OR AIRBAG UNIT FACE DOWN DIAGNOSIS AND TESTING SUPPLEMENTAL RESTRAINT SYST...

Page 626: ...and the side impact sensors be closely inspected and restored to their original conditions fol lowing any vehicle impact damage Because the ACM and each impact sensor are used by the supplemental restraint system to monitor or confirm the direction and severity of a vehicle impact improper orientation or insecure fastening of these components may cause airbags not to deploy when required or to dep...

Page 627: ...EANUP PROCEDURE Following a supplemental restraint deployment the vehicle interior will contain a powdery residue This residue consists primarily of harmless particu late by products of the small pyrotechnic charge that initiates the propellant used to deploy a supplemen tal restraint However this residue may also contain traces of sodium hydroxide powder a chemical by product of the propellant ma...

Page 628: ...R SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGA TIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT 1 During the following test the battery negative cable remains disco...

Page 629: ...rther service 2 Using a trim stick or another suitable wide flat bladed tool gently pry each side of the ACM cover away from the instrument panel at each side of the center bracket on the floor panel transmission tunnel far enough to disengage the two snap clip retainers from the instrument panel receptacles Fig 6 3 Remove the ACM cover from the instrument panel INSTALLATION The Airbag Control Mod...

Page 630: ...The microprocessor in the Airbag Control Module ACM contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components The ACM uses On Board Diagnostics OBD and can communicate with other electronic modules in the vehicle as well as with the DRBIIIt scan tool using the Programma ble Communications Interface PCI data bus net work This method o...

Page 631: ...second safing sensor is a bi directional unit that detects impact forces from either side of the vehicle Pre programmed decision algorithms in the ACM microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sen sors indicate an impact that is severe enough to require supplemental restraint system protection and based upon the severity of the monitored i...

Page 632: ...OR DEATH ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN AIRBAG SEAT BELT TENSIONER IMPACT SENSOR OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS ...

Page 633: ...actor spool of an inertia type emergency locking retractor mechanism The automatic locking mechanism is integral to the passenger side front seat belt and retractor unit and is concealed beneath a molded plastic cover located on the same side of the retractor spool as the seat belt tensioner housing The retractor is secured to the inner B pillar on the right side of the vehicle and is concealed be...

Page 634: ...ED FOR OUTBOARD SEATING POSITION ONLY 2 TETHER ANCHOR PROVIDED FOR CENTER AND OUTBOARD SEATING POSITIONS Fig 11 Child Restraint Anchor Location Quad Cab 1 LOWER ANCHOR PROVIDED FOR REAR OUTBOARD SEATING POSITIONS ONLY 2 TETHER ANCHOR PROVIDED FOR REAR CENTER AND OUTBOARD SEATING POSITIONS DR RESTRAINTS 8O 15 ...

Page 635: ...it with the cab back trim panel The three upper tether anchor straps for quad cab models are secured to the upper cab back panel rein forcement with screws Fig 13 These anchor straps are concealed behind the upright rear seat back The upper tether anchor straps are available for individ ual service replacement The lower anchors for all models are integral to their respective front or rear seat cus...

Page 636: ...H DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE CARE FULLY INSPECT ALL SEAT BELTS BUCKLES MOUNTING HARDWARE RETRACTORS TETHER STRAPS AND ANCHORS FOR PROPER INSTALLA TION OPERATION OR DAMAGE REPLACE ANY BELT THAT IS CUT FRAYED OR TORN STRAIGHTEN ANY BELT THAT IS TWISTED TIGHTEN ANY LOOSE FASTENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ...

Page 637: ... ft lbs 3 Reinstall the rear seat into the vehicle Refer to 23 BODY SEATS SEAT REAR INSTALLA TION CLOCKSPRING DESCRIPTION The clockspring assembly is secured with two screws onto the multi function switch mounting housing near the top of the steering column behind the steering wheel Fig 17 The clockspring consists of a flat round molded plastic case with a stubby tail that hangs below the steering...

Page 638: ...h to provide automatic turn sig nal cancellation Two short yellow sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag while a steering wheel wire harness connects the two connector recep tacles on the upper surface of the clockspring rotor to the horn switch feed pigtail wire connector and if the vehicle is so equipped to the optional sp...

Page 639: ...LOCKSPRING REMOVAL 3 Rotate the clockspring rotor clockwise to the end of its travel Do not apply excessive torque 4 From the end of the clockwise travel rotate the rotor about two and one half turns counterclockwise The engagement dowel and yellow rubber boot should end up at the bottom and the arrows on the clockspring rotor and case should be in alignment 5 The clockspring is now centered Secur...

Page 640: ...lumn 12 Disconnect the two instrument panel wire harness connectors for the clockspring from the two connector receptacles below the steering column on the back of the clockspring housing 13 Remove the two screws that secure the clock spring to the multi function switch mounting housing Fig 20 14 Remove the clockspring from the multi func tion switch mounting housing The clockspring can not be rep...

Page 641: ...steering col umn If the vehicle is equipped with an automatic transmission be certain to engage the gearshift lever gap hider into the openings in the right side of the upper and lower shrouds 8 Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together 9 From below the steering column install and tighten the two screws that s...

Page 642: ...ntegral retainer in a locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out and connector of the steering wheel wire harness Both horn switch wires are routed through an integral notch in the center of the upper edge of the airbag housing stamping The airbag used in this model is a multistage Next Generation ty...

Page 643: ... by these actions contact a physician REMOVAL The following procedure is for replacement of a faulty or damaged driver airbag If the airbag is faulty or damaged but not deployed review the rec ommended procedures for handling non deployed supplemental restraints Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the driver airbag has been deployed...

Page 644: ...RVICE DISCONNECT AND ISOLATE THE BATTERY NEGA TIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT WARNING TO AVOID PERSONAL INJURY OR DEATH SERVICE OF THIS UNIT SHOULD BE...

Page 645: ...walls and finish with the lower wall To disen gage the hooks use hand pressure to push firmly and evenly downward into the receptacle on the adja cent edge of the airbag housing while at the same time pushing outward on the upper edge of the receptacle wall 8 With all of the hooks disengaged lift the hous ing inflator and cushion as a unit from the recepta cle on the back of the driver airbag trim...

Page 646: ...prevent the trim cover from receiving cosmetic damage during the following procedures 5 Be certain that the horn switch feed and ground pigtail wires are routed through the clearance notch at the top of the airbag housing between the housing and the upper vertical wall of the trim cover receptacle Fig 25 6 Work around the perimeter of the unit engag ing each of the twelve hooks on the driver airba...

Page 647: ...URE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT WARNING TO AVOID PERSONAL INJURY OR DEATH THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED REPLACEMENT AIRBAGS ARE SERVICED WITH TRIM COVERS IN THE ORIG INAL COLORS PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT FAIL URE TO OBSERVE THIS WARNING COULD RESULT IN O...

Page 648: ...keyed lower anchor buckle Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle 2 Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit 3 Using a trim stick or another suitable wide flat bladed tool gently pry at each side of the front center seat belt bezel on the cab back trim panel...

Page 649: ...e ment Tighten the screws to 20 N m 15 ft lbs 5 Reinstall the trim onto the cab back panel Refer to 23 BODY INTERIOR REAR CAB BACK PANEL TRIM INSTALLATION 6 Route the webbing of the front center seat belt through the bezel and position the bezel to the belt opening near the top of the cab back trim panel Fig 28 7 Using hand pressure press firmly and evenly on each side of the front center seat bel...

Page 650: ...kle lap belt unit or unique black keyed front center seat belt lower anchor buckle from the front seat INSTALLATION A fixed position front center seat belt buckle is located on the left side of the front center seat sec tion 20 percent used on all models Standard cab models also have a unique fixed position black keyed front center seat belt lower anchor buckle for the three point center seat belt...

Page 651: ...L RESTRAINTS AUTOMATIC LOCK ING RETRACTOR DESCRIPTION If the seat belt or retractor is faulty or damaged but the seat belt tensioner is not deployed review the recommended procedures for handling non de ployed supplemental restraints Refer to 8 ELEC TRICAL RESTRAINTS STANDARD PROCEDURE HANDLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the seat belt tensioner has been deployed review the recommended...

Page 652: ...r mounting hole 15 Disengage the hooks on the upper retractor bracket from the slots in the lower inner B pillar above the retractor mounting hole 16 Remove the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B pillar REMOVAL QUAD CAB The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit which includ...

Page 653: ...O REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG 1 Move the front seat to its most forward position for easiest access to the lower seat belt anchor and the B pillar trim 2 Disconnect and isolate the battery negative cable Wa...

Page 654: ...lt tensioner has been deployed review the recommended procedures for service after a supplemental restraint deployment before removing the front outboard seat belt and retractor from the vehicle Refer to 8 ELECTRI CAL RESTRAINTS STANDARD PROCEDURE SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT WARNING TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPLEMENTAL R...

Page 655: ...AD CAB The following procedure is for replacement of a faulty or damaged front outboard seat belt and retractor unit which includes a seat belt tensioner for this model Refer to 8 ELECTRICAL RE STRAINTS SEAT BELT TENSIONER DESCRIP TION The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that pre vents the latch...

Page 656: ...B pillar 10 Install and tighten the screw that secures the seat belt turning loop to the height adjuster Tighten the screw to 40 N m 29 ft lbs 11 Engage the lower snap features of the new trim cover over the front outboard seat belt turning loop and using hand pressure press firmly and evenly on the top of the trim cover until it snaps into place 12 Position the lower seat belt anchor to the floor...

Page 657: ...RE RETRACTORS TETHER STRAPS AND ANCHORS FOR PROPER INSTALLA TION OPERATION OR DAMAGE REPLACE ANY BELT THAT IS CUT FRAYED OR TORN STRAIGHTEN ANY BELT THAT IS TWISTED TIGHTEN ANY LOOSE FASTENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCH...

Page 658: ...le the lower fas teners and mounting flange are concealed beneath the instrument panel lower surround The passenger airbag unit is secured by four screws through four brackets two front and two rear that are integral to the base of the airbag housing to the instrument panel structural support The passenger airbag unit used in this model is a multistage Next Generation type that complies with revis...

Page 659: ...ocedure is for replacement of a faulty or damaged passenger airbag If the airbag is faulty or damaged but not deployed review the rec ommended procedures for handling non deployed supplemental restraints Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the passenger airbag has been deployed review the recommended procedures for service after a s...

Page 660: ...maged but not deployed review the rec ommended procedures for handling non deployed supplemental restraints Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE HAN DLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If the passenger airbag has been deployed review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle Refer to 8 ELECTRIC...

Page 661: ...ews to 6 N m 55 in lbs 7 Install and tighten the six screws that secure the inboard and lower flanges of the passenger air bag door to the instrument panel Fig 36 Tighten the screws to 2 N m 20 in lbs 8 Install and tighten the screw that secures the mounting tab of the panel outlet housing to the upper glove box opening reinforcement Tighten the screw to 2 N m 20 in lbs 9 Reinstall the lower surro...

Page 662: ...top the key actuator slot will be in a vertical position the Off indicator will be extinguished and the passenger air bag is enabled The passenger airbag on off switch connects one of two internal resistors in series between the passen ger airbag mux switch sense and passenger airbag mux switch return circuits of the Airbag Control Module ACM The ACM continually monitors the resistance in these ci...

Page 663: ...bracket and is serviced separately from the two buckles The center anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket Refer to 8 ELECTRICAL RESTRAINTS REAR SEAT BELT BUCKLE REMOVAL CEN TER ANCHOR RIGHT OUTBOARD WARNING TO AVOID PERSONAL INJURY OR DEATH DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE CARE FULLY INSPECT ALL SE...

Page 664: ...unting bracket unit 10 Remove the rear center seat belt and retractor unit from the vehicle INSTALLATION The rear center seat belt retractor is secured with a single screw to a mounting bracket that includes the unique black keyed center seat belt lower anchor buckle and the right outboard occupant buckle but can be removed from the mounting bracket and is serviced separately from the two buckles ...

Page 665: ...r the cover and belt bracket 8 Reinstall the rear seat into the vehicle On models with the optional 60 40 split rear bench only the 60 percent section right side of the rear seat must be reinstalled Refer to 23 BODY SEATS SEAT REAR INSTALLATION 9 Reach between the rear seat cushion and the rear seat back to buckle the rear center seat belt lower anchor latch plate to the unique black keyed lower a...

Page 666: ...EN ANY LOOSE FASTENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAI...

Page 667: ... INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT NEW AND UNUSED REPLACEMENT PAR...

Page 668: ...AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG 1 Reach between the rear seat cushion and the rear seat back to access and unbuckle the rear center seat belt lower anchor latch plate from the unique black keyed lower anchor buckle Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle 2 Remove the rear seat from the ...

Page 669: ...ts normal seating position INSTALLATION CENTER ANCHOR RIGHT OUTBOARD The unique black keyed center seat belt lower anchor buckle and the right outboard occupant buckle are serviced as a unit with their mounting bracket The rear center seat belt retractor is also secured to the mounting bracket with these two buckles but can be removed from the mounting bracket and is serviced separately from the t...

Page 670: ...connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment The seat belt switch cannot be adjusted or repaired and if faulty or damaged the entire driver side front seat belt buckle half unit must be replaced OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroM...

Page 671: ...ess connector for the seat belt switch and the instrument panel wire harness connector Connector C2 for the instrument cluster There should be continuity If OK test and replace the faulty instrument cluster as required Refer to 8 ELECTRICAL INSTRUMENT CLUSTER DIAGNOSIS AND TESTING If not OK repair the open seat belt switch sense circuit between the seat belt switch and the instrument cluster as re...

Page 672: ... steering col umn instrument panel and or windshield The tor sion bar is designed to deform in order to control the loading being applied to the occupant by the seat belt during a frontal impact further reducing the poten tial for occupant injuries The ACM monitors the condition of the seat belt tensioners through circuit resistance The ACM will illuminate the airbag indicator in the ElectroMe cha...

Page 673: ... STEERING WHEEL STEERING COLUMN AIRBAG SEAT BELT TENSIONER IMPACT SENSOR OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGA TIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS ...

Page 674: ...djuster far enough to remove the adjuster from the upper B pillar Fig 50 6 Disengage the tab near the lower end of the seat belt turning loop height adjuster from the slot in the sheet metal and remove the adjuster from the inner B pillar INSTALLATION WARNING TO AVOID PERSONAL INJURY OR DEATH DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE CAREFULLY INSPECT ALL SEAT BELTS BUCK...

Page 675: ...e roof rail from the A pillar at the front of the vehicle to just behind the B pillar on standard cab models and to just behind the C pil lar on quad cab models A tether extends down the A pillar from the front of the airbag cushion where it is retained to the pillar with plastic push in routing clips and it is secured to the base of the A pillar near the belt line with a screw The hybrid type inf...

Page 676: ...T WARNING TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH AIRBAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYS TEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN AIRBAG SEAT BELT TENSIONER IMPACT SENSOR OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGA TIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMIN...

Page 677: ...AL INJURY OR DEATH WHEN REMOVING A DEPLOYED AIRBAG RUBBER GLOVES EYE PROTECTION AND A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES IN LARGE DOSES THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES WARNING TO AVOID PERSONAL INJURY OR DEATH USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE SIDE CURTAIN AIRBAG OR BECOMIN...

Page 678: ...l Module ACM The ACM microprocessor continu ously monitors all of the passive restraint system electrical circuits to determine the system readiness If the ACM detects a monitored system fault it sets a Diagnostic Trouble Code DTC and controls the airbag indicator operation accordingly The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus...

Page 679: ...ABLE THE SUPPLEMENTAL RESTRAINT SYS TEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN AIRBAG SEAT BELT TENSIONER IMPACT SENSOR OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGA TIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS ABLE THE SUPPLEME...

Page 680: ...arness connector for the side impact sensor to the sensor connector recep tacle 3 Reach through the retractor mounting hole in the inner B pillar to position and engage the locating pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B pillar 4 Install and tighten the nut that secures the side impact sensor stud to the inner B pillar Tighten the...

Page 681: ...he body wire harness connector for the side impact sensor to the sensor connector recep tacle 3 Reach through the large hole above the retrac tor mounting hole in the inner B pillar to position and engage the locating pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B pillar 4 Install and tighten the nut that secures the side impact sensor st...

Page 682: ...the speed control system is inte grated into the Engine Control Module ECM The controls consist of two steering wheel mounted switches The switches are labeled ON OFF RES ACCEL SET COAST and CANCEL The system is designed to operate at speeds above 30 mph 50 km h WARNING THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT PERMIT MAINTAINING A CONSTANT SPEED SUCH AS IN HEAVY T...

Page 683: ... per second indicates that the vehicle may have decelerated at an extremely high rate Once the speed control has been disengaged depressing the RES ACCEL switch when speed is greater than 30 mph restores the vehicle to the tar get speed that was stored in the PCM the ECM with a diesel engine While the speed control is engaged the driver can increase the vehicle speed by depressing the RES AC CEL s...

Page 684: ...on should be smooth and without flut ter at all speeds Flutter in the speedometer indicates a problem which might cause surging in the speed control sys tem The cause of any speedometer problems should be corrected before proceeding Refer to Instrument Cluster for speedometer diagnosis If a road test verifies a system problem and the speedometer operates properly check for A Diagnostic Trouble Cod...

Page 685: ... towards right side of vehicle to remove throttle cable from throttle body bracket 5 Using finger pressure only disconnect servo cable connector Fig 3 at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle DO NOT try to pull connector off per pendicular to the bellcrank pin Connector will be broken 6 Slide speed control cable plastic mount towards right of v...

Page 686: ...e accelerator pedal to check for any binding 5 9L Diesel Auto Trans 1 Install connect end of speed control servo cable to speed control servo Refer to Speed Control Servo Removal Installation 2 Install cable through mounting hole on mount ing bracket Cable snaps into bracket 3 Connect servo cable to throttle lever by push ing cable connector rearward onto lever pin while holding lever forward 4 Co...

Page 687: ...cles the vacuum and vent solenoids to maintain the set speed or to accelerate and decelerate the vehicle To increase throttle open ing the PCM ECM grounds the vacuum and vent solenoids To decrease throttle opening the PCM ECM removes the grounds from the vacuum and vent solenoids When the brake is released if vehicle speed exceeds 30 mph to resume 35 mph to set and the RES ACCEL switch has been de...

Page 688: ...ss the SET switch while the vehicle is moving at a speed between approxi mately 35 and 85 mph In order for the speed control to engage the brakes cannot be applied nor can the gear selector be indicating the transmission is in Park or Neutral The speed control can be disengaged manually by Stepping on the brake pedal Depressing the OFF switch Depressing the CANCEL switch The speed control can be d...

Page 689: ...he ON OFF switch oper ates two components the PCM s ECM s ON OFF input and the battery voltage to the brake switch REMOVAL Depending on engine control computer JTEC having a 3 plug connector or 5 7L V 8 NGC hav ing a 4 plug connector 2 types of switches are used Both types of switches are internally and externally different The switches used with the NGC system have attached pigtail leads Fig 9 Th...

Page 690: ...rvoir refer to Vacuum Reservoir Remov al Installation in this group Disconnect vacuum line at reservoir and connect a hand operated vacuum pump to reservoir fitting Apply vacuum Reservoir vacuum should not bleed off If vacuum is being lost replace reservoir 5 Verify operation of one way check valve and check it for leaks Certain models may be equipped with 2 check valves a Locate one way check val...

Page 691: ...ne to reservoir fitting 4 Install cowl grill Refer to Cowl Grill Removal Installation 5 Install wiper arms blades Refer to Wiper Arm Removal Installation Fig 11 VACUUM RESERVOIR REMOVAL INSTALLATION 1 COWL BELOW WIPER ARMS 2 VACUUM LINE CONNECTION 3 MOUNTING NUTS 2 4 VACUUM RESERVOIR 5 WELDED STUDS 8P 10 SPEED CONTROL DR VACUUM RESERVOIR Continued ...

Page 692: ...ZER SYSTEM SKIS The Sentry Key Immobilizer System SKIS is designed to provide passive protection against unau thorized vehicle use by preventing the engine from operating while the system is armed The primary components of this system are the Sentry Key Immo bilizer Module SKIM the Sentry Key transponder the Vehicle Theft Security System VTSS indicator LED and the Powertrain Control Module PCM The...

Page 693: ...lant to access the SKIS for initialization or by the dealer technician to access the system for service The SKIM also stores in its memory the Vehicle Identification Number VIN which it learns through a PCI bus message from the PCM during initializa tion The SKIM and the PCM both use software that includes a rolling code algorithm strategy which helps to reduce the possibility of unauthorized SKIS...

Page 694: ...ink Connector DLC 2 With the key in the ignition turn the key to the RUN position 3 After the DRBIIIt scan tool initialization per form the following a Select Theft Alarm b Select VTSS c Select Miscellaneous 4 Once in the Miscellaneous screen a If you wish to configure a new module select Configure Module b If you wish to put the module into customer usage mode select Enable VTSS c If you wish to ...

Page 695: ...leted in the proper sequence or within the allotted time the SKIS will automatically exit the Customer Learn programming mode The SKIS will also automatically exit the Customer Learn programming mode if it sees a non blank Sentry Key transponder when it should see a blank if it has already programmed eight valid Sentry Keys or if the ignition switch is turned to the OFF position for more than abou...

Page 696: ... the instrument cluster to turn the LED off based upon the results if the SKIS self test If the indicator illuminates and remains illuminated after the bulb test it indicates that the SKIM has detected a system malfunction and or the system has become inoperative If the SKIM detects a invalid key when the ignition switch is turned on it sends a message to the instrument cluster to flash the Secu r...

Page 697: ......

Page 698: ... DESCRIPTION 22 OPERATION 23 REMOVAL 23 INSTALLATION 23 WIPER ON OFF RELAY DESCRIPTION 24 OPERATION 25 DIAGNOSIS AND TESTING WIPER ON OFF RELAY 25 REMOVAL 26 INSTALLATION 26 WIPERS WASHERS DESCRIPTION An electrically operated intermittent wiper and washer system is standard factory installed safety equipment on this model Fig 1 The wiper and washer system includes the following major compo nents w...

Page 699: ...es to dedicated openings in the cowl plenum cover grille panel located near the base of the windshield Washer Plumbing The plumbing for the washer system consists of rubber hoses and molded plastic fittings The plumbing is routed along the right side of the engine compartment from the washer reservoir and through a trough near the right end of the cowl plenum cover grille panel into the cowl plenu...

Page 700: ...ontinuous Wipe Mode The control knob on the control stalk of the multi function switch has two continuous wipe positions Low and High When selected these switch positions will cause the two speed wiper motor to operate in a continuous low or high speed cycle Intermittent Wipe Mode The control knob on the control stalk of the multi function switch has five minor detent intermittent wipe positions W...

Page 701: ...from a B fuse in the Integrated Power Module IPM to the wiper on off relay and the wiper high low relay in the IPM through a fused B circuit The FCM uses low side drivers to control wiper system operation by energizing or de energizing the wiper high low and wiper on off relays The FCM uses a high side driver to control the operation of the washer pump motor unit The multi function switch circuitr...

Page 702: ...parking the wiper blades near the base of the windshield WASH MODE When the control knob on the control stalk of the multi function switch is depressed to the momentary Wash position for more than about one half second the instrument cluster sends an electronic washer switch message to the FCM then the FCM directs battery current to the washer pump motor unit This will cause the washer pump motor ...

Page 703: ... BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DIS ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT CLEANING WIPER WASHER SYSTEM WIPER SYSTEM The squeegees of wiper blades exposed to the ele ments for a long time tend to lose their wiping effec tiveness Periodic cleaning of the squeegees is sug...

Page 704: ...es are contaminated with any foreign material clean them and the glass as required Refer to 8 ELEC TRICAL WIPERS WASHERS CLEANING After cleaning the wiper blade and the glass if the wiper blade still fails to clear the glass without smearing streaking chattering hazing or beading replace the wiper blade Also if a wiper blade is damaged or the squeegee rubber is damaged or deteriorated replace the ...

Page 705: ... the check valve prevents washer fluid from siphoning through the washer noz zles after the washer system is turned Off When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing the fluid pressure unseats a diaphragm from over a sump well within the valve by overriding the spring pressure applied to it by a piston Fig 4 With the diaphragm unseated washe...

Page 706: ...ithin the switch mounting flange The washer fluid level switch cannot be adjusted or repaired If faulty or damaged the switch must be replaced OPERATION The washer fluid level switch uses a pivoting oblong float to monitor the level of the washer fluid in the washer reservoir The float contains a small magnet When the float pivots the proximity of this magnet to a stationary reed switch within the...

Page 707: ...ch and open the hood 2 Disconnect and isolate the battery negative cable 3 Disconnect the washer hose from the barbed outlet nipple of the washer pump motor unit and allow the washer fluid to drain into a clean container for reuse 4 Disconnect the right except diesel engine or left diesel engine only headlamp and dash wire har ness connector for the washer fluid level switch from the switch connec...

Page 708: ...ouse to the dash panel The engine compartment washer hose is connected to the washer reservoir washer hose and to the cowl plenum washer hose with molded plastic in line fit tings that have a barbed nipple on each end The cowl plenum washer hose is routed from the engine compartment into the cowl plenum area through a trough formation located near the right end of the cowl plenum cover grille pane...

Page 709: ... 4 From the underside of the cowl plenum cover grille panel disconnect the washer nozzle hose from the barbed nipple of the washer nozzle Fig 11 5 From the underside of the cowl plenum cover grille panel release the integral snap features of the washer nozzle and push the nozzle out through the mounting hole toward the top side of the cowl ple num cover grille panel 6 Remove the washer nozzle from...

Page 710: ...ngine only headlamp and dash wire harness On models without the diesel engine a single eyelet terminal connector is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment On models with a diesel engine an eyelet terminal connector is secured by a ground screw to the left front fender inner shield in the engine compartment The motor receives batte...

Page 711: ... rubber grommet seal in the washer res ervoir Fig 13 3 Using hand pressure press on the washer pump motor unit firmly and evenly until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole 4 Align the washer pump motor snap post on the top of the motor housing with the snap post recepta cle in the washer reservoir 5 Using hand pressure press firml...

Page 712: ...ainer or a coolant pressure container must be detached from the top of the cooling module and moved aside to access the washer fluid reservoir for service This may be accomplished without opening or draining the engine cooling system OPERATION The washer fluid reservoir provides a secure on vehicle storage location for a large reserve of washer fluid for operation of the washer system The washer r...

Page 713: ...e radiator fan shroud Fig 16 4 Disconnect the reservoir washer hose from the barbed nipple of the inline fitting at the engine com partment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir into a clean container for reuse 5 Disconnect the left headlamp and dash wire harness connector for the washer fluid level switch from the switch con...

Page 714: ...from the reservoir during the removal procedure 9 Reconnect the battery negative cable 10 Close and latch the hood INSTALLATION DIESEL ENGINE 1 Position the washer reservoir into the left side of the engine compartment Fig 17 2 Install and tighten the two screws that secure the washer reservoir to the left vertical member of the radiator support Tighten the screws to 10 N m 85 in lbs 3 Reconnect t...

Page 715: ...d keyway on the outer circumference of the wiper pivot shaft provid ing positive engagement and alignment of this con nection The latch positively locks the wiper arm to the wiper pivot shaft when the arm is fully installed The spring loaded wiper arm hinge controls the down force applied through the tip of the wiper arm to the wiper blade on the glass The hook formation on the tip of the wiper ar...

Page 716: ...the glass surface The wiper element flexor provides the claws of the blade superstructure with a rigid yet flexible component on the element which can be gripped The rubber ele ment is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper bla...

Page 717: ...by spring pressure When the relay coil is energized an electromagnetic field is produced by the coil windings This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point and holds it against the fixed normally open contact point When the relay coil is de energized spring pressure returns the movable contact point back against the fixed normall...

Page 718: ...LOW RELAY REMOVAL 2 A relay in the de energized position should have continuity between terminals 87A and 30 and no continuity between terminals 87 and 30 If OK go to Step 3 If not OK replace the faulty relay 3 Resistance between terminals 85 and 86 elec tromagnet should be 75 8 ohms If OK go to Step 4 If not OK replace the faulty relay 4 Connect a battery to terminals 85 and 86 There should now b...

Page 719: ...shing on each end The right side drive link has a plastic socket type bushing on one end and a plastic sleeve type bushing on the other end The socket type bushing on one end of each drive link is snap fit over the ball stud on the lever arm of its respective pivot The right side drive link sleeve type bushing end is then fit over the motor crank arm ball stud and the other socket type bushing of ...

Page 720: ...lle panel from over the cowl plenum Refer to 23 BODY EX TERIOR COWL GRILLE REMOVAL 5 Disconnect the left headlamp and dash wire harness connector for the wiper motor from the motor pigtail wire connector Fig 26 6 Remove the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets 7 Remove the two screws that secure the wiper module to the bottom of the cowl...

Page 721: ...ained within a small rectangular molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade type terminals that extend from the bottom of the relay base Fig 26 Wiper Module Remove Install 1 COWL PLENUM WASHER HOSE 2 PLASTIC FASTENER 6 3 SCREW 2 4 WIPER ARM BLADE 2 5 COWL PLENUM COVER GRILLE PANEL 6 WIPER MODULE 7 WIRE HARNESS CONNECTOR 8 PLENUM PA...

Page 722: ...fuse in the IPM through a fused ignition switch output run acc circuit Normally Open Terminal The normally open terminal 87 receives battery current at all times from a fuse in the IPM through a fused ignition switch output run acc circuit and provides battery current to the wiper on off relay output circuit when ever the relay is energized Normally Closed Terminal The normally closed terminal 87A...

Page 723: ...r Module IPM Fig 29 3 Remove the wiper on off relay by grasping it firmly and pulling it straight out from the receptacle in the IPM INSTALLATION 1 Position the wiper on off relay to the proper receptacle in the Integrated Power Module IPM Fig 29 2 Align the wiper on off relay terminals with the terminal cavities in the IPM receptacle 3 Push firmly and evenly on the top of the wiper on off relay u...

Page 724: ...cess The system includes Span ish and French voice recognition in addition to English Two buttons on the rearview mirror identified with ISO icons control the system A 9phone9 button turns the system on and off a 9voice recognition9 or voice command button prompts the hands free system to listen for a voice command OPERATION TELECOMMUNICATION Two buttons on the rearview mirror identified with ISO ...

Page 725: ...ng fasteners Fig 1 4 Disconnect the electrical harness connector and remove module INSTALLATION 1 Connect the electrical harness connector and position module 2 Install and tighten the mounting fasteners 3 Install the instrument panel right side end cap 4 Connect battery negative cable Fig 1 HANDS FREE MODULE 8T 2 NAVIGATION TELECOMMUNICATION DR ...

Page 726: ... SECURITY SYSTEM 8W 39 1 INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 AUDIO SYSTEM 8W 47 1 REAR WINDOW DEFOGGER 8W 48 1 OVERHEAD CONSOLE 8W 49 1 FRONT LIGHTING 8W 50 1 REAR LIGHTING 8W 51 1 TURN SIGNALS 8W 52 1 WIPERS 8W 53 1 TRAILER TOW 8W 54 1 NAVIGATION TELECOMMUNICATION 8W 55 1 POWER WINDOWS 8W 60 1 ...

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Page 728: ...wiring content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the page Fig 1 All switches components ...

Page 729: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION DR WIRING DIAGRAM INFORMATION Continued ...

Page 730: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 DR 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued ...

Page 731: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION DR WIRING DIAGRAM INFORMATION Continued ...

Page 732: ...es Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and color Fig 4 WIRE COLOR CODE CHART COLOR CODE COLOR BL BLUE BK BLACK BR BROWN DB DARK BLUE DG DARK GREEN GY GRAY LB LIGHT BLUE LG LIGHT GREEN OR ORANGE PK PINK RD RED TN TAN VT VIOLET WT WHITE YL YELLOW WITH TR...

Page 733: ...ar group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can however be shown partially in another group if it contains some associated wiring Splice diagrams in Section 8W 70 show the entire splice and provide references to other sections the splices serves Sectio...

Page 734: ...f general warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER A VEHICLE WARNING BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION UNLESS THE PROCEDURE REQUIRES IT TO BE ON WARNING SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE AN AUTOMATIC TRAN...

Page 735: ... for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify the problem 2 Verify any related symptoms Do this by per forming operational checks on components that are in the same circuit Refer to the wiring diagrams 3 Analyze the symptoms Use the wiring dia ...

Page 736: ...er lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with the fuse 2 Connect a test light or a voltmeter across the terminals of the fuse 3 Starting at the fuse block wiggle the wiring harness about six to eight inches apart and watch the voltmeter test la...

Page 737: ...ground has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 1 Connect the positive lead of the voltmeter to the side of the circuit closest to the battery Fig 9 2 Connect the other lead of the voltmeter to the other side of the switch component or circuit 3 Operate the item 4 The voltmeter will show the difference in volt age between the two points SPECIAL TOOLS WIRING TERMINAL Fig 9 TE...

Page 738: ...emoved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pin out identification refer to the wiring diagrams 3 When the connector is re assembled the sec ondary terminal lock must be placed in the locked position to prevent terminal push out 4 Replace dress ...

Page 739: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION DR CONNECTOR Continued ...

Page 740: ...3 APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPECIAL TOOL 8638 DR 8W 01 WIRING DIAGRAM INFORMATION 8W 01 13 CONNECTOR Continued ...

Page 741: ...fected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired 2 Cut the repair wire to the proper length and remove one half 1 2 inch of insulation 3 Splice the repair wi...

Page 742: ...e of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION DO NOT USE ACID CORE SOLDER 6 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing...

Page 743: ......

Page 744: ... Connector 8W 18 Data Link Connector Engine 8W 18 Dome Lamp 8W 44 49 Door Ajar Switches 8W 40 Door Lock Motor Ajar Switches 8W 40 61 Door Lock Switch Passenger 8W 61 Component Page Door Module 8W 60 61 62 EGR Solenoid 8W 30 Electric Backlight 8W 48 Electric Brake Provision 8W 54 Electronic Throttle Control Module 8W 30 Engine Control Module 8W 30 Engine Coolant Temperature Sensor 8W 30 Engine Oil ...

Page 745: ... 40 Seat Heater Interface Module 8W 63 Sentry Key Immobilizer Module 8W 39 Side Impact Sensors 8W 43 Speakers 8W 47 Component Page Speed Control Servo 8W 33 Speed Control Switches 8W 33 Splices 8W 70 Starter Motor 8W 21 Starter Motor Relay 8W 21 Tail Stop Lamp 8W 52 Tail Stop Turn Signal Lamps 8W 51 52 Tail Turn Lamp 8W 52 Tailgate Lamp 8W 51 Throttle Position Sensor 8W 30 Tow Haul Overdrive Switc...

Page 746: ... 10 14 31 Fuse 22 8W 10 14 31 Fuse 23 8W 10 14 31 Fuse 24 8W 10 14 30 Component Page Fuse 25 8W 10 14 31 Fuse 26 8W 10 49 Fuse 27 8W 10 17 18 43 Fuse 28 8W 10 40 41 Fuse 29 8W 10 46 Fuse 32 8W 10 17 34 Fuse 33 8W 10 17 34 Fuse 34 8W 10 17 34 Fuse 35 8W 10 44 Fuse 36 8W 10 43 Fuse 37 8W 10 44 Fuse 38 8W 10 43 44 Fuse 40 8W 10 15 16 32 Fuse 41 8W 10 16 36 Fuse 42 8W 10 14 32 Fuse 43 8W 10 14 32 Fuse...

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Page 798: ...01 8W 15 9 10 Component Page G202 8W 15 11 12 14 G204 8W 15 15 G301 8W 15 16 G302 8W 15 18 Generator 8W 15 6 8 Glove Box Lamp And Switch 8W 15 12 Hands Free Module 8W 15 11 Headlamp Switch 8W 15 14 Headlamp Left 8W 15 3 Headlamp Right 8W 15 7 Heated Seat Cushion Driver 8W 15 18 Heated Seat Cushion Passenger 8W 15 19 Heated Seat Switch Driver 8W 15 12 Heated Seat Switch Passenger 8W 15 12 Horn High...

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Page 818: ...18 2 3 4 5 Data Link Connector Engine 8W 18 4 Engine Control Module 8W 18 4 Front Control Module 8W 18 6 Fuse 51 8W 18 2 4 Component Page G120 8W 18 4 G201 8W 18 2 4 Hands Free Module 8W 18 6 Instrument Cluster 8W 18 5 Integrated Power Module 8W 18 2 4 6 Powertrain Control Module 8W 18 2 3 Radio 8W 18 5 Sentry Key Immobilizer Module 8W 18 6 Transfer Case Control Module 8W 18 6 DR 8W 18 BUS COMMUNI...

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Page 824: ...Fuse 12 8W 20 3 Fuse 23 8W 20 2 Fusible Link 8W 20 2 3 4 G100 8W 20 2 3 G101 8W 20 2 3 G102 8W 20 2 3 Component Page G107 8W 20 2 G108 8W 20 3 G109 8W 20 3 G120 8W 20 3 Generator 8W 20 2 3 Integrated Power Module 8W 20 2 3 4 Powertrain Control Module 8W 20 2 Starter Motor 8W 20 2 3 DR 8W 20 CHARGING SYSTEM 8W 20 1 ...

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Page 828: ...ne Control Module 8W 21 4 Fuse 14 8W 21 2 3 G104 8W 21 4 Ignition Switch 8W 21 2 3 Component Page Integrated Power Module 8W 21 2 3 4 Powertrain Control Module 8W 21 2 Starter Motor 8W 21 2 3 Starter Motor Relay 8W 21 2 3 Transfer Case Control Module 8W 21 4 Transmission Range Sensor 8W 21 4 DR 8W 21 STARTING SYSTEM 8W 21 1 ...

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Page 832: ...W 30 3 Fuse 2 8W 30 4 Fuse 5 8W 30 25 62 Fuse 12 8W 30 60 Fuse 17 8W 30 3 Fuse 19 8W 30 52 Fuse 23 8W 30 2 Component Page Fuse 36 8W 30 54 61 Fuse 40 8W 30 61 Fuse 49 8W 30 4 Fuse 50 8W 30 2 55 58 62 Fusible Link 8W 30 52 G104 8W 30 3 8 25 60 G105 8W 30 56 58 G107 8W 30 2 7 15 18 19 20 21 30 32 G114 8W 30 53 G120 8W 30 51 60 G201 8W 30 6 G202 8W 30 61 Generator 8W 30 7 51 Idle Air Control Motor 8W...

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Page 898: ...egrated Power Module 8W 31 2 7 8 11 Component Page Line Pressure Sensor 8W 31 6 Output Speed Sensor 8W 31 5 8 Powertrain Control Module 8W 31 2 3 4 5 6 Speed Control Servo 8W 31 9 Speed Control Switch Left 8W 31 10 Speed Control Switch Right 8W 31 10 Starter Motor Relay 8W 31 11 Tow Haul Overdrive Switch 8W 31 3 10 Transfer Case Control Module 8W 31 11 12 13 14 16 Transfer Case Mode Sensor 8W 31 1...

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Page 914: ...k Brake 8W 33 3 Electric Brake Provision 8W 33 2 Engine Control Module 8W 33 3 5 8 Fuse 24 8W 33 2 Component Page Fuse 30 8W 33 4 G104 8W 33 4 5 G201 8W 33 2 Instrument Cluster 8W 33 2 Integrated Power Module 8W 33 2 4 Powertrain Control Module 8W 33 3 4 8 PTC No 1 8W 33 4 Speed Control Servo 8W 33 4 5 Speed Control Switch Left 8W 33 6 7 Speed Control Switch Right 8W 33 6 7 DR 8W 33 VEHICLE SPEED ...

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Page 922: ...ontroller Antilock Brake 8W 34 2 3 Data Link Connector 8W 34 2 Engine Control Module 8W 34 2 3 Fuse 6 8W 34 2 Component Page Fuse 35 8W 34 2 G104 8W 34 2 G201 8W 34 3 Integrated Power Module 8W 34 2 Powertrain Control Module 8W 34 2 3 Wheel Speed Sensor Rear 8W 34 3 DR 8W 34 REAR WHEEL ANTILOCK BRAKES 8W 34 1 ...

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Page 926: ... Link Connector 8W 35 2 Engine Control Module 8W 35 2 3 Fuse 6 8W 35 2 Fuse 35 8W 35 2 Component Page G104 8W 35 2 G201 8W 35 3 Integrated Power Module 8W 35 2 Powertrain Control Module 8W 35 2 3 Wheel Speed Sensor Left Front 8W 35 3 Wheel Speed Sensor Rear 8W 35 3 Wheel Speed Sensor Right Front 8W 35 3 DR 8W 35 ALL WHEEL ANTILOCK BRAKES 8W 35 1 ...

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Page 930: ... 4 Door Lock Motor Ajar Switch Right Rear 8W 39 4 Front Control Module 8W 39 3 Fuse 15 8W 39 3 Fuse 23 8W 39 2 Fuse 45 8W 39 3 Fuse 50 8W 39 2 Component Page G104 8W 39 3 G105 8W 39 3 G201 8W 39 2 G301 8W 39 4 5 Headlamp Left 8W 39 3 Headlamp Right 8W 39 3 Horn Relay 8W 39 3 Instrument Cluster 8W 39 2 4 5 Integrated Power Module 8W 39 2 3 Park Lamp Relay 8W 39 3 Sentry Key Immobilizer Module 8W 39...

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Page 936: ... 8 Fog Lamp Relay 8W 40 3 Fog Lamp Left 8W 40 3 Fog Lamp Right 8W 40 3 Fuse 18 8W 40 5 Fuse 22 8W 40 5 Component Page Fuse 41 8W 40 3 G201 8W 40 3 12 G202 8W 40 10 G301 8W 40 2 6 7 13 Glove Box Lamp And Switch 8W 40 12 Headlamp Switch 8W 40 3 Heated Seat Switch Driver 8W 40 8 12 Heated Seat Switch Passenger 8W 40 8 12 Horn Switch 8W 40 14 Ignition Switch 8W 40 5 14 Instrument Cluster 8W 40 2 3 4 5...

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Page 950: ...use 25 8W 41 3 Fuse 29 8W 41 3 Fuse 42 8W 41 3 Fuse 45 8W 41 2 G104 8W 41 2 G202 8W 41 3 Component Page G302 8W 41 4 Horn Relay 8W 41 2 Horn Switch 8W 41 4 Horn High Note 8W 41 2 Horn Low Note 8W 41 2 Instrument Cluster 8W 41 4 Integrated Power Module 8W 41 2 3 Power Outlet 8W 41 3 Power Outlet Console 8W 41 3 4 DR 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

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Page 954: ...r Actuator 8W 42 5 Engine Control Module 8W 42 7 9 EVAPorator Temperature Sensor 8W 42 4 Fuse 12 8W 42 10 Fuse 16 8W 42 7 Component Page Fuse 36 8W 42 3 4 G104 8W 42 10 G107 8W 42 7 G120 8W 42 7 G202 8W 42 2 3 4 Heated Mirror Relay 8W 42 3 4 Ignition Switch 8W 42 2 Instrument Cluster 8W 42 2 Integrated Power Module 8W 42 3 4 7 10 Mode Door Actuator 1 8W 42 5 6 Mode Door Actuator 2 8W 42 5 6 Passen...

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Page 964: ...tch 8W 43 2 Airbag Passenger Squib 8W 43 3 Airbag Right Curtain 8W 43 4 Clockspring 8W 43 3 Data Link Connector 8W 43 2 Component Page Fuse 52 8W 43 2 Fuse 53 8W 43 2 G204 8W 43 2 Integrated Power Module 8W 43 2 Seat Belt Pretensioner Driver 8W 43 3 Seat Belt Pretensioner Passenger 8W 43 3 Side Impact Sensor Left 8W 43 4 Side Impact Sensor Right 8W 43 4 DR 8W 43 AIRBAG SYSTEM 8W 43 1 ...

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Page 968: ...Motor Ajar Switch Driver 8W 44 3 Door Lock Motor Ajar Switch Left Rear 8W 44 3 Door Lock Motor Ajar Switch Passenger 8W 44 4 Door Lock Motor Ajar Switch Right Rear 8W 44 4 Component Page Fuse 15 8W 44 4 Fuse 32 8W 44 4 Fuse 51 8W 44 3 G104 8W 44 3 G202 8W 44 2 4 Glove Box Lamp And Switch 8W 44 2 Instrument Cluster 8W 44 2 3 4 Integrated Power Module 8W 44 3 4 Overhead Map Reading Lamp 8W 44 2 Park...

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Page 972: ...7 Integrated Power Module 8W 47 5 Radio 8W 47 2 3 4 7 Component Page Remote Radio Switch Left 8W 47 7 Remote Radio Switch Right 8W 47 7 Speaker Center Instrument Panel 8W 47 4 Speaker Left Front Door 8W 47 3 6 Speaker Left Instrument Panel 8W 47 4 Speaker Left Rear 8W 47 3 6 Speaker Right Front Door 8W 47 3 6 Speaker Right Instrument Panel 8W 47 4 Speaker Right Rear 8W 47 3 6 DR 8W 47 AUDIO SYSTEM...

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Page 980: ...mponent Page A C Heater Control 8W 48 2 Electric Backlight 8W 48 2 Fuse 26 8W 48 2 Component Page Heated Mirror Relay 8W 48 2 Integrated Power Module 8W 48 2 Rear Window Defogger Relay 8W 48 2 DR 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

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Page 982: ...ata Link Connector 8W 49 2 Dome Lamp 8W 49 3 Front Control Module 8W 49 3 Fuse 17 8W 49 2 Component Page Fuse 28 8W 49 2 G202 8W 49 2 3 Instrument Cluster 8W 49 3 Integrated Power Module 8W 49 2 3 Overhead Map Reading Lamp 8W 49 3 Powertrain Control Module 8W 49 4 Transmission Range Sensor 8W 49 2 Transmission Solenoid TRS Assembly 8W 49 2 DR 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

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Page 986: ...ont Control Module 8W 50 2 3 4 5 Fuse 15 8W 50 4 Fuse 32 8W 50 4 Fuse 34 8W 50 4 Fuse 41 8W 50 5 Component Page G104 8W 50 3 4 5 G105 8W 50 3 4 G201 8W 50 5 G202 8W 50 6 Headlamp Switch 8W 50 2 5 Headlamp Left 8W 50 3 Headlamp Right 8W 50 3 Instrument Cluster 8W 50 2 5 Integrated Power Module 8W 50 2 3 4 5 Multi Function Switch 8W 50 2 Park Lamp Relay 8W 50 4 Park Turn Signal Lamp Left Front 8W 50...

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Page 992: ...32 8W 51 3 Fuse 33 8W 51 7 Fuse 34 8W 51 2 Fuse 38 8W 51 3 Component Page G104 8W 51 2 4 5 6 G202 8W 51 7 Integrated Power Module 8W 51 2 3 5 6 7 License Lamp Left 8W 51 2 License Lamp Right 8W 51 2 Park Lamp Relay 8W 51 2 3 7 Park Turn Signal Lamp Left Front 8W 51 2 Park Turn Signal Lamp Right Front 8W 51 3 Tail Stop Turn Signal Lamp Left 8W 51 2 5 Tail Stop Turn Signal Lamp Right 8W 51 6 Tailgat...

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Page 1000: ...2 2 3 4 5 6 Multi Function Switch 8W 52 2 Component Page Park Lamp Relay 8W 52 3 Park Turn Signal Lamp Left Front 8W 52 3 Park Turn Signal Lamp Right Front 8W 52 3 Tail Stop Lamp 8W 52 4 5 Tail Stop Turn Signal Lamp Left 8W 52 3 4 Tail Stop Turn Signal Lamp Right 8W 52 5 Tail Turn Lamp 8W 52 4 5 Trailer Tow Connector 8W 52 6 Trailer Tow Connector Add On 8W 52 6 Trailer Tow Left Turn Relay 8W 52 6 ...

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Page 1006: ...4 8W 53 3 4 G105 8W 53 4 Instrument Cluster 8W 53 2 Integrated Power Module 8W 53 2 3 4 Component Page Multi Function Switch 8W 53 2 Washer Fluid Level Switch 8W 53 4 Washer Pump Motor Front 8W 53 4 Wiper High Low Relay 8W 53 3 4 Wiper Motor Front 8W 53 3 4 Wiper On Off Relay 8W 53 3 DR 8W 53 WIPERS 8W 53 1 ...

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Page 1010: ... 54 5 Fuse 24 8W 54 5 Fuse 33 8W 54 2 3 Fuse 46 8W 54 2 3 Component Page Fuse 47 8W 54 2 3 G104 8W 54 2 4 5 Integrated Power Module 8W 54 2 3 5 Park Lamp Relay 8W 54 2 3 PTC No 5 8W 54 2 3 Trailer Tow Connector 8W 54 2 3 4 Trailer Tow Connector Add On 8W 54 3 4 5 Trailer Tow Left Turn Relay 8W 54 2 3 Trailer Tow Right Turn Relay 8W 54 2 3 DR 8W 54 TRAILER TOW 8W 54 1 ...

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Page 1016: ...NICATION Component Page Automatic Day Night Mirror 8W 55 2 Data Link Connector 8W 55 2 G202 8W 55 2 Component Page Hands Free Module 8W 55 2 Instrument Cluster 8W 55 2 Radio 8W 55 2 DR 8W 55 NAVIGATION TELECOMMUNICATION 8W 55 1 ...

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Page 1018: ...dow Circuit Breaker 8W 60 2 4 Power Window Motor Driver 8W 60 2 4 Component Page Power Window Motor Left Rear 8W 60 7 Power Window Motor Passenger 8W 60 3 5 Power Window Motor Right Rear 8W 60 6 Power Window Switch Left Rear 8W 60 4 7 Power Window Switch Passenger 8W 60 3 4 5 Power Window Switch Right Rear 8W 60 4 6 DR 8W 60 POWER WINDOWS 8W 60 1 ...

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Page 1026: ...tch Left Rear 8W 61 4 Door Lock Motor Ajar Switch Passenger 8W 61 3 4 Door Lock Motor Ajar Switch Right Rear 8W 61 4 Door Lock Switch Passenger 8W 61 3 4 Component Page Driver Door Module 8W 61 2 Fuse 28 8W 61 3 4 G301 8W 61 2 3 4 G302 8W 61 2 Instrument Cluster 8W 61 2 3 4 Integrated Power Module 8W 61 3 4 DR 8W 61 POWER DOOR LOCKS 8W 61 1 ...

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Page 1030: ...62 3 Driver Door Module 8W 62 2 3 Fuse 27 8W 62 3 Fuse 36 8W 62 3 Fuse 48 8W 62 2 Component Page G302 8W 62 2 3 Heated Mirror Relay 8W 62 3 Integrated Power Module 8W 62 2 3 Power Mirror Left 8W 62 2 3 Power Mirror Right 8W 62 3 DR 8W 62 POWER MIRRORS 8W 62 1 ...

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Page 1034: ...ar Motor Driver 8W 63 2 Lumbar Motor Passenger 8W 63 3 4 Component Page Passenger Lumbar Switch 8W 63 3 Power Seat Motor Driver Front Vertical 8W 63 2 Power Seat Motor Driver Horizontal 8W 63 2 Power Seat Motor Driver Rear Vertical 8W 63 2 Power Seat Motor Passenger Front Vertical 8W 63 4 Power Seat Motor Passenger Horizontal 8W 63 4 Power Seat Motor Passenger Rear Vertical 8W 63 4 Power Seat Swit...

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Page 1042: ... S187 8W 30 19 S191 8W 10 45 S203 8W 10 41 S204 8W 10 30 S205 8W 10 41 S206 8W 33 6 7 S207 8W 33 6 7 S209 8W 63 5 Component Page S210 8W 10 52 S212 8W 10 46 S214 8W 33 2 S216 8W 63 5 S217 8W 47 4 S218 8W 47 4 S219 8W 47 7 S220 8W 47 7 S221 8W 10 31 S222 8W 10 42 S224 8W 42 2 S225 8W 10 42 S226 8W 42 5 6 S228 8W 33 7 S230 8W 18 5 S231 8W 18 6 S232 8W 18 6 S240 8W 10 31 S241 8W 10 35 S243 8W 48 2 S2...

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Page 1050: ... Lamp Switch 8W 80 13 Brake Transmission Shift Interlock Solenoid 8W 80 14 C102 NGC 8W 80 14 C103 8W 80 14 C106 5 7L A T 8W 80 14 C106 5 7L A T 8W 80 15 C107 5 7L 8W 80 15 C107 5 7L 8W 80 16 C108 Diesel 8W 80 16 C108 Diesel 8W 80 16 C109 Diesel 8W 80 17 C109 Diesel 8W 80 17 C110 Diesel 8W 80 17 C110 Diesel 8W 80 18 C112 Diesel M T 8W 80 18 C112 Diesel M T 8W 80 18 C112 Diesel A T 8W 80 18 Componen...

Page 1051: ...ion Sensor 3 7L 8W 80 52 Crankshaft Position Sensor 4 7L 8W 80 53 Crankshaft Position Sensor 5 7L 8W 80 53 Crankshaft Position Sensor Diesel 8W 80 53 Cylinder Lock Switch Driver Premium 8W 80 53 Data Link Connector 8W 80 53 Data Link Connector Engine Diesel 8W 80 54 Dome Lamp 8W 80 54 Door Ajar Switch Driver 8W 80 54 Door Ajar Switch Left Rear 8W 80 54 Door Ajar Switch Passenger 8W 80 55 Door Ajar...

Page 1052: ...ent Page Oxygen Sensor 2 1 Upstream NGC 8W 80 81 Oxygen Sensor 2 2 Downstream NGC 8W 80 81 Park Turn Signal Lamp Left Front 8W 80 82 Park Turn Signal Lamp Right Front 8W 80 82 Passenger Blend Door Actuator Dual Zone 8W 80 82 Passenger Lumbar Switch 8W 80 82 Power Mirror Left 8W 80 82 Power Mirror Right 8W 80 83 Power Outlet 8W 80 83 Power Outlet Console Except Base 8W 80 83 Power Seat Motor Driver...

Page 1053: ... On 8W 80 99 Transfer Case Control Module C1 Electric 4x4 8W 80 100 Transfer Case Control Module C2 Electric 4x4 8W 80 100 Component Page Transfer Case Control Module C3 Electric 4x4 8W 80 101 Transfer Case Mode Sensor 8W 80 101 Transfer Case Selector Switch 8W 80 101 Transfer Case Shift Motor 8W 80 101 Transmission Range Sensor 8W 80 102 Transmission Solenoid Assembly 48RE 8W 80 102 Transmission ...

Page 1054: ...OUND A C HEATER CONTROL C1 BLACK 16 WAY CAV CIRCUIT FUNCTION 1 F504 20GY PK FUSED IGNITION SWITCH OUTPUT RUN 2 Z24 18BK OR GROUND 3 C121 20DB DG SENSOR GROUND 4 C29 20DB MODE DOOR 2 DRIVER 5 6 C21 20DB LG EVAPORATOR TEMPERATURE SENSOR SIGNAL 7 8 E16 20OR GY PANEL LAMPS DRIVER 9 C61 20DB LG BLEND DOOR DRIVER 10 C801 20DB OR MODE DOOR 1 DRIVER 11 C34 20DB LB COMMON DOOR DRIVER 12 C32 20DB TN RECIRCU...

Page 1055: ...ENSOR GROUND 2 F855 18PK YL 5 VOLT SUPPLY 3 C918 18BK LB A C PRESSURE SENSOR GROUND 4 A C PRESSURE TRANSDUCER NGC 4 WAY CAV CIRCUIT FUNCTION 1 K900 18DB DG SENSOR GROUND 2 F855 18PK YL 5 VOLT SUPPLY 3 C918 18BK LB A C PRESSURE SIGNAL 4 ACCELERATOR PEDAL POSITION SENSOR 5 7L 6 WAY CAV CIRCUIT FUNCTION 1 K29 20WT BR APPS NO 2 SIGNAL 2 F856 20YL PK 5 VOLT SUPPLY 3 F855 20PK YL 5 VOLT SUPPLY 4 K400 20...

Page 1056: ...S NO 1 RETURN ACCELERATOR PEDEL POSITION SENSOR DIESEL A T 6 WAY CAV CIRCUIT FUNCTION 1 K914 18RD WT SENSOR GROUND 2 K556 18OR BR NOT IDLE SWITCH 3 K22 18BR WT TP SIGNAL 4 K922 18LG OR THROTTLE POSITION SENSOR RETURN 5 K851 18VT PK 5 VOLT SUPPLY 6 K565 18OR IDLE SWITCH ADJUSTABLE PEDAL MOTOR EXCEPT MEMORY 2 WAY CAV CIRCUIT FUNCTION 1 P206 18LG LB ADJUSTABLE PEDALS MOTOR REVERSE 2 P205 18LG WT ADJU...

Page 1057: ...T PCI BUS 4 5 Z104 18BK LG GROUND 6 G104 20VT GY PASSENGER AIRBAG INDICATOR DRIVER 7 R104 20LB LG PASSENGER AIRBAG MUX SWITCH RETURN 8 R106 20LG LB PASSENGER AIRBAG MUX SWITCH SENSE 9 10 11 12 13 14 15 16 17 R43 20LG BR DRIVER SQUIB 1 LINE 1 18 R45 20LG OR DRIVER SQUIB 1 LINE 2 19 R44 20LB OR PASSENGER SQUIB 1 LINE 2 20 R42 20LB BR PASSENGER SQUIB 1 LINE 1 21 R61 20LG VT DRIVER SQUIB 2 LINE 1 22 R...

Page 1058: ...N SQUIB 1 LINE 1 16 R2 18WT LB LIGHT DUTY RIGHT CURTAIN SQUIB 1 LINE 2 17 F201 18PK OR FUSED IGNITION SWITCH OUTPUT RUN START 18 F100 18PK VT FUSED IGNITION SWITCH OUTPUT RUN 19 20 21 22 23 24 25 26 27 R14 20TN LG LIGHT DUTY RIGHT SIDE IMPACT SENSOR 1 SIGNAL 28 R16 20BR LG LIGHT DUTY RIGHT SIDE IMPACT SENSOR 1 GROUND 29 R15 20LG BR LIGHT DUTY LEFT SIDE IMPACT SENSOR 1 GROUND 30 R13 20LG TN LIGHT D...

Page 1059: ...NGER SQUIB 4 WAY CAV CIRCUIT FUNCTION 1 R44 20LB OR PASSENGER SQUIB 1 LINE 2 2 R42 20LB BR PASSENGER SQUIB 1 LINE 1 3 R64 20LB WT PASSENGER SQUIB 2 LINE 1 4 R62 20LB VT PASSENGER SQUIB 2 LINE 2 AIRBAG RIGHT CURTAIN YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R4 18OR LB RIGHT CURTAIN SQUIB 1 LINE 1 2 R2 18WT LB RIGHT CURTAIN SQUIB 1 LINE 2 AMBIENT TEMPERATURE SENSOR 2 WAY CAV CIRCUIT FUNCTION 1 G31 20VT LG...

Page 1060: ...1 A116 18YL RD FUSED B 2 3 4 X295 18GY DG LEFT REAR SPEAKER 5 X154 18GY YL RIGHT FRONT DOOR SPEAKER 6 X153 18DG YL LEFT FRONT DOOR SPEAKER 7 X208 18GY DG RIGHT INSTRUMENT PANEL SPEAKER 8 X299 18GY YL LEFT INSTRUMENT PANEL SPEAKER 9 A116 18YL RD FUSED B 10 11 12 X205 18GY LG LEFT REAR SPEAKER 13 X296 18DG GY RIGHT REAR SPEAKER 14 X206 18DG LG RIGHT REAR SPEAKER 15 X156 18GY LB RIGHT FRONT DOOR SPEA...

Page 1061: ...DSFREE MICROPHONE SHIELD 6 X712 20DG LB MICROPHONE 1 IN 7 X793 20DG YL HANDSFREE MICROPHONE HSD FEED 8 9 X730 20GY YL VOICE RECOGNITION PHONE SWITCH SIGNAL 10 11 X835 20OR GY SENSOR GROUND 12 X792 20LB DG MICROPHONE IN BACKUP LAMP SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION A L1 18WT LG BACKUP LAMP FEED B L10 18WT GY FUSED IGNITION SWITCH OUTPUT RUN BATTERY TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT F...

Page 1062: ...ER MOTOR LOW DRIVER 4 C73 14DB VT BLOWER MOTOR M2 DRIVER BRAKE FLUID LEVEL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B20 20DG OR BRAKE FLUID LEVEL SWITCH SENSE 2 Z420 20BK OR GROUND BRAKE LAMP SWITCH 6 WAY CAV CIRCUIT FUNCTION 1 A103 18GY RD FUSED B 2 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 3 V30 20VT WT S C BRAKE SWITCH OUTPUT 3 V30 20VT WT 5 7L FUSED IGNITION SWITCH RUN START 4 V32 20VT YL SPEED CO...

Page 1063: ...V CIRCUIT 1 G31 20VT LG 2 K900 20DB DG C103 HEADLAMP AND DASH SIDE CAV CIRCUIT 1 Z470 20BK LB 2 A114 18GY RD C106 5 7L A T ENGINE SIDE CAV CIRCUIT 1 K11 18BR YL 2 K12 18BR DB 3 K13 18BR LB 4 K14 18BR TN 5 K38 18BR OR 6 K58 18BR VT 7 K26 18BR YL 8 K28 18BR LB 9 K19 18DB DG 10 K17 18DB TN 11 K18 18DB OR 12 K15 18DB GY 13 K16 18DB YL 14 K10 18DB OR 15 K97 18BR 16 K98 18DB YL 8W 80 14 8W 80 CONNECTOR ...

Page 1064: ... DG 10 K17 18DB TN 11 K18 18DB OR 12 K15 18DB GY 13 K16 18DB YL 14 K10 18DB OR 15 K97 18BR 16 K98 18DB YL C107 5 7L BLACK ENGINE SIDE CAV CIRCUIT 1 K900 18DB DG 2 K1 18VT BR 3 K21 18DB LG 4 K922 18BR DB 5 F856 18YL PK 6 K447 18TN YL 7 K342 16BR WT 8 F855 18PK YL 9 K2 18VT OR 10 K122 18BR DG 11 K22 18BR OR 12 13 K448 18TN OR 14 K342 16BR WT DR 8W 80 CONNECTOR PIN OUTS 8W 80 15 ...

Page 1065: ...CAV CIRCUIT 1 B22 18DG YL 2 C13 18LB OR 3 A961 14RD 4 K25 18DB VT 5 N4 18DB WT 6 D25 18WT VT 7 8 V32 18VT YL M T 9 K174 18BR YL 10 11 K176 18BR OR 12 K23 18BR WT M T 13 K852 18BR VT M T 14 K167 18BR YL M T C108 DIESEL BLACK TRANSMISSION SIDE CAV CIRCUIT 1 B22 20DG YL 2 C13 20LB OR 3 A961 14RD 4 K25 18DB VT 5 N4 18DB WT 6 D25 20WT VT 7 8 V32 20VT YL M T 9 K174 18BR YL 10 11 K176 18BR OR 12 K23 20BR...

Page 1066: ... 1 V35 20VT OR 2 V32 20VT YL 3 T41 20YL DB 4 T6 20DG 5 T118 18DG 6 T9 18DG TN 7 8 T38 18YL BR 9 T75 18YL LB 10 T54 18DG OR 11 T515 20YL DB 12 V36 20VT YL 13 T14 18DG BR 14 T13 18DG VT C110 DIESEL BLACK ENGINE SIDE CAV CIRCUIT 1 C3 18DB YL 2 B29 18DG WT 3 4 K900 18DB DG 5 V37 18VT 6 K160 18BR OR 7 K161 18BR LB 8 F856 18YL PK 9 D20 18WT LG 10 D21 18WT BR 10 D21 18PK 11 F202 18PK GY 12 K29 18WT BR M ...

Page 1067: ...4 20VT BR M T 14 K400 20BR VT M T C112 DIESEL A T ENGINE SIDE CAV CIRCUIT 1 C3 18DB YL 2 A961 14RD 3 K615 18VT WT 4 K616 18BR YL C112 DIESEL A T TRANSMISSION SIDE CAV CIRCUIT 1 C3 18DB YL 2 A961 14RD 3 K615 18VT WT 4 K616 18BR YL C112 DIESEL M T ENGINE SIDE CAV CIRCUIT 1 C3 18DB YL 2 A961 14RD 3 K615 18BR WT 4 K616 18BR YL 5 K167 18BR YL 6 K23 18BR WT 7 K852 18BR VT 8 K29 18WT BR 8W 80 18 8W 80 CO...

Page 1068: ...A T A4 K400 20BR VT M T A5 K900 20DB DG A6 K29 20WT BR M T A7 K852 20BR LB M T A8 Z901 18BK MANUAL TRANSFER CASE B1 T16 18YL OR A T B2 L1 18WT LG B3 L10 18WT GY B4 F202 20PK GY B5 B22 20DG YL B6 T515 20YL DB A T B7 K77 18BR WT MANUAL TRANSFER CASE B8 N4 18DB WT C1 K174 18BR YL C2 C13 20LB OR C3 D25 20WT VT C4 K854 20VT BR M T C5 K167 20BR YL M T C6 K23 20BR WT M T C7 T6 20DG A T C8 K176 18BR OR DR...

Page 1069: ...ONIC TRANS FER CASE DK GRAY ENGINE SIDE CAV CIRCUIT 1 D20 18WT LG 2 D21 18WT BR 3 4 C131 4 7L ELECTRONIC TRANSFER CASE ENGINE SIDE CAV CIRCUIT 1 T316 16YL GY 2 D200 20WT LG 3 T313 20YL LG 4 D202 20WT VT 5 T885 20YL GY 6 D201 20WT DG 7 D203 20WT BR 8 T315 16YL BR 9 D20 18WT LG 4 7L 10 D21 18WT BR 4 7L 11 12 8W 80 20 8W 80 CONNECTOR PIN OUTS DR ...

Page 1070: ...C TRANS FER CASE A4 D202 20WT VT ELECTRONIC TRANS FER CASE A5 T885 20YL GY ELECTRONIC TRANS FER CASE A6 D201 20WT DG ELECTRONIC TRANS FER CASE A7 D203 20WT BR ELECTRONIC TRANS FER CASE A8 T315 16YL BR ELECTRONIC TRANS FER CASE B1 B2 D20 20WT LG B3 D21 20WT BR B4 V32 20VT YL DIESEL B5 T117 20DG YL DIESEL A T B6 V36 20VT YL DIESEL A T B7 T917 20YL TN DIESEL A T B8 C1 A961 14RD DIESEL C2 B22 20DG WT ...

Page 1071: ...V32 20VT YL DIESEL B5 T117 20DG YL DIESEL A T B6 V36 20VT YL DIESEL A T B7 T917 20YL TN DIESEL A T B8 C1 A961 14RD DIESEL C2 B22 20DG WT 5 7L C2 V35 20VT OR DIESEL A T C3 F855 20PK YL 5 7L C3 B29 20DG WT DIESEL C4 F856 20YL PK 5 7L C4 F856 18YL PK DIESEL C5 K160 18BR OR DIESEL C6 K161 18BR LB DIESEL C7 V37 20VT DIESEL C8 K25 18DB VT DIESEL C200 HVAC SIDE CAV CIRCUIT 1 C70 10DB YL 2 C34 20DB LB 3 C...

Page 1072: ... PREMIUM 2 Z13 20BK WT PREMIUM 3 L50 20WT TN 4 Z350 20BK TN 5 A919 20RD PREMIUM 6 F21 20PK DG PREMIUM 7 L14 20WT TN 8 Z964 20BK 9 M20 20YL LB 10 M22 20YL OR PREMIUM 11 L1 20WT LG PREMIUM 12 M288 20YL GY PREMIUM C201 WHITE I P SIDE CAV CIRCUIT 1 D25 20WT VT PREMIUM 2 Z13 18BK WT 3 L50 18WT TN 4 Z350 18BK TN 5 A919 20RD PREMIUM 6 F21 20PK DG 7 L14 20WT TN 8 Z964 18BK 9 M20 20YL LB 10 M22 20YL OR 11 ...

Page 1073: ... CIRCUIT 1 L70 20WT GY 2 Z946 20BK C206 I P SIDE CAV CIRCUIT 1 L70 18WT GY 2 Z946 18BK C207 HEADLAMP AND DASH SIDE CAV CIRCUIT 1 A34 16RD WT 2 E11 20OR DB 3 F21 20PK DG 4 T315 16YL BR 5 D25 20VT DB 6 T885 20YL GY 7 D200 20WT LG 8 T316 16YL GY 9 D202 20WT VT 10 D201 20WT DG 11 T41 20YL DB 12 T313 20YL LG 13 D203 20WT BR 14 Z905 16BK 8W 80 24 8W 80 CONNECTOR PIN OUTS DR ...

Page 1074: ...0 D201 20WT DG 11 T41 20YL DB 12 T313 20YL LG 13 D203 20WT BR 14 Z905 16BK C216 CHASSIS SIDE CAV CIRCUIT 1 B4 18DG GY 2 B3 18DG YL 3 L678 18BR 4 L53 18DG WT 5 L62 18WT YL 6 K900 18DB DG 8 L70 18WT GY C216 HEADLAMP AND DASH SIDE CAV CIRCUIT 1 B4 20DG GY 2 B3 20DG YL 3 L678 18BR 4 L53 18DG WT 5 L62 18WT YL 6 K900 20DB DG 7 N4 18DB WT 8 L70 18WT GY DR 8W 80 CONNECTOR PIN OUTS 8W 80 25 ...

Page 1075: ... Z928 16BK C217 BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 L673 18YL 2 B40 14DG TRAILER TOW 3 A100 14RD VT TRAILER TOW 4 L7 18WT YL 5 A109 16OR RD GAS 6 L50 18WT TN 7 Z927 14BK OR 8 9 10 L54 18WT LG 11 L63 18WT DG 12 L1 18WT LG 13 L674 18LG 14 Z928 16BK C218 BODY SIDE CAV CIRCUIT 1 2 A405 18RD DB 3 C16 16DB GY SLT 4 A930 18RD SLT 5 6 7 8 9 A210 12OR RD SLT 10 11 12 C15 16DB WT SLT 8W 80 26 8W 80 C...

Page 1076: ...T NGC 5 D21 20WT BR 6 A103 18GY RD 7 T751 16YL 8 D20 20WT LG 9 E11 20OR DB ELECTRONIC TRANSFER CASE 10 A970 10RD 11 A991 10RD TRAILER TOW 12 13 14 15 16 V38 20VT OR 5 7L 17 V37 20VT 18 T6 20DG GAS DIESEL A T 19 L70 18WT GY 20 F21 20PK DG 21 V32 20VT YL 22 23 A921 16RD 24 B25 20DG WT 25 F202 20PK GY 5 7L 25 V30 20VT WT GAS EXCEPT 5 7L DIE SEL A T 26 A114 18GY RD 27 L1 18WT LG 28 29 30 V937 20VT BR ...

Page 1077: ... MANUAL TRANSFER CASE EXCEPT NGC 48 A205 18RD OR 49 A116 18YL RD 50 51 52 53 R79 20LB VT NGC EXCEPT 5 7L ABS 54 R81 20LB WT NGC EXCEPT 5 7L ABS 55 56 F100 18PK VT 57 R80 20VT LB NGC EXCEPT 5 7L ABS 58 R82 20WT LB NGC EXCEPT 5 7L ABS 59 60 A981 14RD 61 F982 14PK YL 62 63 64 65 66 F922 16PK YL 67 F201 18PK OR 68 L89 18WT YL TRAILER TOW 69 B29 20DG WT 70 A919 20RD 71 72 D25 20VT PK 73 F983 20PK YL 74...

Page 1078: ...6 20DG 19 L70 18WT GY 20 F21 20PK DG 21 V32 20VT YL 22 23 A921 16RD 24 B25 20DG WT 25 V30 20VT WT 26 A114 18GY RD 27 L1 20WT LG 28 29 30 V937 20VT BR 31 A944 20RD 32 F504 20GY PK 33 A941 18RD 34 35 36 F984 18PK YL 37 38 F951 16PK LG 39 T917 20YL TN 40 41 A951 16RD 42 F202 20PK GY EXCEPT BASE 43 A72 18RD OR EXCEPT BASE 44 D16 18WT OR 45 46 K77 18BR WT 47 T117 20DG YL 48 A205 18RD OR 49 A116 18YL RD...

Page 1079: ...RD 71 72 D25 20WT VT 73 F983 20PK YL 74 C220 I P SIDE CAV CIRCUIT 1 F983 20PK YL 2 X295 18GY DG 3 4 X153 18DG YL 5 G75 20VT 6 G77 20VT GY 7 X155 18DG LB 8 G10 20VT LG 9 G163 20VT LB SLT 10 X205 18GY LG 11 P5 18TN OR SLT 12 F100 18PK VT 13 F201 18PK OR 14 15 16 17 P393 18LG SLT 18 G161 20VT DG SLT 19 20 P1 18TN LG SLT 21 22 F30 12PK YL SLT 23 24 8W 80 30 8W 80 CONNECTOR PIN OUTS DR ...

Page 1080: ...T LB SLT 10 X205 18GY LG 11 P5 18TN OR SLT 12 F100 18PK VT 13 F201 18PK OR 14 15 16 17 P393 18LG SLT 18 G161 20VT DG SLT 19 20 P1 18TN LG SLT 21 22 F30 12PK YL SLT 23 24 C250 HANDS FREE I P SIDE CAV CIRCUIT 1 X712 18DG LB 2 X735 22NA 3 X792 18LB DG 4 X835 18OR GY 5 X730 18GY YL 6 X793 18DG YL 7 X722 18LB DG 8 DR 8W 80 CONNECTOR PIN OUTS 8W 80 31 ...

Page 1081: ...AV CIRCUIT 1 G74 20VT WT 2 P195 18LG YL SLT 3 P72 18TN GY SLT 4 X154 18GY YL 5 X156 18GY LB 6 P74 18TN OR SLT 7 Q15 12OR LB SLT 8 9 10 Z74 20BK WT C301 BODY SIDE CAV CIRCUIT 1 G74 20VT WT 2 P195 18LG YL SLT 3 P72 18TN GY SLT 4 X154 18GY YL 5 X156 18GY LB 6 P74 18TN OR SLT 7 Q15 14OR LB SLT 8 9 10 Z74 20BK WT BASE 10 Z461 20BK DG SLT 8W 80 32 8W 80 CONNECTOR PIN OUTS DR ...

Page 1082: ...N OR POWER WINDOWS LOCKS 7 Q15 14OR LB POWER WINDOWS LOCKS 8 9 10 Z74 20BK WT EXCEPT POWER WIN DOWS LOCKS 10 Z461 20BK DG POWER WINDOWS LOCKS C302 SLT BODY SIDE CAV CIRCUIT 1 F21 20PK DG 2 3 4 G778 18VT LB 5 6 G160 20VT LG 7 Q16 14OR TN 8 Q26 14OR GY 9 G162 20VT LB 10 P392 18LG DB 11 Z216 18BK DB 12 13 C16 18DB GY 14 15 16 DR 8W 80 CONNECTOR PIN OUTS 8W 80 33 ...

Page 1083: ...6 P74 18TN OR SLT 7 F30 12PK YL SLT 8 Q15 12OR LB SLT 9 A930 18RD SLT 10 Z75 20BK VT C304 DRIVER DOOR SIDE CAV CIRCUIT 1 G75 20VT 2 P195 18LG YL POWER WINDOW LOCKS 3 P72 20TN GY POWER WINDOW LOCKS EXCEPT SECURITY 3 P72 18 TN GY SECURITY 4 X153 18DG YL 5 X155 18DG LB 6 P74 18TN OR POWER WINDOW LOCKS 7 F30 14PK YL POWER WINDOW LOCKS 8 Q15 14OR LB POWER WINDOW LOCKS 9 A930 18RD POWER WINDOW LOCKS 10 ...

Page 1084: ...VT DG 11 G163 20VT LB 12 Q412 14OR LB 13 Q611 14OR GY 14 Q411 14OR WT 15 16 C305 SLT BLACK DRIVER DOOR SIDE CAV CIRCUIT 1 C16 18DB GY 2 Q16 14OR TN 3 Q26 14OR GY 4 P393 18LG 5 6 P1 18TN LG 7 Z461 14BK DG 8 Q612 14OR DB 9 10 G161 20VT DG 11 G163 20VT LB 12 Q412 14OR LB 13 Q611 14OR GY 14 Q411 14OR WT 15 16 DR 8W 80 CONNECTOR PIN OUTS 8W 80 35 ...

Page 1085: ...Y SIDE CAV CIRCUIT 1 Z79 20LG BK 2 G77 20VT OR 3 P393 18LG SLT 4 P5 18TN OR SLT 5 Q15 14OR LB SLT 6 Q411 14OR WT SLT 7 Q611 14OR GY SLT 8 X295 18GY DG 9 X205 18GY LG 10 C308 BODY SIDE CAV CIRCUIT 1 G74 20VT WT 2 G162 20VT LB SLT 3 D25 20WT VT 4 X154 18GY YL 5 G160 20VT LG SLT 6 G76 20TN YL 7 F201 18PK OR 8 P392 18LG DB SLT 9 G778 18VT LB SLT 10 F21 20PK DG SLT 11 12 13 14 X206 18DG LG 15 X296 18DG...

Page 1086: ...DG 11 12 13 14 X206 18DG LG 15 X296 18DG GY 16 17 18 19 X156 18GY LB C309 NATURAL BODY SIDE CAV CIRCUIT 1 2 P7 20LG DG 3 P81 20TN LB 4 5 P84 20TN VT 6 P8 20LG WT 7 P82 20TN DG 8 P83 20TN WT C309 NATURAL I P SIDE CAV CIRCUIT 1 2 P7 20LG DG 3 P81 20TN LB 4 5 P84 20TN VT 6 P8 20LG WT 7 P82 20TN DG 8 P83 20TN WT DR 8W 80 CONNECTOR PIN OUTS 8W 80 37 ...

Page 1087: ...DB 5 Z951 20BK 6 C311 DRIVER SEAT SIDE CAV CIRCUIT 1 Z939 14BK 2 A210 12OR RD 3 G10 20VT LG 4 A405 12RD DB 5 Z951 20BK 6 C313 DRIVER SEAT SIDE CAV CIRCUIT 1 P105 12LG 2 P13 12LG OR 3 P21 12LG TN 4 P15 12LG BR 5 P107 12LG WT 6 P11 12LG YL 7 A210 12OR RD 8 Z939 14BK 9 P17 12LG DG 10 P19 12LG LB 11 12 8W 80 38 8W 80 CONNECTOR PIN OUTS DR ...

Page 1088: ...405 12RD DB 2 P54 20OR LG HEATED SEATS 3 A210 12OR RD 4 Z939 14BK 5 P188 18LG VT HEATED SEATS 6 P89 20LG OR HEATED SEATS C315 JUMPER SIDE CAV CIRCUIT 1 A405 12RD DB 2 P54 20OR LG HEATED SEATS 3 A210 12OR RD 4 Z939 14BK 5 P188 18LG VT HEATED SEATS 6 P89 18LG OR HEATED SEATS C316 HEATED SEATS JUMPER SIDE CAV CIRCUIT 1 P89 20LG OR 2 P54 20OR LG 3 A210 12OR RD 4 Z939 14BK 5 P188 18LG VT 6 DR 8W 80 CON...

Page 1089: ...05 12RD DB EXCEPT HEATED SEAT 1 Z939 14BK HEATED SEAT 2 Z939 14BK EXCEPT HEATED SEAT 2 A405 12RD DB HEATED SEAT C320 RIGHT REAR DOOR SIDE CAV CIRCUIT 1 Z72 20LG BK 2 G76 20VT GY 3 P392 18LG POWER WINDOW LOCKS 4 G778 18TN OR POWER WINDOW LOCKS 5 Q15 14TN LG POWER WINDOW LOCKS 6 Q412 14OR WT POWER WINDOW LOCKS 7 Q612 14OR GY POWER WINDOW LOCKS 8 X296 18GY DG 9 X206 18GY LG 10 8W 80 40 8W 80 CONNECTO...

Page 1090: ...ATED SEATS DRIVER SEAT SIDE CAV CIRCUIT 1 A930 18RD 2 P81 20TN LB 3 P7 20LG DG 4 G10 20VT LG 5 P83 20TN WT 6 P82 20TN DG 7 Z939 14BK 8 A210 12OR RD 9 P8 20LG WT 10 P84 20TN VT 11 12 Z951 20BK 13 14 A405 12RD DB C322 BODY SIDE CAV CIRCUIT 1 A930 18RD 2 P81 20TN LB 3 P7 20LG DG 4 G10 20VT LG 5 P83 20TN WT 6 P82 20TN DG 7 Z939 14BK 8 A210 12OR RD 9 P8 20LG WT 10 P84 20TN VT 11 12 Z951 18BK 13 14 A405...

Page 1091: ...OR RD 10 Z939 14BK 11 12 C323 EXCEPT HEATED SEATS PASSENGER SEAT SWITCH SIDE CAV CIRCUIT 1 P18 12LG DG 2 P14 12LG OR 3 P10 12LG TN 4 P12 12LG YL 5 P16 12LG BR 6 P20 12LG LB 7 P104 12LG 8 P106 12LG WT 9 A210 12OR RD 10 Z939 14BK 11 12 C323 HEATED SEATS PASSENGER SEAT SIDE CAV CIRCUIT 1 P104 12LG 2 P106 12LG WT 3 A210 12OR RD 4 Z939 14BK 5 6 8W 80 42 8W 80 CONNECTOR PIN OUTS DR ...

Page 1092: ...0 12OR RD 4 Z939 14BK 5 6 C327 DUAL REAR WHEELS CHASSIS SIDE CAV CIRCUIT 1 L7 18WT YL 2 Z948 20BK C327 DUAL REAR WHEELS DRW LAMP SIDE CAV CIRCUIT 1 L7 18WT YL 2 Z947 18BK C328 DUAL REAR WHEELS CHASSIS SIDE CAV CIRCUIT 1 L70 18WT GY 2 Z948 20BK DR 8W 80 CONNECTOR PIN OUTS 8W 80 43 ...

Page 1093: ... VOLT SUPPLY 2 K916 18BR OR SENSOR GROUND 3 K44 18DB GY CMP SIGNAL CAMSHAFT POSITION SENSOR NGC GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K44 20DB GY CMP SIGNAL 2 K900 20DB DG SENSOR GROUND 3 F856 20YL PK 5 VOLT SUPPLY CAPACITOR 3 7L 4 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 8W 80 44 8W 80 CONNECTOR PIN OUTS DR ...

Page 1094: ...ER OUTLET RED 3 WAY CAV CIRCUIT FUNCTION 1 F984 18PK YL FUSED IGNITION SWITCH OUTPUT RUN ACC 2 3 Z736 18BK YL GROUND CLEARANCE LAMP NO 1 HEAVY DUTY 2 WAY CAV CIRCUIT FUNCTION 1 L70 20WT GY FUSED PARK LAMP RELAY OUTPUT 2 Z946 20BK GROUND CLEARANCE LAMP NO 2 HEAVY DUTY 2 WAY CAV CIRCUIT FUNCTION 1 L70 20WT GY FUSED PARK LAMP RELAY OUTPUT 2 Z946 20BK GROUND DR 8W 80 CONNECTOR PIN OUTS 8W 80 45 ...

Page 1095: ... 2 Z946 20BK GROUND CLEARANCE LAMP NO 5 HEAVY DUTY 2 WAY CAV CIRCUIT FUNCTION 1 L70 20WT GY FUSED PARK LAMP RELAY OUTPUT 2 Z946 20BK GROUND CLOCKSPRING C1 6 WAY CAV CIRCUIT FUNCTION 1 Z909 20BK DSAB ETC GROUND 2 X20 20GY WT DSAB ETC RADIO CONTROL MUX 3 V38 20VT OR S C SWITCH NO 2 SIGNAL 4 V37 20VT S C SWITCH NO 1 SIGNAL 5 V937 20VT BR S C SWITCH RETURN 6 X3 20DG VT HORN SWITCH SENSE 8W 80 46 8W 80...

Page 1096: ...2 V937 20VT BR S C SWITCH RETURN 3 V37 20VT S C SWITCH NO 1 SIGNAL 4 V38 20VT OR DSAB ETC S C SWITCH NO 2 SIGNAL CLOCKSPRING C4 2 WAY CAV CIRCUIT FUNCTION 1 Z909 22BK GROUND 2 X20 22GY WT RADIO CONTROL MUX CLUTCH INTERLOCK BRAKE SWITCH 2 WAY CAV CIRCUIT FUNCTION 1 T41 20YL DB TRS T41 SENSE 2 Z911 18BK GROUND COIL ON PLUG NO 1 3 7L 4 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K19 18DB DG COIL CONTROL NO...

Page 1097: ...CIRCUIT FUNCTION 1 K17 18DB TN COIL CONTROL NO 2 2 K342 16BR WT ASD RELAY OUTPUT 3 COIL ON PLUG NO 2 5 7L 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT ASD RELAY OUTPUT 2 K17 18DB TN COIL CONTROL NO 2 COIL ON PLUG NO 3 3 7L 4 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K18 18DB OR COIL CONTROL NO 3 2 K342 16BR WT ASD RELAY OUTPUT 3 8W 80 48 8W 80 CONNECTOR PIN OUTS DR ...

Page 1098: ...CIRCUIT FUNCTION 1 K15 18DB GY COIL CONTROL NO 4 2 K342 16BR WT ASD RELAY OUTPUT 3 COIL ON PLUG NO 4 5 7L 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT ASD RELAY OUTPUT 2 K15 18DB GY COIL CONTROL NO 4 COIL ON PLUG NO 5 3 7L 4 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K16 18DB YL COIL CONTROL NO 5 2 K342 16BR WT ASD RELAY OUTPUT 3 DR 8W 80 CONNECTOR PIN OUTS 8W 80 49 ...

Page 1099: ...V CIRCUIT FUNCTION 1 K10 18DB OR COIL CONTROL NO 6 2 K342 16BR WT ASD RELAY OUTPUT 3 COIL ON PLUG NO 6 5 7L 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT ASD RELAY OUTPUT 2 K10 18DB OR COIL CONTROL NO 6 COIL ON PLUG NO 7 4 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K97 18DB YL COIL CONTROL NO 7 2 K342 16BR WT ASD RELAY OUTPUT 3 8W 80 50 8W 80 CONNECTOR PIN OUTS DR ...

Page 1100: ...ONTROL NO 8 2 K342 16BR WT ASD RELAY OUTPUT 3 COIL ON PLUG NO 8 5 7L 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT ASD RELAY OUTPUT 2 K98 18DB YL COIL CONTROL NO 8 COMPASS MINI TRIP COMPUTER EXCEPT BASE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 F21 20PK DG FUSED IGNITION SWITCH OUTPUT RUN START 3 Z13 20BK WT GROUND 4 A919 20RD FUSED B 5 D25 20WT VT PCI BUS 6 DR 8W 80 CONNECTOR PIN OUTS 8W 80 51 ...

Page 1101: ...D SENSOR 9 B29 20DG WT BRAKE SWITCH SIGNAL 10 B8 20DG TN ETC LEFT FRONT WHEEL SPEED SENSOR 11 B20 20DG OR BRAKE FLUID LEVEL SWITCH SENSE 12 B22 20DG YL VEHICLE SPEED SIGNAL NO 1 13 Z127 12BK DG ABS GROUND 14 A111 14DG RD ABS FUSED B CONTROLLER ANTILOCK BRAKE C2 ABS BLACK 4 WAY CAV CIRCUIT FUNCTION 1 B9 20DG LG LEFT FRONT WHEEL SPEED SENSOR 2 B8 20DG TN LEFT FRONT WHEEL SPEED SENSOR 3 B6 20DG WT RI...

Page 1102: ...AY CAV CIRCUIT FUNCTION 1 K853 18DB BR 5 VOLT SUPPLY 2 K975 18BR BK SENSOR GROUND 2 K975 18BR OR SENSOR GROUND 3 K24 18BR LB CKP SIGNAL 3 K24 18LB BR CKP SIGNAL CYLINDER LOCK SWITCH DRIVER PREMIUM 2 WAY CAV CIRCUIT FUNCTION 1 G163 20VT LB DRIVER CYLINDER LOCK SWITCH MUX 2 Z463 20BK LB GROUND DATA LINK CONNECTOR BLACK 16 WAY CAV CIRCUIT FUNCTION 1 2 D25 20WT VT PCI BUS 3 4 Z11 18BK LG GROUND 5 Z111...

Page 1103: ...DB CCD BUS 3 Z816 14BK A T GROUND 3 Z11 14BK LG M T GROUND DOME LAMP BLACK 3 WAY CAV CIRCUIT FUNCTION 1 2 M20 20YL LB COURTESY LAMPS DRIVER 3 Z964 20BK GROUND DOOR AJAR SWITCH DRIVER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G75 20VT DRIVER DOOR AJAR SWITCH SENSE 2 Z75 20BK VT GROUND DOOR AJAR SWITCH LEFT REAR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G77 20VT GY LEFT REAR DOOR AJAR SWITCH SENSE 2 Z79 20LG BK G...

Page 1104: ...LOCK MOTOR AJAR SWITCH DRIVER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20VT DRIVER DOOR AJAR SWITCH SENSE 2 Z75 20BK VT GROUND 3 P1 18TN LG DOOR UNLOCK DRIVER LEFT FRONT 4 P393 18LG DOOR LOCK DRIVER LEFT DOORS DOOR LOCK MOTOR AJAR SWITCH LEFT REAR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G77 20VT GY LEFT REAR DOOR AJAR SWITCH SENSE 2 Z79 20LG BK GROUND 3 P5 18TN OR DOOR UNLOCK DRIVER LEFT REAR 4 P393 18LG...

Page 1105: ...RTUAL RIGHT REAR DOOR AJAR SWITCH SENSE 2 Z72 20LG BK VIRTUAL GROUND 3 G778 18TN OR VIRTUAL DOOR UNLOCK DRIVER RIGHT DOORS 4 P392 18LG VIRTUAL DOOR LOCK DRIVER RIGHT DOORS DOOR LOCK SWITCH PASSENGER 6 WAY CAV CIRCUIT FUNCTION 1 G160 20VT LG PASSENGER DOOR LOCK SWITCH MUX 2 F21 20PK DG FUSED IGNITION SWITCH OUTPUT RUN START 3 4 5 Z461 20BK DG GROUND 6 DRIVER BLEND DOOR ACTUATOR DUAL ZONE 2 WAY CAV ...

Page 1106: ...FT REAR WINDOW DRIVER DOWN 11 Z941 20BK GROUND 12 Q21 14OR WT LEFT FRONT WINDOW DRIVER DOWN DRIVER DOOR MODULE C2 BLUE 8 WAY CAV CIRCUIT FUNCTION 1 P71 18TN DG LEFT MIRROR UP DRIVER 2 P195 18LG YL LEFT MIRROR COMMON DRIVER RIGHT DOWN 3 A930 18RD FUSED B 4 P74 18TN OR RIGHT MIRROR LEFT DRIVER 5 Z461 20BK DG GROUND 6 P75 18TN LG LEFT MIRROR LEFT DRIVER 7 P72 18TN GY RIGHT MIRROR UP DRIVER 8 Q15 14OR...

Page 1107: ...D72 18WT LB CCD BUS 5 D71 18WT DB CCD BUS 6 K65 18BR LB FUEL PUMP RELAY RETURN 7 K20 18BR GY GEN FIELD CONTROL 8 9 10 11 K2 18TN BK A T ECT SIGNAL 11 K2 18VT OR M T ECT SIGNAL 12 K181 18BR YL FUEL PUMP DRIVER 13 14 K22 18BR WT A T TP SIGNAL 14 K23 18DB WT M T APPS NO 1 SIGNAL 15 K21 18DB LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 16 K29 18WT BR M T APPS NO 2 SIGNAL 17 18 19 K31 18BR FUEL PUMP RELA...

Page 1108: ...NTROL NO 3 40 K13 16BR LB M T INJECTOR CONTROL NO 3 41 42 K851 18VT PK A T 5 VOLT SUPPLY 42 K852 18BR VT M T APPS 1 5 VOLT SUPPLY 43 K37 18LB A T BOOST PRESSURE SENSOR SIGNAL 43 K37 18BR OR M T BOOST PRESSURE SENSOR SIGNAL 44 K556 18OR BR NOT IDLE SWITCH 45 N2 18DB YL LIFT PUMP FEED 46 K58 16BR VT INJECTOR CONTROL NO 6 47 48 49 50 K12 16BR DB INJECTOR CONTROL NO 2 51 52 K975 18BR BK A T SENSOR GRO...

Page 1109: ...VE PCM 20 A209 16RD FUSED B 21 Z902 16BK GROUND 22 23 F856 18YL PK 5 VOLT SUPPLY 24 K900 18DB DG SENSOR GROUND 25 T75 18YL LB A T TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 N4 18DB WT FUEL LEVEL SENSOR SIGNAL 27 28 D25 18WT VT PCI BUS 29 T54 18DG OR A T TRANSMISSION TEMPERATURE SENSOR SIGNAL 30 A209 16RD FUSED B 31 T515 18YL DB A T TRANSMISSION CONTROL RELAY CONTROL 32 F202 18PK GY FUSED IGNITION...

Page 1110: ...GNAL ENGINE COOLANT TEMPERATURE SENSOR GAS BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K900 18DB DG SENSOR GROUND 2 K2 18VT OR ECT SIGNAL ENGINE OIL PRESSURE SWITCH 2 WAY CAV CIRCUIT FUNCTION 1 G6 18VT GY OIL PRESSURE SIGNAL 2 EVAP PURGE SOLENOID NGC 2 WAY CAV CIRCUIT FUNCTION 1 K52 18DB WT EVAP PURGE CONTROL 2 K70 18DB BR EVAP PURGE RETURN DR 8W 80 CONNECTOR PIN OUTS 8W 80 61 ...

Page 1111: ...UT 2 Z947 18BK GROUND FENDER LAMP FRONT RIGHT DUAL REAR WHEELS 2 WAY CAV CIRCUIT FUNCTION 1 L70 18WT YL FUSED PARK LAMP RELAY OUTPUT 2 Z948 18BK GROUND FENDER LAMP REAR LEFT DUAL REAR WHEELS 2 WAY CAV CIRCUIT FUNCTION 1 L7 18WT YL FUSED PARK LAMP RELAY OUTPUT 2 Z947 18BK GROUND FENDER LAMP REAR RIGHT DUAL REAR WHEELS 2 WAY CAV CIRCUIT FUNCTION 1 L70 18WT YL FUSED PARK LAMP RELAY OUTPUT 2 Z948 18BK...

Page 1112: ...L CONTROL ACTUATOR DIESEL 3 WAY CAV CIRCUIT FUNCTION 1 K915 18VT RD FUEL RAIL SENSOR RETURN 2 K181 18BR YL FUEL PUMP DRIVER 3 F855 18PK YL 5 VOLT SUPPLY FUEL HEATER DIESEL 2 WAY CAV CIRCUIT FUNCTION A Z816 14BK GROUND B A961 14RD FUEL HEATER RELAY OUTPUT FUEL INJECTOR NO 1 GAS 2 WAY CAV CIRCUIT FUNCTION 1 K11 18BR YL INJECTOR CONTROL NO 1 2 K342 16BR WT ASD RELAY OUTPUT DR 8W 80 CONNECTOR PIN OUTS...

Page 1113: ...RCUIT FUNCTION 1 K13 18BR LB INJECTOR CONTROL NO 3 2 K342 16BR WT ASD RELAY OUTPUT FUEL INJECTOR NO 4 GAS 2 WAY CAV CIRCUIT FUNCTION 1 K14 18BR TN INJECTOR CONTROL NO 4 2 K342 16BR WT ASD RELAY OUTPUT FUEL INJECTOR NO 5 GAS 2 WAY CAV CIRCUIT FUNCTION 1 K38 18BR OR INJECTOR CONTROL NO 5 2 K342 16BR WT ASD RELAY OUTPUT 8W 80 64 8W 80 CONNECTOR PIN OUTS DR ...

Page 1114: ...OUTPUT FUEL INJECTOR NO 8 GAS 2 WAY CAV CIRCUIT FUNCTION 1 K28 18BR LB INJECTOR CONTROL NO 8 2 K342 16BR WT ASD RELAY OUTPUT FUEL INJECTOR PACK NO 1 DIESEL 4 WAY CAV CIRCUIT FUNCTION 1 K227 14BR LG ENG INJECTOR HIGH SIDE DRIVER BANK 1 2 K12 14BR DB INJECTOR CONTROL NO 2 3 K227 14BR LG ENG INJECTOR HIGH SIDE DRIVER BANK 1 4 K11 14BR YL INJECTOR CONTROL NO 1 4 K11 14WT DB INJECTOR CONTROL NO 1 DR 8W...

Page 1115: ...E DRIVER BANK 2 1 K229 14TN PK ENG INJECTOR HIGH SIDE DRIVER BANK 2 2 K58 14BR VT INJECTOR CONTROL NO 6 3 K229 14TN PK ENG INJECTOR HIGH SIDE DRIVER BANK 2 3 K229 14BR LB ENG INJECTOR HIGH SIDE DRIVER BANK 2 4 K38 14BR OR INJECTOR CONTROL NO 5 4 K38 14GY INJECTOR CONTROL NO 5 FUEL PUMP MODULE LT GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z201 12BK OR GROUND 2 K900 18DB DG SENSOR GROUND 3 N4 18DB WT FUEL LE...

Page 1116: ... F983 20PK YL FUSED IGNITION SWITCH OUTPUT RUN ACC 3 4 5 X722 18LB DG MICROPHONE 2 IN 6 7 8 X703 18DG OR LEFT AUDIO OUTPUT 9 X704 18DG YL RIGHT AUDIO OUTPUT 10 X795 18DG HANDS FREE AUDIO OUTPUT COMMON 11 12 13 14 D25 20WT VT PCI BUS 15 X730 18GY YL VOICE RECOGNITION PHONE SWITCH SIGNAL 16 X712 18DG LB MICROPHONE 1 IN 17 X792 18LB DG MICROPHONE IN 18 X735 22NA HANDSFREE MICROPHONE SHIELD 19 20 X793...

Page 1117: ...V CIRCUIT FUNCTION A L43 18WT DB LEFT LOW BEAM OUTPUT B Z345 18BK LB GROUND C L33 18WT LG LEFT HIGH BEAM OUTPUT HEADLAMP RIGHT BLUE 3 WAY CAV CIRCUIT FUNCTION A L44 18WT TN RIGHT LOW BEAM OUTPUT B Z346 18BK LG GROUND C L34 18WT GY RIGHT HIGH BEAM OUTPUT HEATED SEAT CUSHION DRIVER BLUE 4 WAY CAV CIRCUIT FUNCTION 1 P187 18LG BR DRIVER SEAT TEMPERATURE SENSOR INPUT 2 Z939 20BK GROUND 3 P53 20LG OR DR...

Page 1118: ...Z301 20TN BK GROUND 4 P85 20LG WT HEATED SEAT SWITCH SUPPLY 5 P83 20TN WT DRIVER SEAT HIGH HEAT LED DRIVER 6 P7 20LG DG DRIVER SEAT HEATER MUX SWITCH HEATED SEAT SWITCH PASSENGER 6 WAY CAV CIRCUIT FUNCTION 1 P82 20TN DG PASSENGER SEAT LOW HEAT LED DRIVER 2 P301 20LG OR PANEL LAMPS DRIVER 3 Z302 20LG BK GROUND 4 P85 20LG WT HEATED SEAT SWITCH SUPPLY 5 P84 20TN VT PASSENGER SEAT HIGH HEAT LED DRIVER...

Page 1119: ...970 10RD FUSED B 2 F1 16PK WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 3 F951 16PK LG FUSED IGNITION SWITCH OUTPUT RUN START 4 A951 16RD FUSED B 5 G15 20VT TN KEY IN IGNITION SWITCH SENSE 6 Z943 20BK GROUND 7 A921 16RD FUSED B 8 C7 10DB BLOWER MOTOR FEED 9 F982 14PK YL FUSED IGNITION SWITCH OUTPUT RUN ACC 10 F991 10PK YL POWER WINDOWS FUSED IGNITION SWITCH OUTPUT RUN START 11 A981 14RD FUSED B 1...

Page 1120: ... LEFT FRONT 2 A941 18RD FUSED B 3 K32 18DB YL BTSI SOLENOID CONTROL 4 5 6 7 E16 20OR GY PANEL LAMPS DRIVER 8 E14 20OR TN PANEL LAMPS DRIVER 9 E19 20OR BR PANEL LAMPS DIMMER SIGNAL 10 P393 18LG SLT DOOR LOCK DRIVER LEFT DOORS 11 P392 18LG DB SLT DOOR LOCK DRIVER RIGHT DOORS 12 13 Z921 18BK GROUND 14 Z108 20BK LG GROUND 15 M288 18YL GY FUSED B 16 P85 20LG WT SLT HEATED SEAT SWITCH SUPPLY 17 M228 18Y...

Page 1121: ...SWITCH SENSE 2 G77 20VT GY LEFT REAR DOOR AJAR SWITCH SENSE 3 G76 20VT YL RIGHT REAR DOOR AJAR SWITCH SENSE 4 G74 20VT WT PASSENGER DOOR AJAR SWITCH SENSE 5 6 7 K77 18BR WT TRANSFER CASE POSITION SENSOR INPUT 8 L900 20WT YL WIPER TURN BEAM SELECT SWITCH RETURN 9 L115 20WT YL HEADLAMP SWITCH RETURN 10 T917 20YL TN TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX 11 12 13 Z18 20BK LB GROUND 14 X3 20DG VT H...

Page 1122: ...CIRCUIT FUNCTION 1 A960 14RD DIESEL FUSED B 1 A16 16RD BR NGC FUSED B 2 F21 20PK DG FUSED IGNITION SWITCH OUTPUT RUN START 3 4 F500 20DG PK FUSED IGNITION SWITCH OUTPUT RUN 5 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT 6 7 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT 8 A981 14RD FUSED B 9 A114 18GY RD FUSED B 10 L70 18WT GY FUSED PARK LAMP RELAY OUTPUT 11 F951 16PK LG FUSED IGNITION SWITCH OUTPU...

Page 1123: ... 18YL RD FUSED B 14 A951 16RD FUSED B 15 INTEGRATED POWER MODULE C3 16 WAY CAV CIRCUIT FUNCTION 1 W10 20BR WASHER PUMP MOTOR CONTROL 2 L62 18WT YL RIGHT REAR TURN LAMP DRIVER 3 Z117 18BK WT GROUND 4 G31 20VT LG DIESEL AAT SIGNAL 5 Z118 18BK YL GROUND 6 L1 18WT LG BACKUP LAMP FEED 7 8 9 10 D25 20VT PK PCI BUS 11 12 L61 18WT LG LEFT FRONT TURN LAMP DRIVER 13 L53 18DG WT LEFT STOP LAMP FEED 14 L63 18...

Page 1124: ...USED IGNITION SWITCH OUTPUT RUN 5 6 7 8 Z920 12BK GROUND 9 C110 20DB LB DEFOGGER RELAY CONTROL 10 11 C13 20LB OR A C CLUTCH RELAY CONTROL 12 13 14 Z114 20BK LG DIESEL GROUND 14 K173 18BR VT NGC CONDENSER FAN RELAY CONTROL 15 F202 20PK GY DIESEL FUSED IGNITION SWITCH OUTPUT RUN START 15 A16 16RD BR NGC FUSED B 16 T515 20YL DB TRANSMISSION CONTROL RELAY CONTROL 17 C16 16DB GY HEATED MIRROR RELAY OUT...

Page 1125: ...LAY LOW SPEED OUTPUT 3 F983 20PK YL FUSED IGNITION SWITCH OUTPUT RUN ACC 4 A930 18RD FUSED B 5 6 L43 18WT DB LEFT LOW BEAM OUTPUT 7 L34 18WT GY RIGHT HIGH BEAM OUTPUT 8 9 A109 16OR RD GAS FUEL PUMP RELAY OUTPUT 10 11 K51 20BR WT GAS ASD RELAY CONTROL 13 14 15 L33 18WT LG LEFT HIGH BEAM OUTPUT 16 16 A72 18RD OR ADJUSTABLE PEDAL RELAY OUTPUT 17 17 C15 16DB WT REAR WINDOW DEFOGGER RELAY OUTPUT 18 19 ...

Page 1126: ...K42 18DB YL KNOCK SENSOR NO 1 SIGNAL 2 K942 18BR LG KNOCK SENSOR NO 1 RETURN KNOCK SENSOR RIGHT 5 7L 2 WAY CAV CIRCUIT FUNCTION 1 K242 18BR WT KNOCK SENSOR NO 2 SIGNAL 2 K924 18WT BR KNOCK SENSOR NO 2 RETURN LICENSE LAMP LEFT 2 WAY CAV CIRCUIT FUNCTION 1 L7 18WT YL FUSED PARK LAMP RELAY OUTPUT 2 Z367 18BK BR GROUND LICENSE LAMP RIGHT 2 WAY CAV CIRCUIT FUNCTION 1 L7 18WT YL FUSED PARK LAMP RELAY OU...

Page 1127: ... DG SENSOR GROUND 2 F856 18YL PK 5 VOLT SUPPLY 3 T38 18YL BR LINE PRESSURE SENSOR SIGNAL 4 LUMBAR MOTOR DRIVER 2 WAY CAV CIRCUIT FUNCTION 1 P105 12LG LUMBAR MOTOR FORWARD 2 P107 12LG WT LUMBAR MOTOR REARWARD LUMBAR MOTOR PASSENGER 2 WAY CAV CIRCUIT FUNCTION 1 P104 12LG LUMBAR MOTOR FORWARD 2 P106 12LG WT RIGHT SEAT REAR UP 8W 80 78 8W 80 CONNECTOR PIN OUTS DR ...

Page 1128: ...B COMMON DOOR DRIVER 2 C801 20DB OR MODE DOOR 1 DRIVER MODE DOOR ACTUATOR 2 DEFROST TO FLOOR 2 WAY CAV CIRCUIT FUNCTION 1 C34 20DB LB COMMON DOOR DRIVER 2 C29 20DB MODE DOOR 2 DRIVER MULTI FUNCTION SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G194 20VT LG WASH BEAM SELECT SWITCH SIGNAL 2 L900 20WT YL WIPER TURN BEAM SELECT SWITCH RETURN 3 L12 20WT OR TURN LAMPS SWITCH SIGNAL 4 W52 20BR YL INTERMITTEN...

Page 1129: ...AY CAV CIRCUIT FUNCTION 1 T14 18DG BR OUTPUT SPEED SENSOR SIGNAL 2 T13 18DG VT SPEED SENSOR GROUND OUTPUT SPEED SENSOR 47RE 2 WAY CAV CIRCUIT FUNCTION 1 T14 18DG BR OUTPUT SPEED SENSOR SIGNAL 2 T13 18DG VT SPEED SENSOR GROUND OVERHEAD MAP READING LAMP EXCEPT BASE 3 WAY CAV CIRCUIT FUNCTION 1 M288 20YL GY FUSED B 2 Z964 20BK GROUND 3 M22 20YL OR COURTESY LAMPS DRIVER 8W 80 80 8W 80 CONNECTOR PIN OU...

Page 1130: ... CONTROL 2 Z43 18BK LB GROUND 3 K904 18DB DG O2 RETURN DOWN 4 K141 18DB YL O2 1 2 SIGNAL OXYGEN SENSOR 2 1 UPSTREAM NGC 4 WAY CAV CIRCUIT FUNCTION 1 K199 18BR VT O2 2 1 HEATER CONTROL 2 Z934 18BK GROUND 3 K902 18BR DG O2 RETURN UP 4 K43 18DB LG O2 2 1 SIGNAL OXYGEN SENSOR 2 2 DOWNSTREAM NGC 4 WAY CAV CIRCUIT FUNCTION 1 K399 18BR GY O2 2 2 HEATER CONTROL 2 Z992 18BK GROUND 3 K904 18DB DG O2 RETURN ...

Page 1131: ...OR DUAL ZONE 2 WAY CAV CIRCUIT FUNCTION 1 C34 20DB LB COMMON DOOR DRIVER 2 C33 20LB BR PASSENGER BLEND DOOR DRIVER PASSENGER LUMBAR SWITCH 5 WAY CAV CIRCUIT FUNCTION 1 Z939 14BK GROUND 2 P106 12LG WT RIGHT SEAT REAR UP 3 A210 12OR RD FUSED B 4 P104 12LG LUMBAR MOTOR FORWARD 5 Z939 14BK GROUND POWER MIRROR LEFT BLACK 8 WAY CAV CIRCUIT FUNCTION 1 C16 18DB GY HEATED MIRROR RELAY OUTPUT 2 P195 18LG YL...

Page 1132: ...OR UP DRIVER 5 Z216 20BK DB GROUND 6 7 8 POWER OUTLET RED 3 WAY CAV CIRCUIT FUNCTION 1 A205 18RD OR FUSED B 2 3 Z737 18BK LB GROUND POWER OUTLET CONSOLE EXCEPT BASE 3 WAY CAV CIRCUIT FUNCTION 1 A405 18RD DB FUSED B 2 3 Z939 18BK GROUND POWER SEAT MOTOR DRIVER FRONT VERTICAL RED 2 WAY CAV CIRCUIT FUNCTION 1 P21 12LG TN LEFT SEAT FRONT DOWN 2 P19 12LG LB LEFT SEAT FRONT UP DR 8W 80 CONNECTOR PIN OUT...

Page 1133: ...LEFT SEAT REAR UP POWER SEAT MOTOR PASSENGER FRONT VERTICAL 2 WAY CAV CIRCUIT FUNCTION 1 P20 12LG LB RIGHT SEAT FRONT UP 2 P18 12LG DG RIGHT SEAT FRONT DOWN POWER SEAT MOTOR PASSENGER HORIZONTAL 2 WAY CAV CIRCUIT FUNCTION 1 P16 12LG BR RIGHT SEAT HORIZONTAL REARWARD 2 P14 12LG OR RIGHT SEAT HORIZONTAL FORWARD POWER SEAT MOTOR PASSENGER REAR VERTICAL 2 WAY CAV CIRCUIT FUNCTION 1 P12 12LG YL RIGHT S...

Page 1134: ...19 12LG LB LEFT SEAT FRONT UP POWER SEAT SWITCH PASSENGER 12 WAY CAV CIRCUIT FUNCTION A A210 12OR RD FUSED B B Z939 14BK GROUND C P106 12LG WT RIGHT SEAT REAR UP D P10 12LG TN RIGHT SEAT REAR DOWN E P104 12LG LUMBAR MOTOR FORWARD F Z939 14BK GROUND G A210 12OR RD FUSED B H P12 12LG YL RIGHT SEAT REAR UP I P16 12LG BR RIGHT SEAT HORIZONTAL REARWARD J P14 12LG OR RIGHT SEAT HORIZONTAL FORWARD K P18 ...

Page 1135: ...N A Q21 14OR WT LEFT FRONT WINDOW DRIVER DOWN B Q11 14OR LG LEFT FRONT WINDOW DRIVER UP POWER WINDOW MOTOR LEFT REAR 2 WAY CAV CIRCUIT FUNCTION A Q211 14TN LB DRIVER REAR WINDOW DRIVER DOWN B Q111 14TN YL DRIVER REAR WINDOW DRIVER UP POWER WINDOW MOTOR PASSENGER 2 WAY CAV CIRCUIT FUNCTION A Q22 14OR VT RIGHT FRONT WINDOW DRIVER DOWN B Q12 14OR BR RIGHT FRONT WINDOW DRIVER UP 8W 80 86 8W 80 CONNECT...

Page 1136: ...CH FEED POWER WINDOW SWITCH PASSENGER BLUE 6 WAY CAV CIRCUIT FUNCTION 1 Q12 14OR BR RIGHT FRONT WINDOW DRIVER UP 2 Q26 14OR GY MASTER WINDOW SWITCH RIGHT FRONT DOWN 3 4 Q16 14OR TN MASTER WINDOW SWITCH RIGHT FRONT UP 5 Q22 14OR VT RIGHT FRONT WINDOW DRIVER DOWN 6 Q15 14OR LB POWER WINDOW SWITCH FEED POWER WINDOW SWITCH RIGHT REAR BLUE 6 WAY CAV CIRCUIT FUNCTION 1 Q112 14TN YL PASSENGER REAR WINDOW...

Page 1137: ... YL VEHICLE SPEED SIGNAL NO 1 14 15 16 17 18 Z131 16BK DG GROUND 19 20 G6 18VT GY OIL PRESSURE SIGNAL 21 C918 18BK LB A C PRESSURE SIGNAL 22 G31 18VT LG AAT SIGNAL 23 24 25 D20 20WT LG 5 7L SCI RECEIVE PCM 25 D20 17WT LG EXCEPT 5 7L SCI RECEIVE PCM 26 D16 18WT OR EXCEPT 3 7L M T SCI RECEIVE TCM 27 F856 18YL PK 5 VOLT SUPPLY 28 29 A919 20RD FUSED B 30 T751 16YL FUSED IGNITION SWITCH OUTPUT START 31...

Page 1138: ...HEATER CONTROL 18 K99 18BR LG O2 1 1 HEATER CONTROL 19 K20 18BR GY GEN FIELD CONTROL 20 K2 18VT OR ECT SIGNAL 21 K22 18BR OR TP NO 1 SIGNAL 22 K34 18DB LG 5 7L LIGHT DUTY EGR SENSOR SIGNAL 23 K1 18VT BR MAP SIGNAL 24 K942 18BR LG EXCEPT 4 7L KNOCK SENSOR NO 1 RETURN 25 K42 18DB YL EXCEPT 4 7L KNOCK SENSOR NO 1 SIGNAL 26 27 K900 18DB DG SENSOR GROUND 28 K122 18BR DG 5 7L TP NO 2 SIGNAL 28 K961 18BR...

Page 1139: ...RN 17 K400 20BR VT 5 7L APPS NO 2 RETURN 18 V38 20VT OR 5 7L S C SWITCH NO 2 SIGNAL 19 K342 16BR WT ASD RELAY OUTPUT 20 K52 18DB WT EVAP PURGE CONTROL 21 T41 20YL DB TRS T41 SENSE 22 G113 18VT PTO SWITCH SENSE 23 B29 20DG WT BRAKE SWITCH SIGNAL 24 25 K23 20BR WT 5 7L APPS NO 1 SIGNAL 26 27 28 K342 16BR WT ASD RELAY OUTPUT 29 K70 18DB BR EVAP PURGE RETURN 30 K66 18DB WT P S SWITCH SIGNAL 31 32 K25 ...

Page 1140: ...TRANSMISSION CONTROL RELAY CONTROL 19 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPUT 20 T48 18BR YL 4C PRESSURE SWITCH SENSE 21 T29 18YL WT UNDERDRIVE PRESSURE SWITCH SENSE 22 T9 18DG TN OVERDRIVE PRESSURE SWITCH SENSE 23 24 25 26 T4 18DG LB TRS T2 SENSE 27 28 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPUT 29 T50 18YL TN LOW REVERSE PRESSURE SWITCH SENSE 30 T147 18DG YL 2C PRESSURE SWITCH SENSE 31 T...

Page 1141: ... X296 18DG GY RIGHT REAR SPEAKER 21 X206 18DG LG RIGHT REAR SPEAKER 22 Z515 18BK GROUND RADIO C1 INFINITY GRAY 22 WAY CAV CIRCUIT FUNCTION 1 A114 18GY RD FUSED B 2 F983 20PK YL FUSED IGNITION SWITCH OUTPUT RUN ACC 3 E14 20OR TN PANEL LAMPS DRIVER 4 5 6 7 X56 20GY BR RIGHT FRONT SPEAKER 8 X54 20GY RIGHT FRONT SPEAKER 9 X55 20DG BR LEFT FRONT SPEAKER 10 X53 20DG LEFT FRONT SPEAKER 11 Z514 18BK LG GR...

Page 1142: ...ION DOOR ACTUATOR 2 WAY CAV CIRCUIT FUNCTION 1 C34 20DB LB COMMON DOOR DRIVER 2 C32 20DB TN RECIRCULATION DOOR DRIVER REMOTE RADIO SWITCH LEFT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X20 22GY WT RADIO CONTROL MUX 2 Z909 22BK GROUND REMOTE RADIO SWITCH RIGHT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X20 22GY WT RADIO CONTROL MUX 2 Z909 22BK GROUND DR 8W 80 CONNECTOR PIN OUTS 8W 80 93 ...

Page 1143: ...B DG PASSENGER SEAT BELT TENSIONER LINE 1 SEAT HEATER INTERFACE MODULE GREEN 14 WAY CAV CIRCUIT FUNCTION 1 P7 20LG DG DRIVER SEAT HEATER MUX SWITCH 2 P89 20LG OR SEAT HEATER DRIVER 3 P188 18LG VT PASSENGER SEAT TEMPERATURE SENSOR INPUT 4 A930 18RD FUSED B 5 P187 18LG BR DRIVER SEAT TEMPERATURE SENSOR INPUT 6 A930 18RD FUSED B 7 P54 20OR LG PASSENGER SEAT TEMPERATURE 5 VOLT SUPPLY 8 P53 20LG OR DRI...

Page 1144: ... SIDE IMPACT SENSOR 1 GROUND 3 4 SIDE IMPACT SENSOR RIGHT 4 WAY CAV CIRCUIT FUNCTION 1 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 2 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 3 4 SPEAKER CENTER INSTRUMENT PANEL 2 WAY CAV CIRCUIT FUNCTION 1 X299 18GY YL LEFT INSTRUMENT PANEL SPEAKER 2 X208 18GY DG RIGHT INSTRUMENT PANEL SPEAKER SPEAKER LEFT FRONT DOOR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X155 1...

Page 1145: ...R SPEAKER SPEAKER RIGHT FRONT DOOR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X156 18GY LB RIGHT FRONT DOOR SPEAKER 2 3 X154 18GY YL RIGHT FRONT DOOR SPEAKER SPEAKER RIGHT INSTRUMENT PANEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X208 18GY DG RIGHT INSTRUMENT PANEL SPEAKER 2 X298 18GY LG RIGHT INSTRUMENT PANEL SPEAKER SPEAKER RIGHT REAR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X206 18GY LG RIGHT REAR SPEAKER 2 3 X296...

Page 1146: ... RETURN 3 V37 20VT S C SWITCH NO 1 SIGNAL SPEED CONTROL SWITCH LEFT EXCEPT ETC 2 WAY CAV CIRCUIT FUNCTION A V37 20VT S C SWITCH NO 1 SIGNAL B V937 20VT BR S C SWITCH RETURN SPEED CONTROL SWITCH RIGHT ETC 3 WAY CAV CIRCUIT FUNCTION 1 V38 20VT OR S C SWITCH NO 2 SIGNAL 2 V937 20VT BR S C SWITCH RETURN 3 V37 20VT S C SWITCH NO 1 SIGNAL SPEED CONTROL SWITCH RIGHT EXCEPT ETC 2 WAY CAV CIRCUIT FUNCTION ...

Page 1147: ...PUT 1 L70 18WT YL FUSED PARK LAMP RELAY OUTPUT 2 3 Z928 18BK GROUND 4 L54 18DG WT RIGHT STOP LAMP FEED 4 L54 18WT LG RIGHT STOP LAMP FEED 5 L62 18WT YL RIGHT REAR TURN LAMP DRIVER 5 L62 18WT DG RIGHT REAR TURN LAMP DRIVER 6 L1 18WT LG BACKUP LAMP FEED TAILGATE LAMP 2 WAY CAV CIRCUIT FUNCTION 1 L7 18WT YL FUSED PARK LAMP RELAY OUTPUT 2 Z942 20BK GROUND THROTTLE POSITION SENSOR 3 7L 3 WAY CAV CIRCUI...

Page 1148: ...T FUNCTION 1 Z999 14BK GROUND 2 L678 18BR PARK LAMP RELAY OUTPUT 3 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT 4 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT TRAILER TOW CONNECTOR ADD ON 10 WAY CAV CIRCUIT FUNCTION 1 2 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT 3 L1 18WT LG BACKUP LAMP FEED 4 A100 14RD VT FUSED B 5 L678 18BR PARK LAMP RELAY OUTPUT 6 7 B40 14DG TRAILER TOW BRAKE B 8 Z999 14BK ...

Page 1149: ...20VT BR NEUTRAL INDICATOR A13 G2 20BR WT IGNITION SWITCH SENSE A14 D200 20WT LG MODE SENSOR D A15 A16 Z905 20BK GROUND TRANSFER CASE CONTROL MODULE C2 ELECTRIC 4x4 16 WAY CAV CIRCUIT FUNCTION B1 D202 20WT VT MODE SENSOR B B2 D201 20WT DG MODE SENSOR A B3 B4 B5 B6 T41 20YL DB TRS T41 SENSE B7 B8 T313 20YL LG 5 VOLT MODE SENSOR SUPPLY B9 B10 D203 20WT BR MODE SENSOR C B11 B12 B13 B14 B15 B16 T322 20...

Page 1150: ...DG MODE SENSOR A 6 D203 20WT BR MODE SENSOR C TRANSFER CASE SELECTOR SWITCH 12 WAY CAV CIRCUIT FUNCTION 1 T322 20DG GY 5 VOLT SELECTOR SWITCH SUPPLY 2 G2 20BR WT IGNITION SWITCH SENSE 3 4 G95 20VT BR NEUTRAL INDICATOR 5 K977 20BR WT MODE SELECT 6 E11 20OR DB PANEL LAMPS DRIVER 7 F21 20PK DG FUSED IGNITION SWITCH OUTPUT RUN START 8 G92 20VT OR 4WD LOW INDICATOR 9 G91 20VT WT 4WD HIGH INDICATOR 10 1...

Page 1151: ...PERATURE SENSOR SIGNAL TRANSMISSION SOLENOID TRS ASSEMBLY NGC 23 WAY CAV CIRCUIT FUNCTION 1 L10 18WT GY FUSED IGNITION SWITCH OUTPUT RUN 2 T20 18DG WT L R SOLENOID CONTROL 3 4 T41 20YL DB TRS T41 SENSE 5 T42 18DG YL TRS T42 SENSE 6 L1 18WT LG BACKUP LAMP FEED 7 T60 18YL GY OVERDRIVE SOLENOID CONTROL 8 T3 18DG DB TRS T3 SENSE 9 T1 18DG LB TRS T1 SENSE 10 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPU...

Page 1152: ...56 18YL PK 5 VOLT SUPPLY 6 F504 20GY PK FUSED IGNITION SWITCH OUTPUT RUN WASHER FLUID LEVEL SWITCH 2 WAY CAV CIRCUIT FUNCTION 1 Z932 20BK GROUND 2 W1 20BR TN WASHER FLUID SWITCH SENSE WASHER PUMP MOTOR FRONT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z945 20BK GROUND 2 W10 20BR WASHER PUMP MOTOR CONTROL WATER IN FUEL SENSOR 2 WAY CAV CIRCUIT FUNCTION A K914 18RD WT A T SENSOR GROUND A K914 18BR WT M T SEN...

Page 1153: ...OR SIGNAL 2 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY WHEEL SPEED SENSOR RIGHT FRONT 2 WAY CAV CIRCUIT FUNCTION 1 B6 20DG WT RIGHT FRONT WHEEL SPEED SENSOR 2 B7 20DG VT RIGHT FRONT WHEEL SPEED SENSOR WIPER MOTOR 4 WAY CAV CIRCUIT FUNCTION A W7 20BR GY WIPER PARK SWITCH SENSE B Z103 18BK WT GROUND C W3 16BR WT WIPER RELAY LOW SPEED OUTPUT D W4 16BR OR WIPER RELAY HIGH SPEED OUTPUT 8W ...

Page 1154: ... Center of Instrument Panel 34 35 Accelerator Pedal Position Sensor Under Battery Tray 22 27 Adjustable Pedal Motor WT Left of Instrument Panel 31 Adjustable Pedal Switch BL Left of Instrument Panel 35 38 Airbag Control Module C1 YL Lower Center of Instrument Panel 35 36 Airbag Control Module C2 YL Lower Center of Instrument Panel 44 46 Airbag Control Module Left Side Impact YL Left B Pillar 44 46...

Page 1155: ... GY Under Instrument Panel 39 C201 WT Near Left Instrument Panel Speaker 35 38 C202 BK Left Rear Side of Engine Compartment 27 C206 BK Right Instrument Panel 35 39 48 C207 Rear Engine Compartment 22 C216 BK Middle Left Frame 22 25 50 C217 BK Middle Left Frame 22 25 50 C218 WT Left Side of Instrument Panel 22 24 40 44 46 C219 GY Left Side of Instrument Panel 22 24 31 35 38 40 44 C220 WT Left Side o...

Page 1156: ...g Column N S Clutch Interlock Brake Switch BK At Clutch Pedal 22 24 Coil On Plug No 1 BK Left Top Side of Intake Manifold 6 Coil On Plug No 2 BK Right Top Side of Intake Manifold 3 Coil On Plug No 3 BK Left Top Side of Intake Manifold 6 Coil On Plug No 4 BK Right Top Side of Intake Manifold 3 Coil On Plug No 5 BK Left Top Side of Intake Manifold 5 6 Coil On Plug No 6 BK Right Top Side of Intake Ma...

Page 1157: ...e 9 Electric Brake Provision Rear of Engine 22 24 Engine Control Module C1 BK Left Engine 10 Engine Control Module C2 BK Left Engine 10 Engine Coolant Temperature Sensor BK Near Generator 6 Engine Oil Pressure Switch BK Lower Left Side of Engine 6 9 Evap Purge Solenoid BK Left Fender Side Shield 23 25 Evaporator Temperature Sensor BK Right Side of HVAC N S Fog Lamp Left WT Left Front Facia N S Fog...

Page 1158: ...ent Cluster 35 Instrument Cluster C3 WT Rear of Instrument Cluster 35 Intake Air Heater Relay Right Engine Compartment 2 Intake Air Temperature Manifold Absolute Pressure Sensor Diesel BK Left rear Engine N S Intake Air Temperature Sensor BK On Intake Manifold 5 Integrated Power Module C1 BK Left Front Fender 26 28 Integrated Power Module C2 WT Left Front Fender 26 28 Integrated Power Module C3 GR...

Page 1159: ...er Mirror Right BK At Mirror 42 Power Outlet RD Center of Instrument Panel 35 Power Outlet Console BK Center of Instrument Panel N S Power Seat Motor Driver Front Vertical RD At Driver Seat N S Power Seat Motor Driver Horizontal BK At Driver Seat N S Power Seat Motor Driver Rear Vertical BK At Driver Seat N S Power Seat Switch Driver BK At Driver Seat N S Power Seat Switch Passenger BK At Passenge...

Page 1160: ...rker Left Rear Dual Wheels BK Rear of Left Rear Fender 52 Side Marker Right Front Dual Wheels BK Front of Right Rear Fender 52 Side Marker Right Rear Dual Wheels BK Rear of Right Rear Fender 52 Speaker Center Instrument Panel WT Center of Instrument Panel 35 36 Speaker Left Front Door WT In Left Front Door 41 Speaker Left Instrument Panel BK Left Side of Instrument Panel 35 38 Speaker Left Rear St...

Page 1161: ... of Instrument Panel 11 12 33 35 36 Transfer Case Shift Motor BK Left Rear of Transmission 13 14 20 Transmission Range Sensor BK Left side of Transmission 11 14 Transmission Solenoid Assembly BK Left Side of Transmission 14 11 Transmission Solenoid TRS Assembly 3 7L 4 7L BK Left Side of Transmission 15 16 Underhood Lamp BK Underside of Hood 29 Vacuum Pump Diesel Right Rear Engine Compartment 21 Vi...

Page 1162: ...er of Instrument Panel 35 36 G204 Right Side of Instrument Panel 35 G301 Left Front Body 40 44 46 G302 Left Front Body 40 44 46 SPLICES SPLICE NUMBER LOCATION FIG S101 Left Front Fender 21 S102 Left Front Fender 23 S103 Left Rear of Engine Compartment 22 25 S104 Front Facia 35 S105 Front Facia N S S106 Left Rear of Engine Compartment 22 S107 Left Front Fender 23 S108 Headlamp and Dash Left Side 22...

Page 1163: ... of Transmission 3 S149 Left Rear of Engine 6 S150 Top Center of Engine 3 9 S153 Rear Engine Compartment N S S154 Left Top Engine N S S155 Left Rear Engine Compartment near T O for Fuel Control Actuator 9 S157 Near T O for Camshaft Position Sensor N S S158 Near T O for C114 10 S159 Near T O for Engine Control Module N S S160 Top Left Engine 10 S162 Left Side Engine N S S163 Right Side Engine N S S...

Page 1164: ...of Instrument Panel N S S221 Center of Instrument Panel 35 39 S222 Center of Instrument Panel 35 S224 Right Side of HVAC N S S225 Center of Instrument Panel 35 S226 Right Side of HVAC N S S228 At Steering Column N S S230 Right Instrument Panel 35 S231 Left Instrument Panel 38 S232 Right Engine Compartment 23 S240 Steering Column 31 38 S241 Center Instrument Panel 35 36 S243 Right Engine Compartmen...

Page 1165: ... Chassis 51 S326 Left Rear Chassis N S S327 Left Rear Chassis 51 S328 At Driver Seat N S S329 At Driver Seat N S S330 Center Rear of Chassis 51 S331 Center Rear of Chassis 51 S332 Left Front Door 41 S333 Left Front Body 40 44 46 S334 Left Front Body 40 44 46 S335 Left Front Body N S S336 Passenger Seat N S S337 Passenger Seat N S S340 Left Rear Fender 52 S341 Right Rear Fender 52 S342 Left Rear Fe...

Page 1166: ...Fig 1 RIGHT SIDE FRONT LIGHTING Fig 2 LEFT FRONT BUMPER AND RIGHT BATTERY TRAY DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 13 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1167: ...Fig 3 RIGHT SIDE ENGINE 4 7L 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1168: ...Fig 4 RIGHT REAR ENGINE COMPARTMENT DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1169: ...Fig 5 RIGHT TOP ENGINE 3 7L 4 7L 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1170: ...Fig 6 LEFT SIDE ENGINE 3 7L 4 7L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1171: ...Fig 7 LEFT SIDE ENGINE 5 7L 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1172: ...Fig 8 RIGHT REAR ENGINE COMPARTMENT 5 7L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1173: ...Fig 9 RIGHT SIDE ENGINE 5 7L 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1174: ...Fig 10 ENGINE DIESEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1175: ...Fig 11 AUTOMATIC TRANSMISSION DIESEL 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1176: ...Fig 12 MANUAL TRANSMISSION DIESEL Fig 13 FRONT MANUAL TRANSMISSION DIESEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1177: ...Fig 14 AUTOMATIC TRANSMISSION DIESEL ETC 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1178: ...Fig 15 TRANSMISSION 45RFE 4X4 3 7L 4 7L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1179: ...Fig 16 1LEFT TRANSMISSION 45RFE 5 7L 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1180: ...Fig 17 MANUAL TRANSMISSION 4X4 3 7L 4 7L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1181: ...Fig 18 RIGHT TRANSMISSION 5 7L 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1182: ...Fig 19 MANUAL TRANSMISSION 5 7L DIESEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1183: ...Fig 20 LEFT FRONT TRANSFER CASE 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1184: ...Fig 21 RIGHT SIDE ENGINE COMPARTMENT DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1185: ...Fig 22 LEFT REAR ENGINE COMPARTMENT 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1186: ...Fig 23 LEFT ENGINE COMPARTMENT DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1187: ...Fig 24 ENGINE COMPARTMENT 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1188: ...Fig 25 LEFT SIDE ENGINE COMPARTMENT DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1189: ...Fig 26 LEFT FRONT ENGINE COMPARTMENT 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1190: ...Fig 27 27 LEFT FRONT FACIA AND BATTERY TRAY DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1191: ...Fig 28 INTEGRATED POWER MODULE AND FAN 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1192: ...080022dc80d6017a 1 9 tif Fig 29 LEFT SIDE ENGINE COMPARTMENT AND HOOD DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1193: ...Fig 30 STEERING COLUMN 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1194: ...Fig 31 LEFT STEERING COLUMN DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1195: ...Fig 32 INSTRUMENT PANEL 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1196: ...Fig 33 REAR INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1197: ...Fig 34 CENTER INSTRUMENT PANEL 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1198: ...Fig 35 INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 45 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1199: ...Fig 36 CENTER INSTRUMENT PANEL 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1200: ...Fig 37 RADIO ANTENNA DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 47 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1201: ...Fig 38 LEFT INSTRUMENT PANEL 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1202: ...Fig 39 RIGHT INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 49 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1203: ...Fig 40 STANDARD CAB FRONT BODY 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1204: ...Fig 41 LEFT FRONT DOOR PREMIUM DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 51 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1205: ...Fig 42 RIGHT FRONT DOOR PREMIUM 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1206: ...Fig 43 LEFT REAR DOOR RIGHT SIDE SIMILAR DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 53 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1207: ...Fig 44 STANDARD CAB LEFT SIDE BODY 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1208: ...Fig 45 STANDARD CAB RIGHT SIDE BODY DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 55 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1209: ...Fig 46 QUAD CAB LEFT SIDE BODY 8W 91 56 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1210: ...Fig 47 QUAD CAB RIGHT SIDE BODY Fig 48 ROOF DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 57 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1211: ...Fig 49 REAR BODY 8W 91 58 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1212: ...Fig 50 CHASSIS DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 59 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1213: ...Fig 51 REAR CHASSIS 8W 91 60 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1214: ...Fig 52 LEFT REAR FENDER RIGHT SIDE SIMILAR DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 61 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1215: ...Fig 53 REAR BUMPER 8W 91 62 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1216: ...ates various types of circuit control and protection fea tures including Automatic resetting circuit breakers Blade type fuses Cartridge fuses Relays Following are general descriptions of the major components in the power distribution system See the owner s manual in the vehicle glove box for more information on the features and use of all of the power distribution system components OPERATION The ...

Page 1217: ... to expand Once the spring clips expand far enough to release the heating element the spring loaded housing forces the knob and heat ing element to pop back outward to their relaxed position When the cigar lighter knob and element are pulled out of the outlet shell the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumferenc...

Page 1218: ...placeable components of the integrated power module assembly are broken down into the following components the Power Distribution Center PDC the integrated power module cover the Front Control Module FCM and the Integrated Power Module Assembly which includes the power distribution cen ter the cover and FCM Refer to the Front Con trol Module in the Electronic Control Module section of this service...

Page 1219: ... a bench and remove the four front control module retaining screws 8 Disconnect the front control module by pulling it straight off the integrated power module LLATION INSTALLATION 1 Connect the front control module by pushing it straight on the integrated power module electrical receptacle 2 Install the four front control module retaining screws Torque to 30 in lbs 5 NOTE Integrated power module ...

Page 1220: ...sages and con trols power to some of the vehicles electrical systems by completing the circuit to ground low side driver or completing the circuit to 12 volt power high side driver The following functions are Controlled by the Front Control Module Headlamp Power with Voltage Regulation Windshield Wiper ON OFF Relay Actuation Windshield Wiper HI LO Relay Actuation Windshield Washer Pump Motor Fog L...

Page 1221: ...ower Module cover to ensure proper fuse identification The IOD fuse is a 20 ampere mini blade type fuse located in fuse cavity 51 Fig 6 The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its Integrated Power Module cavity and as a fuse holder that conveniently stores the fuse in the same Inte grate...

Page 1222: ...eceptacle unit and the accessory power outlet protective cap are available for service The power outlet receptacle cannot be repaired and if faulty or damaged it must be replaced OPERATION The power outlet base or receptacle shell is con nected to ground and an insulated contact in the bottom of the shell is connected to battery current The power outlet receives battery voltage from a fuse in the ...

Page 1223: ...e harness connector from the cigar lighter or power outlet receptacle base connector receptacle 8 Remove the cigar lighter or power outlet mount from the instrument panel INSTALLATION 1 Reconnect the instrument panel wire harness connector to the cigar lighter or power outlet recep tacle base connector receptacle 2 Install the cigar lighter or power outlet mount into the instrument panel 3 Align t...

Page 1224: ...OVAL 10 INSTALLATION 11 SPECIFICATIONS SPECIFICATIONS 3 7L ENGINE 12 TORQUE 16 SPECIAL TOOLS 17 AIR CLEANER ELEMENT REMOVAL 21 INSTALLATION 21 CYLINDER HEAD LEFT DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 21 REMOVAL 22 INSTALLATION 24 CAMSHAFT S DESCRIPTION 25 REMOVAL 25 INSTALLATION 27 CYLINDER HEAD COVER S DESCRIPTION 27 REMOVAL 28 INSTALLATION 28 INTAKE EXHAUST VALVES SEATS DESCRIPTION 28 STAND...

Page 1225: ...CATION DESCRIPTION 61 OPERATION 61 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE OIL LEAK 64 DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 65 DIAGNOSIS AND TESTING REAR SEAL AREA LEAKS 65 OIL PAN DESCRIPTION 66 REMOVAL 66 CLEANING 66 INSPECTION 66 INSTALLATION 66 OIL PRESSURE SENSOR SWITCH DESCRIPTION 67 OPERATION 67 REMOVAL 67 INSTALLATION 67 OIL PUMP REMOVAL 67 DISASSEMBLY 68 INSPECTIO...

Page 1226: ...ck the second component is the bed plate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings The cylinders are numbered from front to rear with the left bank being numbered 1 3 and 5 and the right bank being numbered 2 4 and 6 The firing order is 1 6 5 4 3 2 The engine serial number is located at the right front side of the engine block ...

Page 1227: ...ure Diagnosis Refer to 9 ENGINE CYLINDER HEAD DIAGNO SIS AND TESTING Intake Manifold Leakage Diagnosis Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAGNOSIS PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1 Weak battery 1 Charge or replace as necessary 2 Corroded or loose battery connections 2 Clean and tighten battery connec...

Page 1228: ...xhaust system 7 Inspect and replace as necessary 8 Faulty coil 8 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 9 Incorrect cam timing 9 Refer to Engine TIming in this section 1 ENGINE MISSES ON ACCELERATION 1 Spark plugs dirty or incorrectly gapped 1 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Dirt in fuel system 2 Clean fuel system 3 Burned warped or pitted valves ...

Page 1229: ...OISE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or diluted oil 3 Change oil and filter 4 Excessive bearing clearance 4 Replace as necessary 5 Connecting rod journal out of round 5 Service or replace crankshaft 6 Misaligned connecting rods 6 Replace bent connecting rods M...

Page 1230: ...INE BLOCK CRANKSHAFT OIL SEAL FRONT REMOVAL 6 Scratched or damaged vibration damper hub 6 Polish or replace damper OIL PRESSURE DROP 1 Low oil level 1 Check and correct oil level 2 Faulty oil pressure sending unit 2 Replace sending unit Refer to 9 ENGINE LUBRICATION OIL PRESSURE SENSOR SWITCH REMOVAL 3 Low oil pressure 3 Check oil pump and bearing clearance 4 Clogged oil filter 4 Replace oil filte...

Page 1231: ...or the remaining cylin ders 7 Refer to 9 ENGINE SPECIFICATIONS for the correct engine compression pressures DIAGNOSIS AND TESTING CYLINDER COMBUSTION PRESSURE LEAKAGE The combustion pressure leakage test provides an accurate means for determining engine condition Combustion pressure leakage testing will detect Exhaust and intake valve leaks improper seat ing Leaks between adjacent cylinders or int...

Page 1232: ...al unless specified Bead size continuity and location are of great importance Too thin a bead can result in leakage while too much can result in spill over which can break off and obstruct fluid feed lines A continuous bead of the proper width is essential to obtain a leak free gasket There are numerous types of form in place gasket materials that are used in the engine area Mopart Engine RTV GEN ...

Page 1233: ...n evenly over the sealing surfaces Material in an aerosol can should be used on engines with multi layer steel gaskets STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components and multi layer steel cylinder head gaskets Never use the following to clean gasket surfaces Meta...

Page 1234: ...and secure out of way NOTE It is necessary to disconnect the front prop shaft for access to the starter and left side exhaust flange 35 Remove the starter 36 Remove the ground straps from the left and right side of the block 37 Disconnect the right and left exhaust pipes at the manifolds and from the crossover and remove from the vehicle NOTE The exhaust clamps at the manifolds cannot be reused Ne...

Page 1235: ... power steering pump 33 Install the generator 34 Install the A C compressor 35 Install the drive belt 36 Install the fan shroud with the viscous fan assembly 37 Install the radiator core support bracket 38 Install the air cleaner assembly 39 Refill the engine cooling system 40 Recharge the air conditioning 41 Install the hood 42 Check and fill engine oil 43 Connect the battery negative cable 44 St...

Page 1236: ...ntrol Steel Rails 0 25 0 76 mm 0 0099 0 30 in Side Clearance Top Compression Ring 051 094 mm 0 0020 0 0037 in Second Compression Ring 0 040 0 080 mm 0 0016 0 0031 in Oil Ring Steel Ring 019 229 mm 0007 0091 in DESCRIPTION SPECIFICATION Metric Standard Ring Width Top Compression Ring 1 472 1 490 mm 0 057 0 058 in Second Compression Ring 1 472 1 490 mm 0 057 0 058 in Oil Ring Steel Rails 0 445 0 470...

Page 1237: ...75 200 mm 0 003 0 0079 in End Play MAX 200 mm 0 0079 in VALVE TIMING DESCRIPTION SPECIFICATION Intake Opens ATDC 0 0 Closes ATDC 236 Duration 236 Exhaust Opens BTDC 233 Closes ATDC 17 Duration 250 Valve Overlap 17 VALVES DESCRIPTION SPECIFICATION Metric Standard Face Angle 45 45 5 Head Diameter Intake 48 52 48 78 mm 1 9103 1 9205 in Exhaust 36 87 37 13 mm 1 4516 1 4618 in Length Overall Intake 113...

Page 1238: ...Intake 40 12 mm 1 579 in Exhaust w damper 40 12 mm 1 579 in CYLINDER HEAD DESCRIPTION SPECIFICATION Metric Standard Gasket Thickness Compressed 0 7 mm 0 0276 in Valve Seat Angle 44 5 45 0 Valve Seat Runout MAX 0 051 mm 0 002 in Valve Seat Width Intake 1 75 2 36 mm 0 0698 0 0928 in Exhaust 1 71 2 32 mm 0 0673 0 0911 in Guide Bore Diameter Std 6 975 7 00 mm 0 2747 0 2756 in Cylinder Head Warpage Fla...

Page 1239: ...Bolts 25 18 Exhaust Manifold Heat Shield Nuts 8 72 Then loosen 45 DESCRIPTION N m Ft Lbs In Lbs Flexplate Bolts 95 70 Engine Mount Bracket to Block Bolts 61 45 Rear Mount to Transmission Bolts 46 34 Generator Mounting Bolts M10 Bolts 54 40 M8 Bolts 28 250 Intake Manifold Bolts 12 105 Refer to Procedure for Tightening Sequence Oil Pan Bolts 15 130 Oil Pan Drain Plug 34 25 Oil Pump Bolts 28 250 Oil ...

Page 1240: ...pter Pins 8346 Front Crankshaft Seal Remover 8511 Front Crankshaft Seal Installer 8348 Handle C 4171 Rear Crankshaft Seal Installer 8349 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 DR ENGINE 3 7L 9 17 ENGINE 3 7L Continued ...

Page 1241: ... 8512 Puller 1026 Crankshaft Damper Removal Insert 8513 Chain Tensioner Wedge 8379 Chain Tensioner Pins 8514 VALVE SPRING COMPRESSOR 8426 ENGINE LIFTING FIXTURE 8427 CAMSHAFT HOLDER 8428 9 18 ENGINE 3 7L DR ENGINE 3 7L Continued ...

Page 1242: ...Rocker Arm 8516 Idler Shaft Remover 8517 Valve Spring Compressor Adapters 8519 INSTALLER REMOVER COUNTER BALANCE SHAFT 8641 Valve Spring Tester C 647 Dial Indicator C 3339 Valve Spring Compressor C 3422 B DR ENGINE 3 7L 9 19 ENGINE 3 7L Continued ...

Page 1243: ...Bore Size Indicator C 119 Oil Pressure Gauge C 3292 Piston Ring Compressor C 385 Pressure Tester Kit 7700 Bloc Chek Kit C 3685 A ENGINE SUPPORT FIXTURE 8534 9 20 ENGINE 3 7L DR ENGINE 3 7L Continued ...

Page 1244: ...air duct to air cleaner cover and tighten hose clamp to 3 N m 30 in lbs torque 5 If any other hose clamps were removed from air intake system tighten them to 3 4 N m 30 in lbs torque 6 If any bolts were removed from air resonator housing or air intake tubing tighten them to 4 5 N m 40 in lbs torque CYLINDER HEAD LEFT DIAGNOSIS AND TESTING CYLINDER HEAD GASKET A cylinder head gasket leak can be loc...

Page 1245: ...ETHOD Combustion leaks into the cooling system can also be checked by using Bloc Chek Kit C 3685 A or equivalent Perform test following the procedures supplied with the tool kit REMOVAL 1 Disconnect the negative cable from the battery 2 Raise the vehicle on a hoist 3 Disconnect the exhaust pipe at the left side exhaust manifold 4 Drain the engine coolant Refer to 7 COOL ING STANDARD PROCEDURE 5 Lo...

Page 1246: ...t drive gear 18 Remove the left side secondary chain ten sioner Refer to Timing Chain and Sprockets 19 Remove the cylinder head access plug Fig 8 Fig 6 CAMSHAFT SPROCKET V6 MARKS 1 TDC Exhaust stroke 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD Fig 7 Using Special Tool 8429 1 SPECIAL TOOL 8429 2 CAMSHAFT CHAIN 3 CRANKSHAFT TIMING GEAR Fig 8 Cylinder Head Access Plugs 1 RIGHT CYLINDER HEAD ACCESS PLU...

Page 1247: ... be replaced Fig 9 CAUTION When cleaning cylinder head and cylin der block surfaces DO NOT use a metal scraper because the surfaces could be cut or ground Use only a wooden or plastic scraper 1 Clean the cylinder head and cylinder block mating surfaces Fig 10 2 Position the new cylinder head gasket on the locating dowels CAUTION When installing cylinder head use care not damage the tensioner arm o...

Page 1248: ...AN INSTALLATION 17 Install the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 18 Install the master cylinder and booster assem bly Refer to 5 BRAKES HYDRAULIC MECHANI CAL POWER BRAKE BOOSTER INSTALLATION 19 Install the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 20 Refill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE ...

Page 1249: ... chain wedge between the timing chain strands tap the tool to securely wedge the timing chain against the ten sioner arm and guide Fig 12 6 Hold the camshaft with Special Tool 8428 Cam shaft Wrench while removing the camshaft sprocket bolt and sprocket Fig 13 7 Using Special Tool 8428 Camshaft Wrench gently allow the camshaft to rotate 5 clockwise until the camshaft is in the neutral position no v...

Page 1250: ...aligning the V6 mark between the two marked chain links Two links marked during removal 7 Using Special Tool 8428 Camshaft Wrench rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the sprocket onto the camshaft CAUTION Remove excess oil from camshaft sprocket bolt Failure to do so can cause bolt over torque resulting in bolt failure 8 R...

Page 1251: ...ionary lash adjuster All valves use three bead lock keepers to retain the springs and promote valve rotation STANDARD PROCEDURE REFACING NOTE Valve seats that are worn or burned can be reworked provided that correct angle and seat width are maintained Otherwise the cylinder head must be replaced NOTE When refacing valves and valve seats it is important that the correct size valve guide pilot be us...

Page 1252: ...g to loosen the spring retainers locks enough to be removed 4 Remove the two spring retainer lock halves NOTE the valve spring is under tension use care when releasing the valve spring compressor 5 Remove the valve spring compressor 6 Remove the spring retainer and the spring NOTE Check for sharp edges on the keeper grooves Remove any burrs from the valve stem before removing the valve from the cy...

Page 1253: ...e sure the seal is fully seated and that the garter spring at the top of the seal is intact 3 Install the spring and the spring retainer Fig 20 4 Using the valve spring compressor compress the spring and install the two valve spring retainer halves 5 Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated 6 lubricate the camshaft jo...

Page 1254: ...ard on the valve spring remove rocker arm Fig 22 INSTALLATION CAUTION Make sure the rocker arms are installed with the concave pocket over the lash adjusters Failure to do so may cause severe damage to the rocker arms and or lash adjusters NOTE Coat the rocker arms with clean engine oil prior to installation 1 For rocker arm installation on cylinders No 4 Rotate the crankshaft until cylinder No 1 ...

Page 1255: ...E The valve stem seals are common between intake and exhaust INSTALLATION NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 1 Apply shop air to the cylinder to hold the valves in place while the spring is installed NOTE The valve stem seals are common between intake and exhaust 2 Install the valve stem seal NOTE The valve...

Page 1256: ... VIBRATION DAMPER REMOVAL 14 Remove the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 15 Lock the secondary timing chains to the idler sprocket using Special Tool 8429 Timing Chain Hold ing Fixture NOTE Mark the secondary timing chain prior to removal to aid in installation 16 Mark the secondary timing chain one link on each side of the V6 mark on the camshaft...

Page 1257: ... to be added to them before install ing Failure to do so may cause leaks 4 Lubricate the cylinder head bolt threads with clean engine oil and install the eight M10 bolts 5 Coat the four M8 cylinder head bolts with Mopar Lock and Seal Adhesive then install the bolts NOTE The cylinder head bolts are tightened using an angle torque procedure however the bolts are not a torque to yield design 6 Tighte...

Page 1258: ...onto the right exhaust manifold 23 Lower the vehicle 24 Reconnect battery negative cable 25 Start the engine and check for leaks CAMSHAFT S DESCRIPTION The camshafts consist of powdered metal steel lobes which are sinter bonded to a steel tube Four bearing journals are machined into the camshaft Camshaft end play is controlled by two thrust walls that border the nose piece journal Engine oil enter...

Page 1259: ... the stamped numbers on the caps are in numerical order 1 thru 4 from the front to the rear of the engine All caps should be installed so that the stamped arrows on the caps point toward the front of the engine 4 Working in 1 2 turn increments tighten the bearing cap retaining bolts starting with the middle cap working outward Fig 27 5 Torque the camshaft bearing cap retaining bolts to 11 N m 100 ...

Page 1260: ...ec tors and harness retaining clips 5 Install the oil fill tube 6 Install PCV hose 7 Install heater hoses 8 Install air conditioning compressor retaining bolts 9 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 10 Fill Cooling system Refer to 7 COOLING STANDARD PROCEDURE 11 Install air cleaner assembly resonator assem bly and air inlet hose 12 Connect batt...

Page 1261: ... common between intake and exhaust INSTALLATION NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 1 Apply shop air to the cylinder to hold the valves in place while the spring is installed NOTE The valve stem seals are common between intake and exhaust 2 Install the valve stem seal NOTE The valve springs are NOT common be...

Page 1262: ...wn strokes increase the cross hatch angle 5 After honing it is necessary that the block be cleaned to remove all traces of abrasive Use a brush to wash parts with a solution of hot water and deter gent Dry parts thoroughly Use a clean white lint free cloth to check that the bore is clean Oil the bores after cleaning to prevent rusting CLEANING Thoroughly clean the oil pan and engine block gas ket ...

Page 1263: ... cross drilled to improve rod bearing lubrication The No 6 counterweight has provisions for crankshaft position sensor target wheel mounting The select fit main bearing markings are located on the rear side of the target wheel Fig 31 The crankshaft oil seals are one piece design The front oil seal is retained in the timing chain cover and the rear seal is pressed in to a bore formed by the cylinde...

Page 1264: ...the piston and rod assemblies If the bedplate or the cylinder block main bearing bores show damage the engine must be replaced 1 If required remove the main bearing halves from the cylinder block and bedplate 2 Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores Remove all oil and sealant residue 3 Inspect the bedplate main bearing bores for cracks scoring or se...

Page 1265: ...lock mating surface must be coated with MoparT Engine RTV sealant prior to installation Failure to do so will cause severe oil leaks NOTE Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other con taminants Contaminants on the sealing surfaces may cause main bearing distortion and or oil leaks 5 Apply a 2 5mm 0 100 inch bead of Mopart Engine RTV sealant ...

Page 1266: ...Tighten bolts 1A 1J to 54 N m 40 ft lbs Tighten bolts 1 8 to 7 N m 5 ft lbs Turn bolts 1 8 an additional 90 Tighten bolts A E 27 N m 20 ft lbs 8 Measure crankshaft end play 9 Install the connecting rods and measure side clear ance Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECTING ROD STANDARD PROCEDURE 10 Install oil pump Refer to 9 ENGINE LUBRI CATION OIL PUMP INSTALLATION 11 Install the engine Re...

Page 1267: ...ns Inspect the upper insert locking tabs for damage Replace all damaged or worn bearing inserts MAIN BEARING JOURNAL DIAMETER CRANKSHAFT REMOVED Remove the crankshaft from the cylinder block Re fer to 9 ENGINE ENGINE BLOCK CRANKSHAFT REMOVAL Clean the oil off the main bearing journal Determine the maximum diameter of the journal with a micrometer Measure at two locations 90 apart at each end of th...

Page 1268: ...haft 9U9 0958 0960 in Lower Bearing Main 919 and 949 919 2 441 2 447 mm Use with crankshaft 9R S9 0961 0963 in 929 2 435 2 441 mm Use with crankshaft 9T U9 0958 0962 in Crankshaft Marking JOURNAL SIZE SIZE mm in Lower Main Bearing 929 and 939 939 2 429 2 435 mm Use with crankshaft 9R S9 0956 0958 in 949 2 423 2 429 mm Use with crankshaft 9T U9 0953 0956 in Bearing Clearances Main 91 49 Crankshaft ...

Page 1269: ...EMOVAL 9 Remove crankshaft damper bolt 10 Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller Fig 37 11 Using Special Tool 8511 remove crankshaft front seal Fig 38 INSTALLATION CAUTION To prevent severe damage to the Crank shaft Damper or Special Tool 8512 thoroughly clean the damper bore and the crankshaft nose before installing Damper 1 Using Special Tool 8348 and 8512 instal...

Page 1270: ...moval NOTE The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal Continue to tighten the removal tool into the seal until the tool can not be turned farther Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine 3 Using Special Tool 8506 Fig 40 remove the crankshaft rear oil seal INSTALLATION 1...

Page 1271: ...uence shown Fig 43 3 Install the transmission PISTON CONNECTING ROD DESCRIPTION CAUTION Do not use a metal stamp to mark con necting rods as damage may result instead use ink or a scratch awl The pistons are made of a high strength aluminum alloy The connecting rods are made of forged pow dered metal with a fractured cap design A full floating piston pin is used to attach the piston to the connect...

Page 1272: ...s indicate the probability of a misaligned connecting rod inspect it for correct rod alignment Replace misaligned bent or twisted con necting rods 1 Wipe the oil from the connecting rod journal 2 Lubricate the upper bearing insert and position in connecting rod Center bearing insert in connect ing rod Fig 47 Fig 45 Connecting Rod Bearing Inspection 1 UPPER BEARING HALF 2 MATING EDGES 3 GROOVES CAU...

Page 1273: ...the insert If the clearance varies it may be caused by either a tapered journal bent connecting rod or foreign material trapped between the insert and cap or rod 7 If the correct clearance is indicated replace ment of the bearing inserts is not necessary Remove the Plastigage from crankshaft journal and bearing insert Proceed with installation 8 If bearing to journal clearance exceeds the specific...

Page 1274: ...erial is applied to the piston after the final piston machining process Measuring the outside diameter of a coated piston will not pro vide accurate results Fig 51 Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in increments is required 5 Piston ins...

Page 1275: ... the connecting rod journal for excessive wear taper and scoring Refer to 9 ENGINE EN GINE BLOCK CONNECTING ROD BEARINGS STANDARD PROCEDURE Check the connecting rod for signs of twist or bend ing Check the piston for taper and elliptical shape before it is fitted into the cylinder bore Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECT ING ROD STANDARD PROCEDURE Check the piston for scoring or scraping...

Page 1276: ...linder bore clean 2 Insert the ring in the cylinder bore NOTE The ring gap measurement must be made with the ring positioned at least 12mm 0 50 inch from bottom of cylinder bore 3 Using a piston to ensure that the ring is squared in the cylinder bore slide the ring downward into the cylinder 4 Using a feeler gauge check the ring end gap Fig 55 Replace any rings not within specification Fig 53 PIST...

Page 1277: ... 0 004 in Oil Control Ring 019 229 mm 25 mm Steel Rails 0007 0090 in 0 010 in Ring Position Ring Gap Wear Limit Upper Ring 0 20 0 36 mm 0 43 mm 0 0079 0 0142 in 0 0017 in Intermediate Ring 0 37 0 63 mm 0 74 mm 0 0146 0 0249 in 0 029 in Oil Control Ring 0 025 0 76 mm 1 55 mm Steel Rail 0 0099 0 03 in 0 061 in 7 The No 1 and No 2 piston rings have a differ ent cross section Ensure No 2 ring is insta...

Page 1278: ...irection VIBRATION DAMPER REMOVAL 1 Disconnect negative cable from battery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 4 Remove radiator upper hose 5 Remove upper fan shroud 6 Using Special Tools 6958 Spanner with Adapter Pins 8346 loosen fan and viscous assembly from water pump Fig 60 7 Remove fa...

Page 1279: ...e and severe damage to either the tool or the crankshaft 2 Assemble Special Tool 8512 A as follows The nut is threaded onto the shaft first Then the roller bearing is placed onto the threaded rod The hard ened bearing surface of the bearing MUSTface the nut Then the hardened washer slides onto the threaded rod Fig 62 Once assembled coat the threaded rod s threads with Mopart Nickel Anti Seize or e...

Page 1280: ... structural cover Fig 64 in the sequence shown 5 Pivot the exhaust pipe downward and remove the structural cover INSTALLATION CAUTION The structural cover must be installed as described in the following steps Failure to do so will cause severe damage to the cover 1 Position the structural cover in the vehicle 2 Install all four bolts retaining the cover to en gine DO NOT tighten the bolts at this ...

Page 1281: ...ble to remove the left and right engine mounts 13 Remove the 8 mount to engine attaching bolts 14 Remove the engine mounts 4WD 1 Disconnect the negative cable from the battery CAUTION Remove the viscous fan before raising engine Failure to do so may cause damage to the fan blade fan clutch and fan shroud 2 Remove the viscous fan Refer to 7 COOL ING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Raise t...

Page 1282: ... to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 9 Reconnect the negative battery cable 4WD NOTE For mount to engine block and left engine bracket to front axle bolts apply MoparT Lock and Seal Adhesive Medium Strength Threadlocker 1 Install the right and left side engine mounts to the front axle Torque nuts to 94 N m 70 ft lbs 2 Raise the front axle into the frame and install the left and ri...

Page 1283: ... engine oil filter 11 Install the front crossmember 12 Install the skid plate 13 Lower the vehicle 14 Install the viscous fan Refer to 7 COOL ING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 15 Reconnect the negative battery cable Fig 69 ENGINE INSULATOR MOUNTS 4X4 1 RH INSULATOR TO AXLE BOLT 2 NUT 3 PINION SUPPORT MOUNT 4 LH INSULATOR MOUNT 5 LH INSULATOR TO AXLE BOLT 6 FRONT AXLE 7 NUT 8 RH INSULATOR...

Page 1284: ...ation system is a full flow filtration pres sure feed type OPERATION Oil from the oil pan is pumped by a gerotor type oil pump directly mounted to the crankshaft nose Oil pressure is controlled by a relief valve mounted inside the oil pump housing For lubrication flow refer to Fig 71 The camshaft exhaust valve lobes and rocker arms are lubricated through a small hole in the rocker arm oil flows th...

Page 1285: ...Lubrication Flow Chart Cylinder Heads Table 2 The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads ENGINE LUBRICATION FLOW CHART CYLINDER HEADS TABLE 2 FROM TO Cylinder Head Oil Port in bolt hole Diagonal Cross Drilling to Main Oil Gallery Main Oil Gallery drilled through head from rear to front 1 Base of Camshaft Towers 2 Lash Adjuster Towers Base of Camshaft...

Page 1286: ...L FLOW TO BOTH SECONDARY TENSIONERS 5 OIL FLOW TO LEFT CYLINDER HEAD 6 OIL PRESSURE SENSOR LOCATION 7 OIL FLOW TO COUNTER BALANCE SHAFT 8 OIL PUMP OUTLET TO CYLINDER BLOCK 9 OIL PUMP 10 OIL FLOW TO CRANKSHAFT MAIN JOURNALS 11 CRANKSHAFT MAIN BEARING JOURNALS 12 RIGHT CYLINDER HEAD OIL GALLERY DR ENGINE 3 7L 9 63 LUBRICATION Continued ...

Page 1287: ... Inspection for Rear Seal Area Leak 6 If no leaks are detected turn off the air supply and remove the air hose and all plugs and caps Install the PCV valve and breather cap hose 7 Clean the oil off the suspect oil leak area using a suitable solvent Drive the vehicle at various speeds approximately 24 km 15 miles Inspect the engine for signs of an oil leak by using a black light INSPECTION FOR REAR...

Page 1288: ...ng cap to cylinder block mating sur faces See Engine for proper repair procedures of these items 4 If no leaks are detected pressurized the crank case as outlined in the section Inspection Engine oil Leaks in general CAUTION Do not exceed 20 6 kPa 3 psi 5 If the leak is not detected very slowly turn the crankshaft and watch for leakage If a leak is detected between the crankshaft and seal while sl...

Page 1289: ...e 10 Inspect the integral windage tray Fig 73 and gasket and replace as needed CLEANING 1 Clean oil pan in solvent and wipe dry with a clean cloth 2 Clean the oil pan gasket surface DO NOT use a grinder wheel or other abrasive tool to clean seal ing surface 3 Clean oil screen and tube thoroughly in clean solvent INSPECTION 1 Inspect oil drain plug and plug hole for stripped or damaged threads Repa...

Page 1290: ...ltage signal back to the PCM relating to engine oil pres sure This signal is then transferred bussed to the instrument panel on either a CCD or PCI bus circuit depending on vehicle line to operate the oil pressure gauge and the check gauges lamp Ground for the sensor is provided by the PCM through a low noise sensor return REMOVAL 1 Disconnect the negative cable from the battery 2 Raise vehicle on...

Page 1291: ...f the oil pump housing should be smooth If the pump cover is scratched or grooved the oil pump assembly should be replaced 2 Lay a straight edge across the pump cover sur face Fig 76 If a 0 025 mm 0 001 in feeler gauge can be inserted between the cover and the straight edge the oil pump assembly should be replaced 3 Measure the thickness of the outer rotor Fig 77 If the outer rotor thickness measu...

Page 1292: ...EMBLY 1 Wash all parts in a suitable solvent and inspect carefully for damage or wear 2 Install inner and outer rotors 3 Install oil pump cover plate and install cover bolts and tighten them to 12 N m 105 in lbs 4 Prime oil pump before installation by filling rotor cavity with engine oil 5 If oil pressure is low and pump is within spec ifications inspect for worn engine bearings or other causes fo...

Page 1293: ...When filter separates from cylinder block oil filter boss tip gasket end upward to minimize oil spill Remove filter from vehicle NOTE Make sure filter gasket was removed with fil ter 5 With a wiping cloth clean the gasket sealing surface of oil and grime INSTALLATION 1 Lightly lubricate oil filter gasket with engine oil 2 Thread filter onto adapter nipple When gasket makes contact with sealing sur...

Page 1294: ... ple viscosities such as 5W 30 or 10W 30 in the 3 7L engines These are specified with a dual SAE viscos ity grade which indicates the cold to hot temperature viscosity range Select an engine oil that is best suited to your particular temperature range and vari ation Fig 85 ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines The designation of ENERGY CON SERVING ...

Page 1295: ...ain 5 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for stretching or other damage Replace drain plug if damaged 6 Install drain plug in crankcase 7 Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec tion 8 Install oil fill cap 9 Start engine and inspect for leaks 10 Stop engine and inspect oil level USE...

Page 1296: ...core 16 Unclip and remove heater hoses and tubes from intake manifold 17 Remove coolant temperature sensor Refer to 7 COOLING ENGINE ENGINE COOLANT TEMP SENSOR REMOVAL 18 Remove intake manifold retaining fasteners in reverse order of tightening sequence 19 Remove intake manifold INSTALLATION 1 Install intake manifold gaskets 2 Install intake manifold 3 Install intake manifold retaining bolts and t...

Page 1297: ... Remove bolts nuts and washers attaching manifold to cylinder head 7 Remove manifold and gasket from the cylinder head LEFT EXHAUST MANIFOLD 1 Disconnect the negative cable from the battery 2 Raise and support the vehicle 3 Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold 4 Lower the vehicle 5 Remove the exhaust heat shields Fig 93 6 Remove bolts nuts and washers...

Page 1298: ...install new studs Apply sealer on the coarse thread ends Water leaks may develop at the studs if this precau tion is not taken 1 Position the engine exhaust manifold and gas ket on the two studs located on the cylinder head Install conical washers and nuts on these studs 2 Install remaining conical washers Starting at the center arm and working outward tighten the bolts and nuts to 25 N m 18 ft lb...

Page 1299: ...ash lubrication from the secondary chain drive and designed oil pump leak age The idler sprocket assembly connects the pri mary chain drive secondary chain drives and the counterbalance shaft The idler sprocket assembly consists of two integral 26 tooth sprockets a 50 tooth sprocket and a helical gear that is press fit to the assembly The spline joint for the 50 tooth sprocket is a non serviceable...

Page 1300: ...ioners STANDARD PROCEDURE MEASURING TIMING CHAIN WEAR NOTE This procedure must be performed with the timing chain cover removed 1 Remove the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 2 To determine if the secondary timing chains are worn rotate the engine clockwise until maximum tensioner piston extension is obtained Measure the distance between the ...

Page 1301: ...at TDC with both camshaft sprocket V6 marks in the 12 o clock posi tion Fig 100 2 Look down the left cylinder head chain cavity The timing dot on the counter balance shaft drive gear should be in the 6 o clock position Fig 97 TIMING SINGLE CAMSHAFT NOTE to adjust the timing on one camshaft pre form the following procedure 1 Using Chain Tensioner Wedge Fig 99 Special Tool 8379 stabilize the seconda...

Page 1302: ...90 ft Lbs 7 Remove Special Tool 8379 Fig 98 SECURING TIMING CHAIN TENSIONER USING TIMING CHAIN WEDGE 1 CYLINDER HEAD 2 SPECIAL TOOL 8379 3 TIMING CHAIN Fig 99 CAMSHAFT DRIVE GEAR REMOVAL INSTALLATION 1 SPECIAL TOOL 8379 TIMING CHAIN WEDGE 2 CAMSHAFT DRIVE GEAR 3 RETAINING BOLT 4 CYLINDER HEAD Fig 100 CAMSHAFT SPROCKET V6 MARKS 1 TDC Exhaust stroke 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD DR ENGI...

Page 1303: ...Coat counterbalance shaft bearing journals with clean engine oil NOTE The balance shaft is heavy and care should be used when installing shaft so bearings are not damaged 2 Using Special Tool 8641 Counterbalance shaft remover installer tool carefully install counterbal ance shaft into engine 3 Install Counterbalance shaft thrust plate retaining bolt finger tight Do not tighten bolt at this time 4 ...

Page 1304: ...tive cable 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Remove electric cooling fan and fan shroud assembly 4 Remove fan and fan drive assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 5 Disconnect both heater hoses at timing cover 6 Disconnect lower radiator hose at engine 7 Remove accessory drive belt tensioner assembly Fig 103 8 Remove crankshaft damper Refer...

Page 1305: ...ON 6 Install the A C compressor Refer to 24 HEAT ING AIR CONDITIONING PLUMBING A C COM PRESSOR INSTALLATION 7 Install the generator Refer to 8 ELECTRI CAL CHARGING GENERATOR INSTALLATION 8 Install accessory drive belt tensioner assembly Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS INSTALLATION 9 Install radiator upper and lower hoses 10 Install both heater hoses 11 Install electric fan shrou...

Page 1306: ... ING ENGINE RADIATOR FAN REMOVAL 5 Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover Fig 108 and the camshaft sprocket V6 marks are at the 12 o clock position No 1 TDC exhaust stroke Fig 107 6 Remove power steering pump Refer to 19 STEERING PUMP REMOVAL Fig 107 CAMSHAFT SPROCKET V6 MARKS 1 TDC EXHAUST STROKE 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD F...

Page 1307: ...ocket Slowly rotate the camshaft approximately 5 degrees clockwise to a neutral posi tion 15 While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench remove the right camshaft sprocket 16 Remove idler sprocket assembly bolt 17 Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the pri mary and secondary chains 18 Remove both pivoting ten...

Page 1308: ...secondary chains to be visible through the two lower openings on the idler sprocket 4 o clock and 8 o clock Once the secondary timing chains are installed position special tool 8429 to hold chains in place for installa tion 8 Align primary chain double plated links with the timing mark at 12 o clock on the idler sprocket Align the primary chain single plated link with the timing mark at 6 o clock ...

Page 1309: ...N After pulling locking pins out of each tensioner DO NOT manually extend the tensioner s ratchet Doing so will over tension the chains resulting in noise and or high timing chain loads 17 Using Special Tool 6958 Spanner with Adap tor Pins 8346 tighten left Fig 114 and right Fig 115 camshaft sprocket bolts to 122 N m 90 ft lbs 18 Rotate engine two full revolutions Verify tim ing marks are at the f...

Page 1310: ...hread Sealant with Teflon then install into the right cylinder head and tighten to 81 N m 60 ft lbs 24 Install the oil fill housing 25 Install access plug in left cylinder head 26 Install power steering pump Refer to 19 STEERING PUMP INSTALLATION 27 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 28 Connect negative cable to battery Fig 115 TIGHTENING RIGHT SIDE CAMSHAFT SPROCKET BOLT 1 ...

Page 1311: ...NSTALLATION RIGHT CYLINDER HEAD 113 CAMSHAFT S LEFT DESCRIPTION 114 REMOVAL 115 INSTALLATION 116 CAMSHAFT S RIGHT DESCRIPTION 119 REMOVAL 119 INSTALLATION 120 CYLINDER HEAD COVER S DESCRIPTION 122 REMOVAL REMOVAL RIGHT SIDE 122 REMOVAL LEFT SIDE 122 CLEANING 123 INSTALLATION INSTALLATION RIGHT SIDE 123 INSTALLATION LEFT SIDE 123 INTAKE EXHAUST VALVES SEATS DESCRIPTION 123 REMOVAL 124 INSTALLATION ...

Page 1312: ...153 OIL FILTER REMOVAL 154 INSTALLATION 155 OIL PAN REMOVAL 155 INSTALLATION 155 OIL PRESSURE SENSOR SWITCH DESCRIPTION DESCRIPTION 156 DESCRIPTION 156 OPERATION OPERATION 156 OPERATION 156 REMOVAL 156 INSTALLATION 156 OIL PUMP REMOVAL 156 DISASSEMBLY 157 CLEANING 157 INSPECTION 157 ASSEMBLY 158 INSTALLATION 159 INTAKE MANIFOLD DESCRIPTION 159 DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKAGE 159 REMO...

Page 1313: ...5 Incorrect spark plug gap 5 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 6 Dirt or water in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump relay or wiring 7 Repair or replace as necessary ENGINE STALLS OR ROUGH IDLE 1 Idle speed set to low 1 Refer to 14 FUEL SYSTEM FUEL INJECTION IDLE AIR CONTROL MOTOR REMOVAL 2 Idle mixture too lean or too rich 2 Refer to Pow...

Page 1314: ...Inspect and replace as necessary 8 Faulty coil 8 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 1 ENGINE MISSES ON ACCELERATION 1 Spark plugs dirty or incorrectly gapped 1 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Dirt in fuel system 2 Clean fuel system 3 Burned warped or pitted valves 3 Replcae as necessary 4 Faulty coil 4 Refer to 8 ELECTRICAL IGNITION CONTROL IG...

Page 1315: ...OISE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or diluted oil 3 Change oil and filter 4 Excessive bearing clearance 4 Replace as necessary 5 Connecting rod journal out of round 5 Service or replace crankshaft 6 Misaligned connecting rods 6 Replace bent connecting rods M...

Page 1316: ... source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 psi recom mended 7 Perform the test procedures on each cylinder according to the tester manufacturer s instructions Set piston of cylinder to be tested at TDC compres sion While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubble...

Page 1317: ... lines A continuous bead of the proper width is essential to obtain a leak free gasket There are numerous types of form in place gasket materials that are used in the engine area Mopart Engine RTV GEN II Mopart ATF RTV and Mopart Gasket Maker gasket materials each have different properties and can not be used in place of the other MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal c...

Page 1318: ...le only are identified 1 Disconnect the battery negative and positive cables 2 Remove the battery and the battery tray 3 Raise vehicle on hoist 4 Remove exhaust crossover pipe from exhaust manifolds 5 4X4 vehicles Disconnect axle vent tube from left side engine mount 6 Remove the through bolt retaining nut and bolt from both the left and right side engine mounts 7 4X4 vehicles Remove locknut from ...

Page 1319: ... 3 Fuel Injectors Throttle Position TPS Switch Idle Air Control IAC Motor Engine Oil Pressure Switch Engine Coolant Temperature ECT Sensor Manifold absolute pressure MAP Sensor Camshaft Position CMP Sensor Coil Over Plugs 31 Disconnect the vacuum lines at the throttle body and intake manifold 32 Release fuel rail pressure Refer to 14 FUEL SYSTEM FUEL DELIVERY STANDARD PROCE DURE then disconnect th...

Page 1320: ...ry to support the transmis sion in order to remove the engine 38 Position a suitable jack under the transmis sion 39 Remove engine from the vehicle INSTALLATION 1 Position engine in the vehicle Fig 4 Engine Lifting Fixture Attachment Locations 1 ATTACHING LOCATION 2 ADJUSTABLE HOOK 3 SPECIAL TOOL 8347 ENGINE LIFT FIXTURE 4 ATTACHING LOCATIONS Fig 5 Body Ground Strap Right Side Removal Installation...

Page 1321: ...he transmission oil cooler lines to the radiator 18 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION fan assembly and shroud Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 19 Install A C compressor Refer to 24 HEAT ING AIR CONDITIONING PLUMBING A C COM PRESSOR INSTALLATION 20 Install both breathers Connect tube to both crankcase breathers Fi...

Page 1322: ...83 37 83 13 mm 3 282 3 273 in No 2 82 833 83 033 mm 3 261 3 310 in No 3 83 88 84 08 mm 3 302 3 310 in PISTON PINS DESCRIPTION SPECIFICATION Metric Standard Clearance In Piston 0 010 0 019 mm 0 0004 0 0008 in Diameter 24 013 24 016 mm 0 9454 0 9455 in PISTON RINGS DESCRIPTION SPECIFICATION Metric Standard Ring Gap Top Compression Ring 0 20 0 36 mm 0 0079 0 0142 in Second Compression Ring 0 37 0 63 ...

Page 1323: ...052 0 282 mm 0 0021 0 0112 in End Play MAX 0 282 mm 0 0112 in Connecting Rod Journal Diameter 50 992 51 008 mm 2 0076 2 0082 in Bearing Clearance 0 015 0 055 0 0006 0 0022 in Out of Round MAX 0 005 mm 0 0002 in Taper MAX 0 008 mm 0 0004 in CAMSHAFT DESCRIPTION SPECIFICATION Metric Standard Bore Diameter 26 02 26 04 mm 1 0245 1 0252 in Bearing Journal Diameter 25 975 25 995 mm 1 0227 1 0235 in Bear...

Page 1324: ...ethod Intake 0 069 mm 0 0028 in Exhaust 0 098 mm 0 0039 in Valve Lift Zero Lash Intake 11 25 mm 0 443 in Exhaust 10 90 mm 0 4292 in VALVE SPRING DESCRIPTION SPECIFICATION Free Length Approx Intake 49 0 mm 1 9291 in Exhaust 49 0 mm 1 9291 in Spring Force Valve Closed Intake and Exhaust 313 0 354 0 N 40 12 mm 70 365 79 582 lbs 1 5795 in Spring Force Valve Open Intake and Exhaust 776 0 870 0 N 28 88 ...

Page 1325: ...ure is zero at curb idle DO NOT run engine at 3000 rpm TORQUE DESCRIPTION N m Ft In Lbs Lbs Camshaft Non Oiled Sprocket Bolt 122 90 Bearing Cap Bolts 11 100 Timing Chain Cover Bolts 58 43 Connecting Rod Cap Bolts 27 20 PLUS 90 TURN Bed Plate Bolts Refer to Procedure Crankshaft Damper Bolt 175 130 Cylinder Head Bolts M11 Bolts 81 60 M8 Bolts 26 19 Cylinder Head Cover Bolts 12 105 Exhaust Manifold B...

Page 1326: ... Drive Idler Sprocket Bolt 34 25 Thermostat Housing Bolts 13 115 Water Pump Bolts 58 43 SPECIAL TOOLS 4 7L ENGINE Spanner Wrench 6958 Adapter Pins 8346 Engine Lifting Studs 8400 Engine Lift Fixture 8347 Front Crankshaft Seal Remover 8511 Front Crankshaft Seal Installer 8348 Handle C 4171 DR ENGINE 4 7L 9 103 ENGINE 4 7L Continued ...

Page 1327: ...ear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 Crankshaft Damper Installer 8512 Puller 1026 Crankshaft Damper Removal Insert 8513 Chain Tensioner Wedge 8379 Chain Tensioner Pins 8514 9 104 ENGINE 4 7L DR ENGINE 4 7L Continued ...

Page 1328: ... 8516 Valve Spring Compressor 8387 Idler Shaft Remover 8517 Valve Spring Compressor Adapters 8519 Valve Spring Tester C 647 Dial Indicator C 3339 Valve Spring Compressor C 3422 B Bore Size Indicator C 119 DR ENGINE 4 7L 9 105 ENGINE 4 7L Continued ...

Page 1329: ...Oil Pressure Gauge C 3292 Piston Ring Compressor C 385 Pressure Tester Kit 7700 Bloc Chek Kit C 3685 A ENGINE SUPPORT FIXTURE 8534 9 106 ENGINE 4 7L DR ENGINE 4 7L Continued ...

Page 1330: ... m 30 in lbs torque 5 If any other hose clamps were removed from air intake system tighten them to 3 4 N m 30 in lbs torque 6 If any bolts were removed from air resonator housing or air intake tubing tighten them to 4 5 N m 40 in lbs torque CYLINDER HEAD DESCRIPTION DESCRIPTION CYLINDER HEAD The cylinder heads are made of an aluminum alloy The cylinder head features two valves per cylinder with pr...

Page 1331: ... REMOVAL 11 Remove the power steering pump and set aside 12 Rotate the crankshaft until the damper tim ing mark is aligned with TDC indicator mark Fig 9 13 Verify the V8 mark on the camshaft sprocket is at the 12 o clock position Fig 11 Rotate the crankshaft one turn if necessary 14 Remove the crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 15 Remove the timing chain cove...

Page 1332: ... can occur CAUTION Do not overlook the four smaller bolts at the front of the cylinder head Do not attempt to remove the cylinder head without removing these four bolts NOTE The cylinder head is attached to the cylinder block with fourteen bolts 22 Remove the cylinder head retaining bolts 23 Remove the cylinder head and gasket Discard the gasket CAUTION Do not lay the cylinder head on its gas ket ...

Page 1333: ...from cylinder head 10 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 11 Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark Fig 13 12 Verify the V8 mark on the camshaft sprocket is at the 12 o clock position Fig 14 Rotate the crankshaft one turn if necessary 13 Remove the crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATIO...

Page 1334: ...to the cylinder block with fourteen bolts 21 Remove the cylinder head retaining bolts 22 Remove the cylinder head and gasket Discard the gasket CAUTION Do not lay the cylinder head on its gas ket sealing surface do to the design of the cylinder head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop erly sealing resulting in leaks CLEANING To ensure engine ...

Page 1335: ... before installing Failure to do so may cause leaks 4 Lubricate the cylinder head bolt threads with clean engine oil and install the ten M11 bolts 5 Coat the four M8 cylinder head bolts with Mopart Lock and Seal Adhesive then install the bolts NOTE The cylinder head bolts are tightened using an angle torque procedure however the bolts are not a torque to yield design 6 Tighten the bolts in sequenc...

Page 1336: ...he bolts must be examined BEFORE reuse If the threads are necked down the bolts should be replaced Necking can be checked by holding a straight edge against the threads If all the threads do not contact the scale the bolt should be replaced Fig 21 CAUTION When cleaning cylinder head and cylin der block surfaces DO NOT use a metal scraper because the surfaces could be cut or ground Use only a woode...

Page 1337: ... ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 15 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 16 Install the fan shroud 17 Install the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 18 Install the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 19 Install oil fill housing onto cylinder...

Page 1338: ...he camshaft sprocket to aid in installation CAUTION Do not hold or pry on the camshaft tar get wheel Located on the right side camshaft sprocket for any reason Severe damage will occur to the target wheel resulting in a vehicle no start condition 4 Loosen but DO NOT remove the camshaft sprocket retaining bolt Leave the bolt snug against the sprocket NOTE The timing chain tensioners must be secured...

Page 1339: ...efore removing camshaft 9 Remove the camshaft bearing caps and the camshaft INSTALLATION 1 Lubricate camshaft journals with clean engine oil NOTE Position the left side camshaft so that the camshaft sprocket dowel is near the 1 o clock posi tion This will place the camshaft at the neutral position easing the installation of the camshaft bearing caps 2 Position the camshaft into the cylinder head 3...

Page 1340: ...es or the sprocket areas 7 Using the adjustable pliers rotate the cam shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the sprocket onto the camshaft Fig 29 CAUTION Remove excess oil from camshaft sprocket bolt Failure to do so can cause bolt over torque resulting in bolt failure Fig 28 Timing Chain to Sprocket Alignment 1 LEFT CYLINDER HEAD 2 RIGHT...

Page 1341: ...que the camshaft sprocket retaining bolt to 122 N m 90 ft lbs 11 Install the cylinder head cover Fig 30 SPECIAL TOOL 8350 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD 3 SPECIAL TOOL 8350 WEDGE 4 SPECIAL TOOL 8350 WEDGE Fig 31 Tightening Left Side Cam Sprocket Retaining Bolt 1 TORQUE WRENCH 2 CAMSHAFT SPROCKET 3 LEFT CYLINDER HEAD 4 SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346 9 118 ENGINE 4 7L D...

Page 1342: ...ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 2 Set engine to TDC cylinder 1 camshaft sprocket V8 marks at the 12 o clock position 3 Mark one link on the secondary timing chain on both sides of the V8 mark on the camshaft sprocket to aid in installation CAUTION Do not hold or pry on the camshaft tar get wheel for any reason Severe damage will occur to the target wheel A damaged target wheel c...

Page 1343: ...ARING CAPS NOTE When the camshaft is removed the rocker arms may slide downward mark the rocker arms before removing camshaft 10 Remove the camshaft bearing caps and the camshaft INSTALLATION 1 Lubricate camshaft journals with clean engine oil NOTE Position the right side camshaft so that the camshaft sprocket dowel is near the 10 o clock position This will place the camshaft at the neutral positi...

Page 1344: ... sprocket areas 7 Using the adjustable pliers rotate the cam shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the sprocket onto the camshaft Fig 37 CAUTION Remove excess oil from camshaft sprocket bolt Failure to do so can cause bolt over torque resulting in bolt failure 8 Remove excess oil from camshaft sprocket bolt then install the camshaft sproc...

Page 1345: ...ompressor to the left 6 Remove heater hoses 7 Disconnect injector and ignition coil connectors 8 Disconnect and remove positive crankcase ven tilation PCV hose 9 Remove oil fill tube 10 Un clip injector and ignition coil harness and move away from cylinder head cover 11 Remove right rear breather tube and filter assembly 12 Remove cylinder head cover retaining bolts 13 Remove cylinder head cover N...

Page 1346: ...ll air cleaner assembly resonator assem bly and air inlet hose 13 Connect battery negative cable INSTALLATION LEFT SIDE CAUTION Do not use harsh cleaners to clean the cylinder head covers Severe damage to covers may occur 1 Clean cylinder head cover and both sealing sur faces Inspect and replace gasket as necessary 2 Install cylinder head cover and hand start all fasteners Verify that all studs ar...

Page 1347: ... Remove the valve stem seal Mark the valve for proper installation TESTING VALVE SPRINGS NOTE Whenever the valves are removed from the cylinder head it is recommended that the valve springs be inspected and tested for reuse Inspect the valve springs for physical signs of wear or damage Turn table of tool C 647 until surface is in line with the 40 12 mm 1 579 in mark on the threaded stud and the ze...

Page 1348: ...produced from several items Check the following items 1 Engine oil level too high or too low This may cause aerated oil to enter the adjusters and cause them to be spongy 2 Insufficient running time after rebuilding cylin der head Low speed running up to 1 hour may be required 3 Turn engine off and let set for a few minutes before restarting Repeat this several times after engine has reached norma...

Page 1349: ...rs 3 and 5 Rotate the crankshaft until cylinder 1 is at TDC exhaust stroke 2 For rocker arm installation on cylinders 2 and 8 Rotate the crankshaft until cylinder 1 is at TDC compression stroke 3 For rocker arm installation on cylinders 4 and 6 Rotate the crankshaft until cylinder 3 is at TDC compression stroke 4 For rocker arm installation on cylinders 1 and 7 Rotate the crankshaft until cylinder...

Page 1350: ...g 47 3 Using Special Tool 8387 Valve Spring Compres sor compress the spring and install the two valve spring retainer halves 4 Release the valve spring compressor and make sure the two spring retainer halves and the spring retainer are fully seated 5 Install the camshaft Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S INSTALLA TION 6 Position the hydraulic lash adjusters and rocker arms Fig 46 7 Instal...

Page 1351: ...roper seating of rings Fig 48 4 A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross hatch angle The number of up and down strokes per minute can be regulated to get the desired 50 to 60 angle Faster up and down strokes increase the cross hatch angle 5 After honing it is necessary that the block be cleaned to remove all traces of abrasive Use a brush to was...

Page 1352: ...rod bearings and crankshaft con necting rod journals If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod inspect it for correct rod alignment Replace misaligned bent or twisted con necting rods 1 Wipe the oil from the connecting rod journal 2 Lubricate the upper bearing insert and install in connecting rod 3 Use piston ring compressor and G...

Page 1353: ... WITH JOURNAL SIZE 025 US 025 mm 50 983 50 967 mm 001 in 2 0073 2 0066 in Std STANDARD 50 992 51 008 mm 2 0076 2 0082 in 250 US 250 mm 50 758 50 742 mm 010 in 1 9984 1 9978 in 9 Repeat the Plastigage measurement to verify your bearing selection prior to final assembly 10 Once you have selected the proper insert install the insert and cap Tighten the connecting rod bolts to 27 N m 20 ft lbs plus a ...

Page 1354: ...he select fit main bearing markings are located on the rear side of the target wheel The crankshaft oil seals are one piece design The front oil seal is retained in the timing chain cover and the rear seal is pressed in to a bore formed by the cylinder block and the bedplate assembly REMOVAL NOTE To remove the crankshaft from the engine the engine must be removed from the vehicle 1 Remove the engi...

Page 1355: ...e all oil and sealant residue 3 Inspect the bedplate main bearing bores for cracks scoring or severe blueing If either condition exists the engine must be replaced 4 Inspect the crankshaft thrust washers for scor ing scratches wear or blueing If either condition exist replace the thrust washer 5 Inspect the oil pan gasket windage tray for splits tears or cracks in the gasket sealing surfaces Repla...

Page 1356: ...ne oil and position the bedplate onto the cylinder block NOTE Lubricate the bedplate retaining bolts with clean engine oil prior to installation 7 Install the bedplate retaining bolts making sure to place the stud bolts in the correct location Torque the bolts in the sequence shown Fig 60 Tighten bolts A L to 54 N m 40 ft lbs Tighten bolts 1 10 to 2 8 N m 25 in lbs Turn bolts 1 10 an additional 90...

Page 1357: ...a micrometer Measure at two locations 90 apart at each end of the journal The maximum allowable taper is 0 008mm 0 0004 inch and maximum out of round is 0 005mm 0 002 inch Compare the measured diameter with the jour nal diameter specification Main Bearing Fitting Chart Select inserts required to obtain the specified bearing to journal clearance CRANKSHAFT MAIN BEARING SELECTION The main bearings a...

Page 1358: ...gular wear patterns Inspect the upper insert locking tabs for damage Replace all damaged or worn bearing inserts CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Disconnect negative cable from battery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Remove A C compressor mouning fasteners and set aside 4 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 5 Remove u...

Page 1359: ... 3 Install radiator cooling fan and shroud Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION 4 Install upper radiator hose 5 Install A C compressor and tighten fasteners to 54 N m 40 ft lbs 6 Install accessory drive belt refer Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 7 Refill cooling system Refer to 7 COOLING STANDARD PROCEDURE 8 Connect negative cable to battery Fig 64 Cranks...

Page 1360: ...urface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth CAUTION Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches The crankshaft seal flange is specially machined to complement the function of the rear oil seal 6 For bubbles that remain steady with shaft rotation no further inspectio...

Page 1361: ...flexplate 5 Install the transmission FLEX PLATE REMOVAL 1 Remove the transmission 2 Remove the bolts and flexplate INSTALLATION 1 Position the flexplate onto the crankshaft and install the bolts hand tight 2 Tighten the flexplate retaining bolts to 60 N m 45 ft lbs in the sequence shown Fig 70 3 Install the transmission Fig 68 Crankshaft Rear Oil Seal Guide Special Tool 8349 2 and Oil 1 REAR CRANK...

Page 1362: ... the piston after the final piston machining process Measuring the outside diameter of a coated piston will not pro vide accurate results Fig 71 Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in increments is required 5 Piston installation into the ...

Page 1363: ...use a wire wheel or other abra sive cleaning devise to clean the pistons or con necting rods The pistons have a Moly coating this coating must not be damaged 1 Using a suitable cleaning solvent clean the pis tons in warm water and towel dry 2 Use a wood or plastic scraper to clean the ring land grooves CAUTION DO NOT remove the piston pin from the piston and connecting rod assembly INSPECTION Chec...

Page 1364: ...Yield Bolts and Must Not Be Reused Always replace the Rod Bolts whenever they are loosened or removed 9 Lubricate rod bolts and bearing surfaces with engine oil Install connecting rod cap and bearing Tighten bolts to 27 N m 20 ft lbs plus 90 10 Install the following components Cylinder head s Refer to 9 ENGINE CYLIN DER HEAD INSTALLATION Timing chain and cover Refer to 9 ENGINE VALVE TIMING TIMING...

Page 1365: ...side clearance as shown Fig 77 make sure the feeler gauge fits snugly between the ring land and the ring Replace any ring not within specification 6 Rotate the ring around the piston the ring must rotate in the groove with out binding PISTON RING SPECIFICATION CHART Ring Position Groove Clearance Maximum Clearance Upper Ring 051 094 mm 0 11 mm 0 0020 0037 in 0 004 in Intermediate Ring 0 04 0 08 mm...

Page 1366: ...ortion to be installed until side rail is in position Repeat this step for the lower side rail 10 Install No 2 intermediate piston ring using a piston ring installer Fig 79 11 Install No 1 upper piston ring using a piston ring installer Fig 79 12 Position piston ring end gaps as shown in Fig 80 It is important that expander ring gap is at least 45 from the side rail gaps but not on the pis ton pin...

Page 1367: ... slightly CAUTION Special Tool 8512 A is assembled in a specific sequence Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft 2 Assemble Special Tool 8512 A as follows The nut is threaded onto the shaft first Then the roller bearing is placed onto the threaded rod The hard ened bearing surface of the bearing MUSTface the ...

Page 1368: ...aining bolts 4 Remove the eight bolts retaining structural cover Fig 85 in the sequence shown 5 Pivot the exhaust pipe downward and remove the structural cover INSTALLATION CAUTION The structural cover must be installed as described in the following steps Failure to do so will cause severe damage to the cover 1 Position the structural cover in the vehicle 2 Install all four bolts retaining the cov...

Page 1369: ...f wood across the full width of the engine oil pan 7 Support the front axle with a suitable jack 8 Remove the 4 bolts that attach the engine mounts to the front axle 9 Remove the 3 bolts that attach the front axle to the left engine bracket 10 Lower the front axle 11 Remove the through bolts 12 Raise the engine far enough to be able to remove the left and right engine mounts 13 Remove the 8 mount ...

Page 1370: ...2 through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts 3 Lower the engine until the through bolts rest onto the slots in the frame brackets 4 Tighten the through bolt nuts to 94 N m 70 ft lbs 5 Install the oil drain trough 6 Install the engine oil filter Fig 87 ENGINE INSULATOR MOUNTS 4X4 1 RH INSULATOR TO AXLE BOLT 2 NUT 3 PINION SUPPORT ...

Page 1371: ... right and left side engine mounts and loose assemble the two nuts onto the through bolts 4 Lower the engine until the left and right side engine brackets rest on the through bolts and the lower engine bracket through holes align with the engine mounts and the left engine bracket holes align with the front axle slots Fig 90 5 Loose assemble the 3 bolts that attach the front axle to the left engine...

Page 1372: ...Remove the two bolts that attach the transmis sion mount to the engine bracket 5 Raise the transmission enough to remove the mount from the crossmember 6 Remove the mount INSTALLATION NOTE Threadlocking compound must be applied to the bolts before installation 1 Install the two bolts that attach the transmis sion mount to the transmission bracket 2 Torque the bolts to 61N m 45 ft lbs torque 3 Lowe...

Page 1373: ...valve mounted inside the oil pump housing For lubrication flow refer to Fig 92 Fig 92 Engine Oil Lubrication System 1 LEFT CYLINDER HEAD OIL GALLERY 2 OIL PRESSURE SENSOR LOCATION 3 TO LEFT CYLINDER HEAD 4 OIL FEED TO IDLER SHAFT 5 OIL PUMP OUTLET TO BLOCK 6 OIL PUMP 7 TO CRANKSHAFT MAIN JOURNALS 8 RIGHT CYLINDER HEAD OIL GALLERY 9 TO RIGHT CYLINDER HEAD 10 CYLINDER BLOCK MAIN GALLERY 11 OIL FEED ...

Page 1374: ...lery Block Main Oil Gallery 1 Crankshaft Main Journal 2 Left Cylinder Head 3 Right Cylinder Head Crankshaft Main Journals Crankshaft Rod Journals Crankshaft Number One Main Journal 1 Front Timing Chain Idler Shaft 2 Both Secondary Chain Tensioners Left Cylinder Head See Table 2 Right Cylinder Head See Table 2 The cylinder head gaskets have an oil restricter to control oil flow to the cylinder head...

Page 1375: ...head cover Cap or plug the PCV valve grommet 3 Attach an air hose with pressure gauge and regulator to the dipstick tube CAUTION Do not subject the engine assembly to more than 20 6 kPa 3 PSI of test pressure 4 Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provide the best bubbl...

Page 1376: ...ND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi fied MOPARt provides...

Page 1377: ...until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Hoist and support vehicle on safety stands 3 Remove oil fill cap 4 Place a suitable drain pan under crankcase drain 5 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for stretch ing or other damage Replace drain plug if damaged 6 Install drain pl...

Page 1378: ...using special tool 8534 to pro vide clearance to remove oil pan NOTE Do not pry on oil pan or oil pan gasket Gas ket is integral to engine windage tray and does not come out with oil pan 9 Remove the oil pan mounting bolts and oil pan 10 Unbolt oil pump pickup tube and remove tube 11 Inspect the integral windage tray and gasket and replace as needed INSTALLATION 1 Clean the oil pan gasket mating s...

Page 1379: ...RATION The oil pressure sensor uses two circuits They are A signal to the PCM relating to engine oil pres sure A sensor ground through the PCM s sensor return The oil pressure sensor returns a voltage signal back to the PCM relating to engine oil pressure This signal is then transferred bussed to the instrument panel on a CCD bus circuit to operate the oil pres sure gauge and the check gauges lamp...

Page 1380: ... grooved the oil pump assembly should be replaced 2 Lay a straight edge across the pump cover sur face Fig 101 If a 0 025 mm 0 001 in feeler gauge can be inserted between the cover and the straight edge the oil pump assembly should be replaced 3 Measure the thickness of the outer rotor Fig 102 If the outer rotor thickness measures at 12 005 mm 0 472 in or less the oil pump assembly must be replace...

Page 1381: ...The 3 7 Oil pump is released as an assem bly There are no DaimlerChrysler part numbers for Sub Assembly components In the event the oil pump is not functioning or out of specification it must be replaced as an assembly ASSEMBLY 1 Wash all parts in a suitable solvent and inspect carefully for damage or wear 2 Install inner and outer rotors 3 Install oil pump cover plate and install cover bolts and ...

Page 1382: ...ELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water at the suspected leak area 3 If a change in RPM is observed the area of the suspected leak has been found 4 Repair as required REMOVAL 1 Disconnect negative cable from battery 2 Remove resonator assembly and air inlet hose 3 Disconnect throttle and speed control cables 4 Disconnect electrical connectors f...

Page 1383: ...or straps 5 Install throttle body assembly 6 Install throttle cable bracket 7 Connect throttle cable and speed control cable to throttle body 8 Install fuel rail Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL RAIL INSTALLATION 9 Install ignition coil towers Refer to 8 ELEC TRICAL IGNITION CONTROL IGNITION COIL INSTALLATION 10 Position and install heater hoses and tubes onto intake manifold 11 Install ...

Page 1384: ...ove air cleaner assembly resonator assem bly and air inlet hose 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove A C compressor Refer to 24 HEAT ING AIR CONDITIONING PLUMBING A C COM PRESSOR REMOVAL 5 Remove A C accumulator support bracket fas tener 6 Drain coolant below heater hose level Refer to 7 COOLING STANDARD PROCEDURE 7 Remove heater hoses at en...

Page 1385: ...ld Right ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE 1 Stud Qty 2 25 N m 18 ft lbs 4 Nut Qty 2 8 N m 72 in lbs then loosen 45 degrees 2 Bolt Qty 4 5 Nut Qty 2 3 Stud Qty 2 9 162 ENGINE 4 7L DR EXHAUST MANIFOLD Continued ...

Page 1386: ...ngine compartment CLEANING 1 Clean the exhaust manifold using a suitable cleaning solvent then allow to air dry 2 Clean all gasket residue from the manifold mating surface INSPECTION 1 Inspect the exhaust manifold for cracks in the mating surface and at every mounting bolt hole 2 Using a straight edge and a feeler gauge check the mating surface for warp and twist 3 Inspect the manifold to exhaust ...

Page 1387: ... then loosen 45 degrees 5 Install starter and fasteners 6 Connect exhaust pipe to manifold 7 Connect heater hoses at engine 8 Install fastener attaching A C accumulator 9 Install A C compressor and fasteners 10 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 11 Install air cleaner assembly resonator assem bly and air inlet hose 12 Install battery and connec...

Page 1388: ...o 25 N m 18 ft lbs CAUTION Over tightening heat shield fasteners may cause shield to distort and or crack 4 Install exhaust manifold heat shield Fig 113 Tighten fasteners to 8 N m 72 in lbs then loosen 45 degrees 5 Connect exhaust pipe to manifold 6 Connect negative cable to battery Fig 113 Exhaust Manifold Left ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE 1 Stud Qty 2 25 N m 18 ft lbs 4 Nut Qt...

Page 1389: ...ckets and a fifty tooth sprocket that is splined to the assembly The spline joint is a non serviceable press fit anti rattle type The idler sprocket assembly spins on a station ary idler shaft The idler shaft is press fit into the cylinder block A large washer on the idler shaft bolt and the rear flange of the idler shaft are used to con trol sprocket thrust movement Pressurized oil is routed thro...

Page 1390: ...ndary timing chain ten sioner housing and the step ledge on the piston Fig 115 The measurement at point A must be less than 15mm 0 5906 inches 3 If the measurement exceeds the specification the secondary timing chains are worn and require replacement Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL NOTE If the secondary chains are to be replaced the primary chain must also be...

Page 1391: ... of the camshaft drive gears are off in the same or opposite directions the primary chain or both secondary chains are at fault Refer to Timing Chain and Sprockets procedure in this section 5 If only one of the camshaft drive gears is off and the other is correct the problem is confined to one secondary chain Refer to Single camshaft tim ing in this procedure 6 If both camshaft drive gear V8 marks...

Page 1392: ...ripping the camshaft place the pliers on the tube portion of the camshaft only Do not grip the lobes or the sprocket areas 5 Using a suitable pair of adjustable pliers rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear Fig 119 CAUTION Remove excess oil from camshaft sprocket retaining bolt before reinstalling bolt Fail ure to do so may...

Page 1393: ...egative cable 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Disconnect both heater hoses at timing cover 4 Disconnect lower radiator hose at engine 5 Remove crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 6 Remove accessory drive belt tensioner assembly Fig 122 Fig 120 Camshaft Sprocket Left Cylinder Head 1 TORQUE WRENCH 2 CAMSHAFT SPROCKET 3 LEFT CYLINDE...

Page 1394: ... special RTV sealer instead of a carrier gasket to seal the timing cover to the engine block from the factory For service repairs MoparT Engine RTV must be used as a sub stitute if RTV is present 2 Inspect the water passage o rings for any dam age and replace as necessary 3 Apply Mopart Engine RTV sealer to the front cover following the path below using a 3 to 4mm thick bead Fig 124 4 Install cove...

Page 1395: ...ER HEAD CYLIN DER HEAD COVER S REMOVAL 4 Remove radiator fan shroud 5 Rotate engine until timing mark on crankshaft damper aligns with TDC mark on timing chain cover Fig 126 1 cylinder exhaust stroke and the cam shaft sprocket V8 marks are at the 12 o clock posi tion Fig 127 6 Remove power steering pump Refer to 19 STEERING PUMP REMOVAL Fig 126 Engine Top Dead Center TDC Indicator Mark 1 TIMING CH...

Page 1396: ...Do not hold target wheel while loosening or tightening camshaft sprocket Do not place the target wheel near a magnetic source of any kind A damaged or magnetized tar get wheel could cause a vehicle no start condition CAUTION Do not forcefully rotate the camshafts or crankshaft independently of each other Damaging intake valve to piston contact will occur Ensure negative battery cable is disconnect...

Page 1397: ...ar Some tooth markings are normal and not a cause for sprocket replacement Idler sprocket assembly bushing and shaft for excessive wear Idler sprocket assembly spline joint The joint should be tight with no backlash or axial movement Chain guides and tensioner arms Replace these parts if grooving in plastic face is more than 1 mm 0 039 in deep If plastic face is severely grooved or melted the tens...

Page 1398: ...3 SECONDARY TENSIONER ARM 4 LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN 5 CHAIN GUIDE 6 TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN 7 PRIMARY CHAIN 8 IDLER SPROCKET 9 CRANKSHAFT SPROCKET 10 PRIMARY CHAIN TENSIONER 11 TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN 12 SECONDARY TENSIONER ARM DR ENGINE 4 7L 9 175 TIMING BELT CHAIN AND SPROCKETS Continued ...

Page 1399: ...uide Tighten the bolts to 28 N m 250 in lbs CAUTION Overtightening the tensioner arm torxT bolt can cause severe damage to the cylinder head Tighten torxT bolt to specified torque only 5 Install left side chain tensioner arm Apply Mopart Lock N Seal to torxt bolt tighten bolt to 17 N m 150 in lbs 6 Install the right side chain guide Tighten the bolts to 28 N m 250 in lbs 7 Install both secondary c...

Page 1400: ... at the 12 o clock position Fig 133 CAUTION Ensure the plate between the left sec ondary chain tensioner and block is correctly installed 15 Install both secondary chain tensioners Tighten bolts to 28 N m 250 in lbs NOTE Left and right secondary chain tensioners are not common 16 Before installing idler sprocket bolt lubricate washer with oil and tighten idler sprocket assembly retaining bolt to 3...

Page 1401: ...ead covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION NOTE Before installing threaded plug in right cylin der head the plug must be coated with sealant to prevent leaks 24 Coat the large threaded access plug with Mopart Thread Sealant with Teflon then install into the right cylinder head and tighten to 81 N m 60 ft lbs Fig 128 25 Install the oil fill housing 26 Install acce...

Page 1402: ... 4 Using Special Tool 8517 Slide Hammer remove the idler shaft INSTALLATION 1 Thoroughly clean the idler shaft bore 2 Position the idler shaft in the bore NOTE The two lubrication holes in the idler shaft do not require any special alignment NOTE Before using the retaining bolt to install the idler shaft coat the threads and the pilot on the idler shaft with clean engine oil 3 Using the primary id...

Page 1403: ... CYLINDER HEAD COVER S REMOVAL 201 INSTALLATION 201 INTAKE EXHAUST VALVES SEATS DESCRIPTION DESCRIPTION VALVE GUIDES 202 DESCRIPTION 202 STANDARD PROCEDURE REFACING 202 REMOVAL 203 INSTALLATION 203 ROCKER ARM ADJUSTER ASSY REMOVAL 203 INSTALLATION 203 VALVE STEM SEALS DESCRIPTION 203 VALVE SPRINGS REMOVAL 204 INSTALLATION 204 ENGINE BLOCK CLEANING 205 INSPECTION 205 CAMSHAFT BEARINGS IN BLOCK REMO...

Page 1404: ... 220 DIAGNOSIS AND TESTING ENGINE OIL LEAK 220 OIL STANDARD PROCEDURE ENGINE OIL SERVICE 222 OIL FILTER REMOVAL 223 INSTALLATION 223 OIL PAN REMOVAL 224 INSTALLATION 224 OIL PUMP REMOVAL 224 CLEANING 224 INSPECTION 224 INSTALLATION 225 INTAKE MANIFOLD DESCRIPTION 225 DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKAGE 225 REMOVAL 226 CLEANING 226 INSPECTION 226 INSTALLATION 226 EXHAUST MANIFOLD DESCRIPT...

Page 1405: ...s single cam overhead valve engine with hydraulic roller tappets The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs The cyl inders 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 3 6 5 7 2 Fig 1 5 7L ENGINE 9 182 ENGINE 5 7L DR ...

Page 1406: ...s Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING Cylinder Combustion Pressure Leakage Test Refer to 9 ENGINE DIAGNOSIS AND TEST ING Engine Cylinder Head Gasket Failure Diagnosis Refer to 9 ENGINE CYLINDER HEAD DIAGNO SIS AND TESTING Intake Manifold Leakage Diagnosis Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAGNOSIS ...

Page 1407: ...STING 4 Blown cylinder head gasket 4 Replace cylinder head gasket 5 Low compression 5 Refer to 9 ENGINE DIAGNOSIS AND TESTING 6 Burned warped or pitted valves 6 Replace as necessary 7 Plugged or restricted exhaust system 7 Inspect and replace as necessary 8 Faulty coil 8 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 1 ENGINE MISSES ON ACCELERATION 1 Spark plugs dirty or incorrectly ...

Page 1408: ...ISE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or diluted oil 3 Change oil and filter 4 Excessive bearing clearance 4 Replace as necessary 5 Connecting rod journal out of round 5 Service or replace crankshaft 6 Misaligned connecting rods 6 Replace bent connecting rods MA...

Page 1409: ... source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 psi recom mended 7 Perform the test procedures on each cylinder according to the tester manufacturer s instructions Set piston of cylinder to be tested at TDC compres sion While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubble...

Page 1410: ...P 1 Low oil level 1 Check and correct oil level 2 Faulty oil pressure sending unit 2 Replace sending unit 3 Low oil pressure 3 Check pump and bearing clearance 4 Clogged oil filter 4 Replace oil filter 5 Worn oil pump 5 Replace as necessary 6 Thin or diluted oil 6 Change oil and filter 7 Excessive bearing clearance 7 Replace as necessary 8 Oil pump relief valve stuck 8 Replace oil pump 9 Oil picku...

Page 1411: ...ded 7 Worn tappets lash adjusters 7 Install new hydraulic tappets lash adjusters 8 Worn valve guides 8 Inspect all valve guides and replace as necessary 9 Excessive runout of valve seats or valve faces 9 Grind valves and seats CONNECTING ROD NOISE 1 Insufficient oil supply 1 Check engine oil level 2 Low oil pressure 2 Check engine oil level If ok Perform oil pressure test Refer to 9 ENGINE LUBRICA...

Page 1412: ...l 1 Check oil level and fill if necessary 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Clogged oil filter 3 Install new oil filter 4 Worn oil pump 4 Replace oil pump assembly 5 Thin or diluted oil 5 Change oil to correct viscosity 6 Excessive bearing clearance 6 Measure bearings for correct clearance 7 Oil pump relief valve stuck 7 Remove valve to inspect clean and reinstall 8 O...

Page 1413: ...DELIVERY STANDARD PROCEDURE 2 Disconnect the negative cable s from the bat tery 3 Inspect air cleaner induction system and intake manifold to ensure system is dry and clear of foreign material 4 Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head Remove the spark plugs 5 With all spark plugs removed rotate the crank shaft using a br...

Page 1414: ... bly if disturbed Install transmission input shaft into clutch disc while mating engine and transmis sion surfaces Install two transmission to engine block mounting bolts finger tight Automatic Transmission Mate engine and trans mission and install two transmission to engine block mounting bolts finger tight 4 Position the thru bolt into the support cushion brackets 5 Lower engine assembly until e...

Page 1415: ...ns Aluminum Alloy Connecting Rods Powdered Metal CYLINDER BLOCK DESCRIPTION SPECIFICATION Metric Standard Cylinder Bore Diameter 99 50 mm 3 917 in Out of Round MAX 0 0076 mm 0003 in Taper MAX 0 0127 mm 0 0005 in Lifter Bore Diameter 21 45 21 425 mm 0 8444 0 8435 in PISTONS DESCRIPTION SPECIFICATION Metric Standard Clearance at Top of Skirt 0 0215 0 0485 mm 0 0008 0 0019 in Measured at 45 0 mm 1 77...

Page 1416: ...TION SPECIFICATION Metric Standard Main Bearing Journal Diameter 64 988 65 012 mm 2 5585 2 5595 in Bearing Clearance 0 023 0 051 mm 0 0009 0 002 in Out of Round MAX 0 005 mm 0 0002 in Taper MAX 0 003 mm 0 0001 in End Play 0 052 0 282 mm 0 002 0 011 in End Play MAX 0 282 mm 0 011 in Connecting Rod Journal Diameter 53 992 54 008 mm 2 125 2 126 in Bearing Clearance 0 020 0 060 mm 0 0007 0 0023 in Out...

Page 1417: ...y Diameter 21 387 21 405 mm 0 8420 0 8427 in Clearance To Bore 0 020 0 063 mm 0 0007 0 0024 in Dry Lash 3 0 mm at the valve 0 1181 in VALVES DESCRIPTION SPECIFICATION Face Angle 45 0 45 5 Head Diameter Intake 50 67 50 93 mm 1 99 2 00 in Exhaust 39 27 39 53 mm 1 54 1 55 in Length Overall Intake 123 38 123 76 mm 4 857 4 872 in Exhaust 120 475 120 855 mm 4 743 4 758 in Stem Diameter Intake 7 935 7 95...

Page 1418: ...ssure is zero at curb idle DO NOT run engine TORQUE TORQUE CHART 5 7L ENGINE DESCRIPTION N m Ft In Lbs Lbs Block Pipe Plugs 1 4 NPT 20 177 3 8 NPT 27 240 Camshaft Sprocket Bolt 122 90 Camshaft Tensioner Plate Bolts 28 250 Timing Chain Case Cover Bolts 28 250 Lifting Stud 55 40 Connecting Rod Cap Bolts 21 plus 90 Turn 15 plus 90 Turn Main Bearing Cap Bolts M 12 27 plus 90 Turn Crossbolts M 8 28 Cyl...

Page 1419: ...r Insulator to Transmission 68 50 Bolts 4WD Rear Insulator Bracket Bolts 68 50 4WD Automatic Rear Support Bracket to 41 30 Crossmember Flange Nuts Rear Support Plate to Transfer 41 30 Case Bolts Rocker Arm Bolts 22 195 Spark Plugs Thermostat Housing Bolts 28 250 Throttle Body Bolts 12 105 Transfer Case to Insulator 204 105 Mounting Plate Nuts Transmission Support Bracket 68 50 Bolts 2WD Vibration ...

Page 1420: ...ssure Gauge C 3292 Piston Ring Compressor C 385 Pressure Tester Kit 7700 Rear Crankshaft Seal Installer 8349 Rear Crankshaft Seal Remover 8506 Valve Spring Compressor C 3422 B Valve Spring Tester C 647 DR ENGINE 5 7L 9 197 ENGINE 5 7L Continued ...

Page 1421: ...64 ENGINE SUPPORT FIXTURE 8534 ENGINE LIFT FIXTURE 8984 REAR CAM PLUG INSTALLER 9048 VALVE SPRING COMPRESSOR 9065 PUSHROD RETAINING PLATE 9070 FRONT CRANK SEAL REMOVER 9071 FRONT CRANK SEAL INSTALLER 9072 9 198 ENGINE 5 7L DR ENGINE 5 7L Continued ...

Page 1422: ...orque 5 If any other hose clamps were removed from air intake system tighten them to 3 4 N m 30 in lbs torque 6 If any bolts were removed from air resonator housing or air intake tubing tighten them to 4 5 N m 40 in lbs torque CYLINDER HEAD OPERATION CYLINDER HEAD The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition...

Page 1423: ...ollowing the procedures supplied with the tool kit REMOVAL 1 Disconnect the battery negative cable 2 Drain cooling system 3 Remove the air cleaner resonator and duct work 4 Remove the generator 5 Remove closed crankcase ventilation system 6 Disconnect the evaporation control system 7 Perform the Fuel System Pressure Release pro cedure Refer to 14 FUEL SYSTEM FUEL DELIV ERY STANDARD PROCEDURE Disco...

Page 1424: ...aps in those locations only 3 Remove cylinder head cover retaining bolts and ground straps 4 Remove cylinder head cover NOTE The gasket may be used again provided no cuts tears or deformation has occurred INSTALLATION CAUTION Do not use harsh cleaners to clean the cylinder head covers Severe damage to covers may occur CAUTION DO NOT allow other components includ ing the wire harness to rest on or ...

Page 1425: ...ply a small amount of Prussian blue to the valve seat insert the valve into the cylinder head while applying light pressure on the valve rotate the valve Remove the valve and examine the valve face If the blue is transferred below the top edge of the valve face lower the valve seat using a 15 degree stone If the blue is transferred to the bottom edge of the valve face raise the valve seat using a ...

Page 1426: ...g sequence Center center left center right left right CAUTION The rocker shaft assemblies are not interchangeable between intake and exhaust The intake rocker arms are marked with an I 3 Remove the rocker shafts Note location for reassembly CAUTION The longer push rods are for the exhaust side and the shorter push rods are for intake side 4 Remove the pushrods Note pushrod location for reassembly ...

Page 1427: ...pring retainer and locks 4 Release air charge in cylinder 5 Remove spring compressor tool 9065 CAUTION Verify that the pushrods are fully seated into lifter and rocker arm Recheck after rocker arm shaft has been torqued to specification 6 Install rocker arm shaft and pushrods Refer to 9 ENGINE CYLINDER HEAD ROCKER ARM ADJUSTER ASSY INSTALLATION 7 Tighten the rocker shaft bolts to 22 N m 195 in lbs...

Page 1428: ...oundness by comparing the difference between each measurement 7 If cylinder bore taper does not exceed 0 025 mm 0 001 inch and out of roundness does not exceed 0 025 mm 0 001 inch the cylinder bore can be honed If the cylinder bore taper or out of round condition exceeds these maximum limits the cylinder block must be replaced A slight amount of taper always exists in the cylinder bore after the e...

Page 1429: ... it was removed When camshaft is replaced all of the tappets must be replaced 8 Install the tappets and retainer assembly Refer to 9 ENGINE ENGINE BLOCK HYDRAULIC LIFT ERS CAM IN BLOCK INSTALLATION 9 Install both left and right cylinder heads Refer to 9 ENGINE CYLINDER HEAD INSTALLA TION 10 Install pushrods 11 Install rocker arms Refer to 9 ENGINE CYL INDER HEAD ROCKER ARM ADJUSTER ASSY INSTALLATI...

Page 1430: ...all timing drive Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 11 Install oil pump Refer to 9 ENGINE LU BRICATION OIL PUMP INSTALLATION 12 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 13 Install the rear main seal and retainer Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT REAR OIL SEAL RETAINE INSTALLATION 14 Install...

Page 1431: ...E BELTS REMOVAL 3 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 4 Remove upper radiator hose 5 Remove radiator shroud attaching fasteners 6 Remove radiator cooling fan and shroud Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 7 Remove crankshaft damper bolt 8 Remove damper using Special Tools 8513A Insert and 8454 Three Jaw Puller 9 Using Special Tool 9071 remove crankshaft front seal...

Page 1432: ... no further inspection can be done until dis assembled Refer to 9 ENGINE DIAGNOSIS AND TESTING under the Oil Leak row for components inspections on possible causes and corrections 7 After the oil leak root cause and appropriate corrective action have been identified Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL REMOVAL NOTE This procedure can be performed in vehicle 1 If being pr...

Page 1433: ... noisily LOW Low oil level may allow oil pump to take in air When air is fed to the tappets they lose length which allows valves to seat noisily Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action Check the lubrication system from the intake strainer to the pump cover including the relief valve retainer cap When tappet noise is due to aeration it ...

Page 1434: ...ave become quiet 10 Road test vehicle and check for leaks PISTON CONNECTING ROD DESCRIPTION CAUTION Do not use a metal stamp to mark con necting rods as damage may result instead use ink or a scratch awl The pistons are made of a high strength aluminum alloy Piston skirts are coated with a solid lubricant Molykote to reduce friction and provide scuff resis tance The piston top ring groove and land...

Page 1435: ...E Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly 4 Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool Fig 12 CAUTION Care must be taken not to damage the fractured rod and cap joint face surfaces as engine damage may occur 5 Remove connecting rod cap Install Special Tool 8507 Connecti...

Page 1436: ... bore and carefully position connect ing rod guides over crankshaft journal 8 Tap piston down in cylinder bore using a ham mer handle While at the same time guide connect ing rod into position on rod journal CAUTION Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused Always replace the Rod Bolts whenever they are loosened or removed 9 Lubricate rod bolts and bearing surfaces with...

Page 1437: ...ntrol Ring 0 015 0 66mm 1 55mm Steel Rail 0 0059 0 0259 in 0 061 in 7 The No 1 and No 2 piston rings have a differ ent cross section Ensure No 2 ring is installed with manufacturers I D mark Dot facing up towards top of the piston NOTE Piston rings are installed in the following order Oil ring expander Lower oil ring side rail Upper oil ring side rail No 2 Intermediate piston ring No 1 Upper pisto...

Page 1438: ...ere damage to the Crank shaft Damper or Special Tool 8512 A thoroughly clean the damper bore and the crankshaft nose before installing Damper 1 Slide damper onto crankshaft slightly CAUTION Special Tool 8512 A is assembled in a specific sequence Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft 2 Assemble Special Tool 8...

Page 1439: ...all all four bolts retaining the cover to en gine DO NOT tighten the bolts at this time 3 Install the four cover to transmission bolts Do NOT tighten at this time CAUTION The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence Failure to do so may cause damage to the cover 4 Torque the 4 structural dust cover bolts that go into...

Page 1440: ... bolts that go into the block in an X pattern to 54 N m 40 ft lbs 9 Torque the structural cover bolts that go into the clutch housing to 54 N m 40 ft lbs 10 Torque the 7 16 inch engine block to clutch housing bolts to 68 N m 50 ft lbs FRONT MOUNT REMOVAL 2WD 1 Disconnect negative battery cable 2 Raise vehicle 3 Remove engine mount through bolts 4 Raise engine using engine support fixture spe cial ...

Page 1441: ...engine mounts INSTALLATION 2WD 1 Install insulator on the engine Fig 24 NOTE For mount to engine block and left engine bracket to front axle bolts apply MoparT Lock and Seal Adhesive Medium Strength Threadlocker 2 Install upper and lower mount mounting bolts Tighten bolts to 61 N m 45 ft lbs 3 Lower the engine using engine support fixture special tool 8534 Fig 22 LH INSULATOR 1 BOLT 2 INSULATOR Fi...

Page 1442: ... loose assemble the two nuts onto the through bolts 4 Lower the engine using engine support fixture special tool 8534 until the left and right side engine brackets rest on the through bolts and the lower engine bracket through holes align with the engine mounts and the left engine bracket holes align with the front axle slots Fig 25 5 Loose assemble the 3 bolts that attach the front axle to the le...

Page 1443: ...NOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 1 Remove oil pressure sending unit and install gauge assembly C 3292 2 Run engine until thermostat opens 3 Oil Pressure Curb Idle 25 kPa 4 psi minimum 3000 rpm 170 758 kPa 25 110 psi 4 If oil pressure is 0 at idle shut off engine Check for a clogged oil pick up screen or a pressure relief valve stuck open DIAGNOSIS AND TESTING ENGINE OIL LEAK Begin wi...

Page 1444: ...res 4 If the leakage occurs at the rear oil seal area refer to the section Inspection for Rear Seal Area Leak 5 If no leaks are detected turn off the air supply and remove the air hose and all plugs and caps Install the PCV valve 6 Clean the oil off the suspect oil leak area using a suitable solvent Drive the vehicle at various speeds approximately 24 km 15 miles Inspect the engine for signs of an...

Page 1445: ...RDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API SERVICE GRADE CERTIFIED Use an en...

Page 1446: ... to 34 N m 25 ft lbs 7 Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec tion 8 Install oil fill cap 9 Start engine and inspect for leaks 10 Stop engine and inspect oil level USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine Refer to the WARNING at beginning of this sect...

Page 1447: ...gh bolts Tighten the nuts to 68 N m 50 ft lbs 7 Remove special tool 8534 8 Install structural dust cover if equipped 9 Install the front crossmember Refer to 13 FRAME BUMPERS FRAME FRONT CROSS MEMBER INSTALLATION 10 Fill engine oil 11 Reconnect the negative battery cable 12 Start engine and check for leaks OIL PUMP REMOVAL 1 Remove the oil pan and pick up tube Refer to 9 ENGINE LUBRICATION OIL PAN...

Page 1448: ...anifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold vacuum Also one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PU...

Page 1449: ...pattern Torque fasteners to 12 N m 105 in lbs 4 Connect electrical connectors for the following components Manifold Absolute Pressure MAP Sensor Intake Air Temperature IAT Sensor Throttle Position TPS Sensor Coolant Temperature CTS Sensor Idle Air Control IAC Motor 5 Install generator 6 Install A C compressor 7 Connect Brake booster hose and Positive crank case ventilation PCV hose 8 Install reson...

Page 1450: ...haft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL NOTE Do not remove the hoses from the power steering pump 15 Remove power steering pump and set aside 16 Remove the dipstick support bolt 17 Drain the engine oil 18 Remove the oil pan and pick up tube Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL NOTE It is not necessary to remove water pump for timing cover removal 19 Remove timi...

Page 1451: ... to 28 N m 250 in lbs 2 Retract tensioner if required CAUTION The camshaft pin and the slot in the cam sprocket must be clocked at 12 00 The crankshaft keyway must be clocked at 2 00 The crankshaft sprocket must be installed so that the dots and or paint marking is at 6 00 3 Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through b...

Page 1452: ...ON 12 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 13 Connect battery negative cable 14 Start engine and check for oil and coolant leaks TIMING CHAIN TENSIONER DESCRIPTION The timing chain tensioner is a stamped steel con stant tension mechanical design It is mounted to the front of the engine behind the timing chain drive OPERATION The timing chain tension is maintained by routing th...

Page 1453: ...EAD COVER S REMOVAL REMOVAL CYLINDER HEAD COVER 255 REMOVAL ROCKER HOUSING 255 CLEANING 255 INSPECTION 255 INSTALLATION INSTALLATION CYLINDER HEAD COVER 255 INSTALLATION ROCKER HOUSING 255 INTAKE EXHAUST VALVES SEATS DESCRIPTION 256 STANDARD PROCEDURE STANDARD PROCEDURE VALVES GUIDES AND SPRINGS 256 STANDARD PROCEDURE VALVE LASH ADJUSTMENT AND VERIFICATION 259 REMOVAL VALVE SPRINGS AND SEALS 260 I...

Page 1454: ...BRICATION DESCRIPTION 289 OPERATION 289 DIAGNOSIS AND TESTING ENGINE OIL PRESSURE 289 OIL STANDARD PROCEDURE STANDARD PROCEDURE ENGINE OIL LEVEL 292 STANDARD PROCEDURE ENGINE OIL SERVICE 292 OIL COOLER LINES CLEANING CLEANING AND INSPECTION 293 OIL FILTER REMOVAL 293 INSTALLATION 293 OIL PAN REMOVAL 293 CLEANING 293 INSPECTION 293 INSTALLATION 293 OIL PRESSURE RELIEF VALVE REMOVAL 294 CLEANING 294...

Page 1455: ...ad o ring fittings at lubrication oil access points The engine Fig 1 is manufactured with the cylinders being a non sleeved type cylinder However one approved service method is to bore out the cylinders and add cylinder sleeves to the cylinder block The cylinders are numbered front to rear Fig 2 1 to 6 The firing order is 1 5 3 6 2 4 Fig 1 CumminsT 24 Valve Turbo Diesel Engine Fig 2 Cylinder Numbe...

Page 1456: ... plugs 7 Worn oil pump 7 Check and replace oil pump 8 Suction tube loose or seal leaking 8 Check and replace seal 9 Loose main bearing cap 9 Check and install new bearing Tighten cap to proper torque 10 Worn bearings or wrong bearings installed 10 Inspect and replace connecting rod or main bearings Check and replace directed piston cooling nozzles 11 Directed piston cooling nozzles under piston ba...

Page 1457: ...ired repairs 6 Turbocharger leaking oil to the air intake 6 Inspect the air ducts for evidence of oil transfer Repair as required COMPRESSION KNOCKS 1 Air in the fuel system 1 Identify location of air leak and repair Do not bleed high pressure fuel system 2 Poor quality fuel or water gasoline contaminated fuel 2 Verify by operating from a temporary tank with good fuel Clean and flush the fuel tank...

Page 1458: ...enerator and power steering pump turn freely 2 Intake air or exhaust leaks 2 Refer to Excessive Exhaust Smoke Refer to 9 ENGINE DIAGNOSIS AND TESTING 3 Excessive valve lash 3 Adjust valves Make sure the push rods are not bent and rocker arms adjusting screws crossheads are not severely worn Replace bent or severely worn components 4 Turbocharger noise 4 Check turbocharger impeller and turbine whee...

Page 1459: ... fuel brands and note condition Change brand if necessary Fuel injection pump malfunctioning A DTC may have been set If so refer to Powertrain Diagnostic Procedures Information Fuel injector malfunctioning A DTC may have been set Perform 9Cylinder Cutout Test9 using DRB scan tool to isolate individual cylinders Also refer to Powertrain Diagnostic Procedures Information and to Refer to 14 FUEL SYST...

Page 1460: ...ing DRB scan tool to isolate individual cylinders Also refer to Powertrain Diagnostic Procedures Information and Refer to 14 FUEL SYSTEM FUEL INJECTION FUEL INJECTOR DIAGNOSIS AND TESTING Fuel injector hold downs loose Torque to specifications Fuel injector protrusion not correct Check washer shim at bottom of fuel injector for correct thickness Refer to 14 FUEL SYSTEM FUEL INJECTION FUEL INJECTOR...

Page 1461: ...d or guides are worn Remove valves and inspect valves and guides Refer to 9 ENGINE CYLINDER HEAD INTAKE EXHAUST VALVES SEATS STANDARD PROCEDURE Broken or Improperly installed piston rings Tear down engine and inspect piston rings Excessive piston ring end gap Remove pistons and measure piston ring end gap Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS STANDARD PROCEDURE Excessive cylinder bore wear a...

Page 1462: ...on pressure leakage testing will detect Exhaust and intake valve leaks improper seat ing Leaks between adjacent cylinders or into water jacket Any causes for combustion compression pressure loss 1 Start and operate the engine until it attains normal operating temperature 2 Remove the breather cover and cylinder head cover 3 Disconnect all three injector wire harness con nectors at the rocker housi...

Page 1463: ... be circled For corner sealing a 3 17 or 6 35 mm 1 8 or 1 4 in drop is placed in the center of the gasket contact area Uncured sealant may be removed with a shop towel Components should be torqued in place while the sealant is still wet to the touch within 10 minutes The usage of a locating dowel is recommended during assembly to prevent smearing material off the location Mopart Gasket Sealant in ...

Page 1464: ...RTER MOTOR REMOVAL 22 Remove flywheel flexplate 23 Remove transmission adapter 24 Disconnect A C suction discharge hose from the rear of the A C compressor 25 Lower vehicle 26 Disconnect lower radiator hose from radiator outlet 27 Automatic transmission models 28 Disconnect transmission oil cooler lines from in front of radiator using special tool 6931 29 Remove radiator Refer to 7 COOLING EN GINE...

Page 1465: ...e diagram below Install special Tool 9009 Torque bolts to 105N m 77ft lbs 2 Lower engine into the engine compartment and install the engine the engine mount through bolts and nuts 3 Tighten the mount through bolts and nuts to 88 N m 65 ft lbs torque 4 Remove the engine lifting device Tool 9009 5 Check cylinder head capscrew length and install into cylinder head 6 Torque in 4 steps to Step 1 Tighte...

Page 1466: ...e a c refrigerant lines to the a c condenser if equipped 25 Install the radiator upper support panel 26 Install radiator 27 Connect the transmission quick connect oil cooler lines 28 Raise vehicle 29 Connect a c compressor suction discharge hose if equipped 30 Install the radiator lower hose and clamps 31 Install the battery negative cables to the engine block on the driver and passenger side 32 I...

Page 1467: ... 4 Cylinder Block Cast Iron Crankshaft Induction Hardened Forged Steel Cylinder Head Cast Iron With Valve Seat Inserts Combustion Chambers High Swirl Bowl Camshaft Chilled Ductile Iron Pistons Cast Aluminum Connnecting Rods Cross Rolled Micro Alloy PISTONS DESCRIPTION SPECIFICATION Metric Standard Skirt Diameter 101 775 101 793 mm 4 007 4 008 in Ring Groove Clearance Intermediate Min 0 045 mm 0018...

Page 1468: ...ing 344 75 kPa 50 psi TORQUE TORQUE CHART 5 9L DIESEL ENGINE DESCRIPTION N m In Lbs Ft Lbs Connecting Rod Bolts Step 1 30 22 Step 2 60 44 Step 3 Rotate 60 degrees Crankshaft Main Cap Bolts Step 1 50 37 Step 2 80 59 Step 3 Rotate 90 Cylinder Head Bolts Step 1 70 52 Step 2 Back off 360 degrees Step 3 105 77 Step 4 Verify 105 77 Step 5 Rotate All Bolts 1 4 Turn Cylinder Head Cover Bolts 24 18 Breathe...

Page 1469: ...Crankshaft Barring Tool 7471 B Crankshaft Front Oil Seal Installer 8281 Valve Spring Compressor 8319A Test Plug 8442 Adapter 8462 Engine Support Fixture 8534 TAPPET INSTALLATION TOOL 8502 STEEL BRACKET 8534 A 9 246 ENGINE 5 9L DIESEL DR ENGINE 5 9L DIESEL Continued ...

Page 1470: ...9007 Engine Lift Bracket 9009 Fuel Injector Remover 9010 FUEL BLOCKOFF PLUG 9011 FUEL TEST FITTING 9013 Fuel Injector Tube Connector Remover 9015 TURBO TEST ADAPTER 9022 DR ENGINE 5 9L DIESEL 9 247 ENGINE 5 9L DIESEL Continued ...

Page 1471: ...ed within Filter Minder will hold yellow disc at highest restriction that air cleaner ele ment has experienced A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop CAUTION Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder Cover and tape Filter Minder if any engine degreasers or cl...

Page 1472: ... heater core supply and return hoses from the cylinder head and heater pipe 10 Disconnect turbocharger oil supply line at the turbocharger end Cap off open ports to prevent intrusion of dirt or foreign material 11 Remove exhaust manifold to cylinder head bolts spacers heat shield retention straps and cab heater plumbing Remove exhaust manifold and tur bocharger from the vehicle as an assembly 12 R...

Page 1473: ...ts at the intake manifold cover 30 Remove the fuel rail as follows a Remove fuel rail pressure sensor connector b Remove banjo fitting at pressure limiting valve c Remove fuel rail bolts and fuel rail 31 Remove the low pressure lines as follows a Remove the fuel drain banjo fitting on the front side of fuel filter housing b Remove the fuel drain banjo fitting on rear side of fuel filter housing c ...

Page 1474: ... and rocker hous ing and gasket 42 Reinstall the engine lift bracket at the rear of cylinder head Torque to 77 N m 57 ft lbs 43 Remove twenty six 26 cylinder head to block bolts 44 Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle 45 Remove the head gasket and inspect for fail ure CLEANING CLEANING CYLINDER HEAD CAUTION Do not wire brush head ...

Page 1475: ...d to end is 0 305 mm 0 012 inch Fig 13 and maximum overall variation side to side 0 076 mm 003 in DO NOT proceed with the in chassis overhaul if the cylinder head or block surface is damaged or not flat within specifications Check block surface for distortion Maximum vari ation end to end is 0 076 mm 003 in side to side 0 051 mm 002 Visually inspect the cylinder head bolts for dam aged threads cor...

Page 1476: ...s to 70 N m 52 ft lbs b Back off 360 degrees in sequence c Torque bolts to 105 N m 77 ft lbs d Re check all bolts to 105 N m 77 ft lbs e Tighten all bolts an additional 1 4 turn 90 4 Install push rods into their original locations Fig 19 Verify that they are seated in the tap pets 5 Lubricate valve stem tips and install the cross heads in their original locations 6 Lubricate the rocker arms and pe...

Page 1477: ...valve and front of fuel filter housing to 24 Nm 18 ft lbs k Torque fuel line brace bolts to 24 N m 18 ft lbs l Torque rail bolts to 24 Nm 18 ft lbs m Connect fuel pressure sensor 19 Install the engine lift bracket at the rear of cylinder head Torque to 77 N m 57 ft lbs 20 Reposition number 6 fuel line shield and torque to 43 N m 32 ft lbs 21 Install the fuel filter to injection pump low pressure l...

Page 1478: ...ectors 3 Remove injector harness nuts from injectors 4 Remove rocker housing bolts 5 Remove rocker housing and gasket CLEANING Using a suitable solvent Clean and dry gasket mating surfaces on cylinder head and rocker housing Wipe gasket dry and inspect for re use INSPECTION The cylinder head cover gasket and rocker hous ing gasket are reusable However should cracks nicks or tears be present in the...

Page 1479: ...OCEDURE VALVES GUIDES AND SPRINGS REMOVAL 1 Remove cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 2 Support cylinder head on stands or install head bolts upside down through combustion surface side to protect injector tips from damage from work bench 3 Install the valve spring compressor mounting base as shown in Fig 22 4 Install the compressor top plate washer and nut Using a suitable wren...

Page 1480: ...valves for abnormal wear on the heads stems and tips Replace any valve that is worn out or bent Fig 25 Measure the valve stem diameter in three places as shown in Fig 26 Measure the cylinder head valve guide bore Fig 27 VALVE GUIDE BORE SPECIFICATIONS VALVE GUIDE BORE SPECIFICATIONS Valve guide bore diameter Min 7 027 mm 0 2767 in Max 7 077 mm 0 2786 in Installed valve guide depth Intake Min 0 584...

Page 1481: ...33 mm 1 39 in Fig 27 Measure Valve Guide Bore Fig 28 Measure Valve Margin Rim Thickness VALVE MARGIN RIM THICKNESS 0 79 mm 0 031 in MIN Fig 29 Measure Valve Spring Free Length and Max Inclination APPROXIMATE VALVE SPRING FREE LENGTH 47 75 mm 1 88 in MAX INCLINATION 1 5 mm 059 in Fig 30 Testing Valve Spring with Tool C 647 1 SPECIAL TOOL C 647 9 258 ENGINE 5 9L DIESEL DR INTAKE EXHAUST VALVES SEATS...

Page 1482: ...NGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 3 Using the crankshaft barring tool 7471 B rotate crankshaft to align damper TDC mark to 12 00 o clock position a If both number one cylinder rocker levers are loose continue to next step b If both number one clylinder rocker levers are not loose rotate crankshaft 360 degrees 4 With the engine in this position valve lash can be measured at the foll...

Page 1483: ...e mark you just made on the cover 10 Divide the crankshaft damper into three equally sized segments as follows a Using a tape measure measure the circum ference of the crankshaft damper and divide the measurement by three 3 b Measure that distance in a counter clockwise direction from the first balancer mark and place another mark on the balancer c From the second damper mark again mea sure in a c...

Page 1484: ...AKE EXHAUST VALVES SEATS STANDARD PROCEDURE 6 Install cylinder head cover and reusable gasket Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 7 Connect battery negative cables ROCKER ARM ADJUSTER ASSY DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by pas sages intersecting the cylinder block main oil rifle Crossheads are us...

Page 1485: ...als Apply compressed air to lubrication orifices to purge contaminants INSPECTION Rocker Arms 1 Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft Remove socket and inspect ball insert and socket for signs of wear Replace retainer if necessary Measure the rocker arm bore and shaft Fig 39 Fig 40 Fig 36 Rocker Arm and Pedestal Removal 1 ROCKER ARM 2 PEDESTAL Fig 37 Ro...

Page 1486: ... the valve tips and install the cross heads in their original locations 3 Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations Tighten bolts to 36 N m 27 ft lbs torque 4 Verify valve lash adjustment Refer to 9 ENGINE CYLINDER HEAD INTAKE EXHAUST VALVES SEATS STANDARD PROCEDURE 5 Install cylinder head cover and reusable gasket Refer to ...

Page 1487: ...ores 2 De glazing gives the bore the correct surface finish required to seat the rings The size of the bore is not changed by proper de glazing 3 Cover the lube and tappet holes in the top of the block with waterproof tape 4 It crankshaft is installed wrap connecting rod journals with clean cloth Cover cloth with water proof tape 5 A correctly honed surface will have a cross hatch appearance with ...

Page 1488: ... and installing a repair sleeve to return the bore to standard dimensions METHOD 1 OVERSIZE BORE Cylinder bore s can be repaired by one of two methods Oversize pistons and rings are available in two sizes 0 50 mm 0 0197 inch and 1 00 mm 0 0393 inch Any combination of standard 0 50 mm 0 0197 inch or 1 00 mm 0 0393 inch overbore may be used in the same engine If more than 1 00 mm 0 0393 inch overbor...

Page 1489: ...e new repair sleeve thoroughly clean the bore of all metal chips debris and oil residue before installing the sleeve Cool the repair sleeve s to a temperature of 12 C 10 F or below for a minimum of one hour Be ready to install the sleeve immediately after removing it from the freezer Apply a coat of Loctite 620 or equivalent to the bore that is to be sleeved Wear protective gloves to push the cold...

Page 1490: ...bore the intermediate cam bore to the front cam bore oversize dimensions Max imum front and rear camshaft bushing installed diameter is 54 147 mm 2 1318 in Minimum installed diameter is 54 083 mm 2 1293 in Maxi mum intermediate camshaft bore diameter is 54 164 mm 2 1324 in A surface finish of 2 3 micrometers 92 microinch must be maintained Not more than 20 of an area of any one bore may be 3 2 mic...

Page 1491: ...hings If badly worn replace the cylinder block 1 Remove the camshaft Refer to 9 ENGINE ENGINE BLOCK CAMSHAFT BEARINGS IN BLOCK REMOVAL 2 Remove the bushing from the No 1 bore and No 7 using a universal cam bushing tool 3 Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing REMOVAL CAMSHAFT 1 Disconnect both battery negative cables 2 Recover A...

Page 1492: ...emoved by lifting them up and through the provided cowl panel access holes Remove the rubber plugs to expose these relief holes 25 Raise the tappets as follows using the wooden dowel rods Fig 57 provided with the Miller Tool Kit 8502 a Insert the slotted end of the dowel rod into the tappet The dowel rods for the rear two cylinders will have to be cut for cowl panel clearance Press firmly to ensur...

Page 1493: ... mm 2 128 in Journal diameter No 2 through No 6 Min 53 962 mm 2 1245 in Max 54 013 mm 2 1265 in Diameter of peak of lobe Intake Min 47 175 mm 1 857 in Max 47 855 mm Exhaust Min 45 632 mm 1 797 in Max 46 312 mm 1 823 in Camshaft Bushing Bores Camshaft bores No 2 6 do not use a bushing 1 Inspect the camshaft bushing and bores for signs of excessive wear 2 Measure the camshaft bushing and bores Fig 5...

Page 1494: ...rod must be able to pass through the hole Fig 61 3 Install the rear camshaft bushing is flush with the rear face of the block The oil hole must be aligned A 3 2 mm 0 128 inch diameter rod must be able to pass through the hole 4 Measure the installed bushings at the front and rear bores The minimum inside diameter is 54 083 mm 2 1293 inch and the maximum inside diameter is is 54 147 mm 2 1318 in IN...

Page 1495: ... auxiliary oil cooler lines if equipped 25 Lower vehicle 26 Install the fan shroud and tighten the mount ing screws to 6 N m 50 in lbs torque 27 Install the electronically controlled viscous fan drive assembly Connect harness connector Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLATION 28 Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud 29 Connect the coolant ...

Page 1496: ... smooth 2 If removed install a new alignment pin Drive the pin in using a ball peen hammer leaving it pro truding 1 0 mm 0 039 inch to 1 5 mm 0 059 inch above the crankshaft Fig 65 WARNING WEAR PROTECTIVE GLOVES TO PRE VENT INJURY CAUTION DO NOT heat the gear longer than 45 minutes 3 Heat the crankshaft gear for 45 minutes at a temperature of 149 C 300 F Do not use torch gear failure will occur 4 ...

Page 1497: ...ALLED 83 106 mm 3 2719 in BEARINGS REMOVED Min 87 983 mm 3 4639 in Max 88 019 mm 3 4653 in CRANKSHAFT MAIN JOURNAL DIAMETER CHART ITEM SPECIFICATION Minimum diameter 82 962 mm 3 2662 in Maximum diameter 83 013 mm 3 2682 in Maximum out of roundness 0 050 mm 002 in Maximum taper 0 013 mm 0005 in Thrust distance at No 6 position Min 0 065 mm 003 in Max 0 432 mm 017 in 4 Calculate the main bearing jou...

Page 1498: ...table punch and hammer drive the old seal out of the cover from the back side of the cover to the front side Fig 68 INSTALLATION 1 Clean cover and housing gasket mating sur faces Use a suitable scraper and be careful not to damage the gear housing surface Remove any old sealer from the oil seal bore Thoroughly clean the front seal area of the crankshaft The seal lip and the sealing surface on the ...

Page 1499: ...move the flywheel or converter drive plate 5 Drill holes 180 apart into the seal Be careful not to contact the drill against the crankshaft 6 Install 10 sheet metal screws in the drilled holes and remove the rear seal with a slide hammer Fig 71 INSTALLATION CAUTION The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks The crankshaft and seal...

Page 1500: ... 11 Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch INSTALLATION 1 If using the old seal retainer the crankshaft seal must be replaced 2 Inspect oil pan gasket for nickes or cuts If gas ket is damaged the oil pan must be removed and gasket must be replaced Wipe oil pan gasket dry and apply light coating of RTV 3 Using the retainer alignment seal install...

Page 1501: ...nstall the flywheel housing and bolts Torque bolts to 77 N m 57 ft lbs 12 Install the flywheel or converter drive plate Tighten bolts to 137 N m 101 ft lbs 13 Install the starter motor Refer to Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 14 Install the transmission and transfer case if equipped 15 Lower vehicle 16 Fill the crankcase with new engine oil 17 Connect the battery negative...

Page 1502: ...remove trough do not rotate and tappet If the tappet is not being replaced mark it so it can be installed in its original location 6 Re install trough and repeat procedure on remaining tappets CLEANING Clean tappet with a suitable solvent Rinse in hot water and blow dry with a clean shop rag or com pressed air INSPECTION 1 Visually inspect the tappet the tappet socket stem and face for excessive w...

Page 1503: ...n into the tappet bore wiggle the trough while gently pulling up on the tappet 6 With the tappet in place rotate the trough one half turn so the open side is down toward crank shaft Fig 84 7 Remove the tappet installation tool from the tappet 8 Re install a dowel rod and secure the rod with a rubber band 9 Rotate the trough one half turn and repeat the procedure for the remaining tappets 10 Instal...

Page 1504: ...cated on the same side of the rod The long end of the connecting rod must be assembled on the intake or camshaft side of the engine Each matched fractured split connecting rod and cap is an assembly and are not interchangeable If a connecting rod or cap is damaged the entire assem bly must be replaced STANDARD PROCEDURE HEAD GASKET SELECTION 1 Measure piston protrusion for all six pistons 2 Calcul...

Page 1505: ...n sol vent Rinse in hot water and blow dry with com pressed air CONNECTING ROD Clean the connecting rods in a suitable solvent rinse in hot water and blow dry with compressed air INSPECTION INSPECTION PISTONS Inspect the pistons for damage and excessive wear Check top of the piston ring grooves skirt and pin bore Measure the piston skirt diameter If the piston is out of limits replace the piston P...

Page 1506: ...end of the strap does not hook on a ring gap and break the ring 5 Bar the crankshaft so the rod journal for the piston to be installed is at BDC Bottom Dead Cen ter Fig 92 6 Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly 7 Position the piston and rod assembly into the cylinder bore with the front ...

Page 1507: ...on cooling nozzles if equipped 15 Install block stiffener Torque to 43 N m 32 ft lbs 16 Install the suction tube and oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLA TION 17 Install the cylinder head onto the engine Refer to 9 ENGINE CYLINDER HEAD INSTAL LATION 18 Install a new filter and fill the crankcase with new engine oil Prefill the filter with clean oil 19 Connect the battery negative...

Page 1508: ...IVE BELTS REMOVAL 2 Remove the four 4 damper to crankshaft bolts and remove damper and speed indicator ring INSPECTION 1 Inspect the damper hub for cracks and replace if any are found 2 Inspect the index lines on the damper hub and the inertia member Fig 98 If the lines are more than 1 59 mm 1 16 in out of alignment replace the damper 3 Inspect the rubber member for deterioration or missing segmen...

Page 1509: ...NT MOUNT REMOVAL 1 Disconnect the battery negative cables 2 Remove the viscous fan drive assembly Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 3 Raise vehicle on hoist 4 Install engine support fixture tool 8534 and steel bracket tool 8534A 5 Loosen the thru bolt and nut 6 Lift the engine SLIGHTLY and remove the insulator to block bolts Fig 101 Fig 100 7 Remove the insulator from the vehicle Fig ...

Page 1510: ...pport cushion brackets 3 Install the thru bolt nut and tighten the nut to 95 N m 70 ft lbs torque 4 Remove the engine support fixture tool 8534 5 Lower the vehicle 6 Install the viscous fan drive assembly Refer to 7 COOLING ENGINE RADIATOR FAN INSTAL LATION 7 Connect the battery negative cables Fig 102 LH Insulator 1 Bolt 2 Insulator 3 Mount Fig 103 RH Insulator 1 Mount 2 Insulator 3 Bolt DR ENGIN...

Page 1511: ...ission INSTALLATION 1 If removed position the transmission support bracket to the transmission Install new attaching bolts and tighten to 102 N m 75 ft lbs torque 2 Position support cushion to transmission sup port bracket Install stud nuts and tighten to 47 N m 35 ft lbs torque 3 Using the transmission jack lower the trans mission and support cushion onto the crossmember Fig 104 4 Install the sup...

Page 1512: ...ivers oil to the crankshaft main journals and valve train Oil travels to the crankshaft through a series of transfer drillings one for each main bearing and lubricates a groove in the main bearing upper shell From there another drilling feeds the camshaft main journals The saddle jet piston cooling nozzles are also sup plied by the main bearing upper shell J jet piston cooling nozzles are supplied...

Page 1513: ...tem Circulation 1 TO FILTER 2 FROM FILTER 3 TO MAIN OIL RIFLE 4 CLOSED 5 OPEN 6 TO COOLER 7 FROM PUMP 8 CLOSED 9 OPEN 10 OIL DRAINS BACK TO THE PUMP 11 OIL DRAIN 12 OIL SUPPLY 9 290 ENGINE 5 9L DIESEL DR LUBRICATION Continued ...

Page 1514: ...Fig 106 Lubrication System Circulation Cont d DR ENGINE 5 9L DIESEL 9 291 LUBRICATION Continued ...

Page 1515: ...ky discoloration indicates coolant dilution 4 Clean the area around the oil filter head Remove the filter Refer to 9 ENGINE LUBRICA TION OIL FILTER REMOVAL 5 Install new oil filter Refer to 9 ENGINE LU BRICATION OIL FILTER INSTALLATION 6 Clean the drain plug and the sealing surface of the pan Check the condition of the threads and seal ing surface on the oil pan and drain plug 7 Install the drain ...

Page 1516: ...pan to block seal and lower pan slightly and remove oil suction tube fasteners 11 Remove oil pan and suction tube CLEANING Remove all gasket material from the oil pan and cylinder block sealing surfaces Extra effort may be required around T joint areas Clean oil pan and flush suction tube with a suitable solvent INSPECTION Inspect the oil pan suction tube and tube braces for cracks and damage Repl...

Page 1517: ...l pres sure OIL PRESSURE SWITCH REMOVAL 1 Disconnect the battery negative cables 2 Disconnect the oil pressure switch connector 3 Using a suitable socket remove the oil pres sure switch from the block counter clockwise INSTALLATION 1 If the switch is not being replaced replace and lubricate the o ring 2 Install the oil pressure switch and tighten to 18 N m 159 in lbs torque 3 Connect oil pressure ...

Page 1518: ... or damage Inspect the pump housing and gerotor drive for damaged and excessive wear 5 Install the gerotor planetary in the original position 6 Measure the tip clearance Fig 112 Maximum clearance is 0 1778 mm 0 007 inch If the oil pump is out of limits replace the pump 7 Measure the clearance of the gerotor drive gerotor planetary to port plate Fig 113 Maximum clearance is 0 127 mm 0 005 inch If t...

Page 1519: ...nd the idler gear to crankshaft gear back lash Fig 117 The backlash should be 0 15 0 25 mm 0 006 0 010 inch If the backlash is out of lim its replace the oil pump 5 If the adjoining gear moves when you measure the backlash the reading will be incorrect 6 Apply a bead of Mopart Silicone Rubber Adhe sive Sealant or equivalent to the gear housing cover sealing surface 7 Install the gear housing cover...

Page 1520: ...YSTEM FUEL DELIVERY FUEL LINES REMOVAL 11 Remove APPS bracket from cylinder head to gain access to front intake manifold cover bolts 12 Disconnect manifold air temperature pressure sensor connector 13 Remove the remaining intake manifold cover to cylinder head bolts 14 Remove the intake manifold cover and gasket Keep the gasket material and any other material out of the air intake 15 Clean the int...

Page 1521: ...3 Disconnect the exhaust pipe from the turbo charger elbow 4 Disconnect oil drain tube from turbocharger 5 Lower vehicle 6 Disconnect the turbocharger air inlet hose 7 Remove air cleaner assembly 8 Disconnect the turbocharger oil supply line 9 Disconnect the charge air cooler inlet pipe from the turbocharger 10 Remove the turbocharger and gasket from the exhaust manifold 11 Remove the cab heater r...

Page 1522: ... replace the crankshaft gear assembly 7 If the keyway is at 12 o clock position remove front gear cover and verify timing mark alignment between the camshaft gear and crankshaft gear if not aligned inspect keyway on camshaft gear 8 Inspect keyway on camshaft gear for proper alignment with the key in the camshaft if alignment is off replace the camshaft gear assembly 9 If timing marks alignment is ...

Page 1523: ...in Fig 122 9 Install a new front crankshaft seal into the gear cover 10 Apply a bead of Mopart Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover Be sure to surround all through holes 11 Using the seal pilot to align the cover install the cover to the housing and install the bolts Tighten the bolts to 24 N m 18 ft lbs torque 12 Remove the seal pilot Install front seal dust sh...

Page 1524: ...ay from the housing taking care not to mar the gasket surfaces INSTALLATION 1 Install a new front crankshaft oil seal 2 Obtain a seal pilot installation tool from a crankshaft front seal service kit and install the pilot into the seal 3 Apply a bead of Mopart Silicone Rubber Adhe sive Sealant or equivalent to the gear housing cover Be sure to surround all through holes 4 Using the seal pilot to al...

Page 1525: ......

Page 1526: ...LLATION 15 CHARGE AIR COOLER AND PLUMBING DESCRIPTION 16 OPERATION 16 DIAGNOSIS AND TESTING CHARGE AIR COOLER SYSTEM LEAKS 16 REMOVAL 17 CLEANING 17 INSPECTION 17 INSTALLATION 17 EXHAUST SYSTEM DESCRIPTION DESCRIPTION CAUTION Avoid application of rust prevention com pounds or undercoating materials to exhaust sys tem floor pan exhaust heat shields Light overspray near the edges is permitted Applic...

Page 1527: ...ALYTIC CONVERTER 2 TORCA CLAMP 3 INSULATOR 4 MUFFLER 5 TAILPIPE Fig 2 Exhaust System 4 7L Engine Typical 1 CATALYTIC CONVERTER 2 TORCA CLAMP 3 EXTENSION PIPE 4 INSULATOR 5 MUFFLER 6 TAILPIPE RESONATOR 11 2 EXHAUST SYSTEM DR EXHAUST SYSTEM Continued ...

Page 1528: ...st pipe resonator extension pipe muffler and exhaust tailpipe California emission vehicles include a catalytic con verter The exhaust system must be properly aligned to prevent stress leakage and body contact The exhaust components should be kept a minimum of 25 4 mm 1 0 in away from the body and frame If the system contacts any body panel it may amplify objectionable noises from the engine or bod...

Page 1529: ...lace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak between exhaust manifold and cylinder head 6 Tighten exhaust manifold to cylinder head bolts 7 Catalytic converter rusted or blown out 7 Replace catalytic converter assy 8 Restriction in exhaust system 8 Remove restriction if possible Replace restricted part if necessary CAUTION When servicing a...

Page 1530: ...Replace restricted part if necessary SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs Bolt Adjusting Strap 23 200 Nuts Air Heater Power Supply 14 124 Bolts Air Inlet Housing 24 18 Nuts Cab Heater Supply Return Line 24 18 Nuts Exhaust Clamp 54 3 40 Bolts Exhaust Manifold to Cylinder Head Diesel Engine 43 32 Bolts Exhaust Manifold to Cylinder Head 5 9L 31 23 Bolts Exhaust Manifold to Cylinder Hea...

Page 1531: ...ocess aids in reducing emissions output REMOVAL REMOVAL WARNING IF TORCHES ARE USED WHEN WORK ING ON THE EXHAUST SYSTEM DO NOT ALLOW THE FLAME NEAR THE FUEL LINES 1 Raise and support the vehicle 2 Saturate the bolts and nuts with heat valve lubricant Allow 5 minutes for penetration 3 Remove the bolts from the crossover pipe to the catalytic converter connection 4 Disconnect oxygen sensor wiring 5 ...

Page 1532: ...s with heat valve lubricant Allow 5 minutes for penetration 3 Remove exhaust pipe to manifold bolts retain ers and nuts 4 Remove the clamp nuts 5 Remove the exhaust pipe Fig 4 INSPECTION Discard rusted clamps broken or worn supports and attaching parts Replace a component with orig inal equipment parts or equivalent This will assure proper alignment with other parts in the system and provide accep...

Page 1533: ... mm 1 0 in is required between the exhaust system components and body frame parts Make the necessary adjust ments if needed HEAT SHIELDS DESCRIPTION There are two types of heat shields used One is stamped steel the other is molded foil sheets The shields attach to the vehicle around the exhaust sys tem to prevent heat from the exhaust system from entering the passenger area and other areas where t...

Page 1534: ... nuts to 54 2 N m 40 ft lbs torque 4 Lower the vehicle 5 Start the engine and inspect for exhaust leaks Reair exhaust leaks as necessary 6 Check the exhaust system for contact with the body panels A minimum of 25 4 mm 1 0 in is required between the exhaust system components and body frame parts Make the necessary adjust ments if needed Fig 7 HEAT SHIELDS RH QUAD CAB 1 HEAT SHIELD 2 FASTENER 3 NUT ...

Page 1535: ...ystem for contact with the body panels A minimum of 25 4 mm 1 0 in is required between the exhaust system components and body frame parts Make the necessary adjust ments if needed TAILPIPE 5 9L DIESEL REMOVAL 1 Disconnect the battery negative cables 2 Raise and support the vehicle 3 Saturate the clamp nuts with heat valve lubri cant Allow 5 minutes for penetration 4 Disconnect the exhaust tailpipe...

Page 1536: ...h the underbody parts 4 Tighten all clamp nuts to 54 2 N m 40 ft lbs torque 5 Lower the vehicle 6 Start the engine and inspect for exhaust leaks Reair exhaust leaks as necessary 7 Check the exhaust system for contact with the body panels A minimum of 25 4 mm 1 0 in is required between the exhaust system components and body frame parts Make the necessary adjust ments if needed TURBOCHARGER SYSTEM D...

Page 1537: ... which increases the pressure and density of the air entering the engine With the increase of air entering the engine more fuel can be injected into the cylinders which creates more power during com bustion The turbocharger assembly consists of four 4 major component systems Fig 14 Fig 15 Turbine section Compressor section Bearing housing Wastegate Fig 13 INTAKE MANIFOLD TO AIR INLET DUCT RUBBER S...

Page 1538: ... oil that is pressurized cooled and filtered The oil is delivered to the turbocharger by a supply line that is tapped into the oil filter head The oil travels into the bear ing housing where it lubricates the shaft and bear ings Fig 17 A return pipe at the bottom of the bearing housing routes the engine oil back to the crankcase The most common turbocharger failure is bearing failure related to re...

Page 1539: ...m the turbocharger oil drain tube 5 Lower vehicle 6 Disconnect the turbocharger air inlet hose Fig 18 7 Disconnect the turbocharger oil supply line from the turbocharger Fig 19 8 Disconnect the charge air cooler inlet pipe from the turbocharger compressor outlet Fig 19 Fig 17 Turbocharger Oil Supply and Drain 1 BEARINGS 2 OIL SUPPLY FROM FILTER HEAD 3 OIL RETURN TO SUMP Fig 18 Turbocharger Air Inl...

Page 1540: ...ormal operation appears to be a crack Remove this mark with a suitable solvent to verify that it is not a crack 3 Visually inspect the turbocharger compressor housing for an impeller rubbing condition Fig 20 Replace the turbocharger if the condition exists 4 Measure the turbocharger axial end play a Install a dial indicator as shown in Fig 21 Zero the indicator at one end of travel b Move the impe...

Page 1541: ... charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air As the turbocharger increases air pressure the air temperature increases Lowering the intake air temperature increases engine effi ciency and power OPERATION Intake air is drawn through the air cleaner and into the turbocharger compressor housing Pressur ized air from the turbocharge...

Page 1542: ...nlet and outlet tubes are vertical 3 Flush the cooler internally with solvent in the direction opposite of normal air flow 4 Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris 5 Continue flushing until all debris or oil are removed 6 Rinse the cooler with hot soapy water to remove any remaining solvent 7 Rinse thoroughly with clean water and blow dry ...

Page 1543: ......

Page 1544: ...SS 15 SPECIFICATIONS FRAME DIMENSIONS 16 SPECIFICATIONS TORQUE 22 FRONT CROSSMEMBER REMOVAL 22 INSTALLATION 22 FRONT SKID PLATE REMOVAL 23 INSTALLATION 23 FRONT TOW HOOK ASSEMBLY REMOVAL 23 INSTALLATION 23 TRANSMISSION CROSSMEMBER REMOVAL 24 INSTALLATION 24 TRAILER HITCH REMOVAL 25 INSTALLATION 25 TRANSFER CASE SKID PLATE REMOVAL 26 INSTALLATION 26 BUMPERS SPECIFICATIONS TORQUE TORQUE SPECIFICATIO...

Page 1545: ...nd nuts to 95 N m 70 ft lbs 4 Check and adjust the bumper alignment as necessary Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS FRONT FASCIA REMOVAL ST SLT SLT FASCIA REMOVAL 1 Remove the two screws at each trailing edge of the fascia Fig 2 2 Remove the four push pin fasteners from the upper edge of the close out panel 3 Using a trim stick C 4755 or equivalent care fully release the ...

Page 1546: ...f the fascia SPORT FASCIA INSTALLATION 1 Position the fascia onto the bumper 2 Position the step pad onto the fascia and fully seat the attachment clips 3 Install four new upper push pin fasteners 4 Install the five lower screws 5 Install the three screws at each trailing edge of the fascia REAR BUMPER REMOVAL 1 Raise and support the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE...

Page 1547: ...t be installed on any truck equipped with a snow plow or even intended to be equipped with a snow plow CAUTION Do not reuse damaged fasteners quality of repair would be suspect Failure to use only pro duction fasteners or fasteners of equivalent hard ness can result in loosening or failure Do not drill any holes in the frame that are not specifically out lined in this or other DaimlerChrysler proc...

Page 1548: ...nd may weaken the frame and or repair location 11 Using a reciprocating saw or equivalent care fully cut and remove the damaged frame rail tip Fig 6 12 Assemble the service sleeve Refer to SER VICE SLEEVE ASSEMBLY at the end of this proce dure NOTE Any burned surface coatings will need to be removed from the sleeve prior to installation and application of corrosion preventative coatings 13 Smooth ...

Page 1549: ...ove all internal and external OEM e coat within 51 mm 2 0 in of the weld joint on the replacement tip and the existing frame rail NOTE Any burned surface coatings will need to be removed prior to application of corrosion preventa tive coatings CAUTION Shield the surrounding area and compo nents from exposure to the welding spatter and heat Fig 7 REPAIR SLEEVE INSTALLATION TYPICAL 1 REPLACEMENT FRA...

Page 1550: ... tack the ring fillet welds to hold them in place Fig 9 Fig 10 Fig 11 Fig 12 19 On 4X4 models install the sway bar tapping plate and secure with tack welds Fig 11 Fig 12 Fig 9 4X2 SLEEVE INSTALLATION 1 REPLACEMENT FRAME TIP 2 FRAME RAIL 3 SERVICE SLEEVE 4 PLP 5 SWAY BAR MOUNTING BRACKET 6 TAPPING PLATE 7 ROOT WELD GAP Fig 10 4X2 SLEEVE INSTALLATION 1 REPLACEMENT FRAME TIP 2 ROOT WELD GAP 3 SERVICE...

Page 1551: ...ding area and compo nents from exposure to the welding spatter and heat 24 When correctly fitted and a weld root gap of 4 mm minimum to 6 mm maximum 0 16 in 0 24 in is established tack the ring fillet welds to hold the tip in position then complete the ring fillet welds NOTE Ring fillet welds may be filled in with weld material if an improved cosmetic appearance is desired Fig 11 4X4 TAPPING PLATE...

Page 1552: ...ide and out a Apply etch primer to the inside of the frame rail repair area b Inside the rail inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100 coverage including the space between the original frame rail and the rein forcing sleeve c Apply a durable top coat to the outside of the repair area 29 Tighten the front cab mounting bolt to the FESM ...

Page 1553: ...he cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy 4 Remove any burrs at the beveled edges 5 Using the Weld Process Specifications table Refer to 13 FRAME BUMPERS FRAME SPEC IFICATIONS WELDING weld the two halves of the repair sleeve together Fig 17 6 Clean the welds of any flux and other impuri ties and grind smooth before proceeding with the inst...

Page 1554: ...RONT FENDER REMOVAL 5 Remove the A C condenser if required Refer to 24 HEATING AIR CONDITIONING PLUMB ING A C CONDENSER REMOVAL 6 Remove the A C lines if required Refer to the Heating and Air Conditioning section of the manual for recommended procedures 7 Remove the radiator assembly Refer to 7 COOLING ENGINE RADIATOR REMOVAL 8 Remove the air cleaner and support bracket if required Refer to 9 ENGI...

Page 1555: ...three dimen sional measuring equipment to ensure the part is in the correct location Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator and hole in the frame perch mount Also ensure the lower radiator closure tube is bolted into the forward shotgun ends 24 Complete welding by making a 360 butt weld around the fender rails 25 Metal finish the exposed welds...

Page 1556: ...th this repair procedure review the required service warnings and precau tions Refer to 13 FRAME BUMPERS FRAME WARNING 2 Disconnect and isolate the battery negative cable 3 Remove the cargo box Refer to 23 BODY EX TERIOR CARGO BOX REMOVAL 4 Remove the trailer hitch Refer to 13 FRAME BUMPERS FRAME TRAILER HITCH REMOVAL 5 Raise and support the frame so the tires are off floor 6 Remove the shock abso...

Page 1557: ...tions at the end of this section Refer to 13 FRAME BUMPERS FRAME SPECIFICATIONS WELD ING 18 Dress the welded area and apply corrosion resistant coatings inside and out a Inside the rail inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100 coverage including the mating face between the frame and replacement H section b Apply a durable top coat to ...

Page 1558: ...e 9 9 Work Piece 9 9 Shielding Gas Self Shielded 75 Ar 25 CO2 Self Shielded Gas Flow Rate N A 25 35 CFM N A Wire Feed Speed inches per minute 110 130 Vertical Down 70 90 Flat Overhead 245 250 Vertical Down 210 225 Flat Overhead N A Approximate Amperage Vertical 110 130 175 85 3 329 Diameter Flat Overhead 70 90 155 90 3 329 Diameter Voltage 15 18 19 20 N A Direction of Welding Vertical Vertical Dow...

Page 1559: ...tle jacks adjust the vehicle PLP heights to the specified dimension above a level work surface Vertical dimensions can be taken from the work sur face to the locations indicated were applicable INDEX DESCRIPTION FIGURE Frame Dimensional Graphics Side And Top View 23 140 5 In Wheelbase Heavy Duty 2 Wheel Drive 24 140 5 In Wheelbase Heavy Duty 4 Wheel Drive 25 160 5 In Wheelbase Heavy Duty 2 Wheel D...

Page 1560: ...Fig 23 FRAME DIMENSIONS DR FRAMES BUMPERS 13 17 FRAME Continued ...

Page 1561: ...Fig 24 140 5 IN WHEELBASE HEAVY DUTY 2 WHEEL DRIVE 13 18 FRAMES BUMPERS DR FRAME Continued ...

Page 1562: ...Fig 25 140 5 IN WHEELBASE HEAVY DUTY 4 WHEEL DRIVE DR FRAMES BUMPERS 13 19 FRAME Continued ...

Page 1563: ...Fig 26 160 5 IN WHEELBASE HEAVY DUTY 2 WHEEL DRIVE 13 20 FRAMES BUMPERS DR FRAME Continued ...

Page 1564: ...Fig 27 160 5 IN WHEELBASE HEAVY DUTY 4 WHEEL DRIVE DR FRAMES BUMPERS 13 21 FRAME Continued ...

Page 1565: ...34 25 Transercase skid plate crossmember bolts 34 25 Transmission mount to crossmember nuts 54 40 FRONT CROSSMEMBER REMOVAL 1 Raise and support the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove the front skid plate if equipped Refer to 13 FRAME BUMPERS FRAME FRONT SKID PLATE REMOVAL 3 Remove the bolts and remove the crossmember Fig 28 or Fig 29 INSTALLATION 1 Instal...

Page 1566: ...r to 13 FRAME BUMPERS BUMPERS FRONT BUMPER REMOVAL 2 Remove the bolts and remove the tow hook assembly Fig 31 and Fig 32 INSTALLATION 1 Install the tow hook assembly and bolts hand tight 2 Install the front bumper Refer to 13 FRAME BUMPERS BUMPERS FRONT BUMPER INSTALLATION 3 Tighten the tow hook bolts to 68 N m 50 ft lbs Fig 29 FRONT CROSSMEMBER 4WD 1 BOLTS 2 PER SIDE 2 CROSSMEMBER Fig 30 FRONT SK...

Page 1567: ...s On heavy duty vehicles tighten the bolts to 115 N m 85 ft lbs 2 Install the transmission mount nuts and tighten to 54 N m 40 ft lbs 3 Remove the transmission support 4 Install the transfercase skid plate Refer to 13 FRAME BUMPERS FRAME TRANSFER CASE SKID PLATE INSTALLATION Fig 32 FRONT TOW HOOK ASSEMBLY HEAVY DUTY 1 BOLTS 4 PER HOOK 2 HEAVY DUTY TOW HOOKS 2 3 BUMPER CENTER SUPPORT BRACKETS Fig 3...

Page 1568: ...he hitch onto the frame rails and make sure the locators on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly 2 Lower the cargo box and install the rear bolts Refer to 23 BODY EXTERIOR CARGO BOX INSTALLATION 3 Install the hitch bolts and tighten to 170 N m 125 ft lbs 4 Connect all wire harness support push pins 5 Install the rear bumper Refer to 13 ...

Page 1569: ...l the skid plate crossmember and install the bolts 2 Tighten the bolts to 34 N m 25 ft lbs 3 Install the skid plate and install the bolts 4 Tighten the bolts to 34 N m 25 ft lbs Fig 37 TRANSFER CASE SKID PLATE 1 CROSSMEMBER BOLTS 4 2 SKID PLATE CROSSMEMBER 3 SKID PLATE 4 SKID PLATE BOLTS 4 Fig 36 TRAILER HITCH HEAVY DUTY 1 LOCATING TAB HOLE 2 LOCATING PIN HOLE 3 U NUTS 2 4 BUMPER SUPPORT BRACKETS ...

Page 1570: ...PERATION 11 FUEL PUMP MODULE DESCRIPTION 11 OPERATION 11 REMOVAL 12 INSTALLATION 12 FUEL RAIL DESCRIPTION 12 OPERATION 12 REMOVAL 13 INSTALLATION 15 FUEL TANK DESCRIPTION 17 OPERATION 17 REMOVAL EXCEPT DIESEL 17 INSTALLATION EXCEPT DIESEL 19 INLET FILTER REMOVAL 20 INSTALLATION 20 FUEL DELIVERY GAS DESCRIPTION The fuel delivery system consists of a fuel pump module containing the electric fuel pum...

Page 1571: ...on of the Evapora tive Control System is found in Emission Control Systems Both fuel filters at bottom of fuel pump module and within fuel pressure regulator are designed for extended service They do not require normal sched uled maintenance Filters should only be replaced if a diagnostic procedure indicates to do so STANDARD PROCEDURE FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fu...

Page 1572: ...omentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds 11 Place a rag or towel below fuel line quick con nect fitting at fuel rail 12 Disconnect quick connect fitting at fuel rail Refer to Quick Connect Fittings 13 Return fuel pump relay to PDC 14 One or more Diagnostic Trouble Codes DTC s may have been stored in PCM memory due to fuel pump relay r...

Page 1573: ...41 30 IAC Motor Mounting Screws 3 7L 7 60 IAC Motor Mounting Screws 4 7L 7 60 Leak Detection Pump Mounting Bolt 8 5 75 Map Sensor Mounting Screws 3 7L 3 25 Map Sensor Mounting Screws 4 7L 3 25 PCM to Mounting Bracket Mounting Screws 4 35 Power Steering Pressure Switch 3 7L 14 22 124 195 Power Steering Pressure Switch 4 7L 14 22 124 195 TPS Mounting Screws 3 7L 7 60 TPS Mounting Screws 4 7L 7 60 Th...

Page 1574: ... at bottom of fuel pump module and within fuel pressure regulator are designed for extended service They do not require normal sched uled maintenance Filters should only be replaced if a diagnostic procedure indicates to do so FUEL PRESSURE TESTER 8978 TEST KIT FUEL PRESSURE 8 0L ENGINE 5069 ADAPTERS FUEL PRESSURE TEST 8 0L 6539 AND OR 6631 SPANNER WRENCH 6856 FITTING AIR METERING 6714 O2S OXYGEN ...

Page 1575: ...This is fed directly from the Powertrain Control Module PCM NOTE For diagnostic purposes this 12V power source can only be verified with the circuit opened fuel pump module electrical connector unplugged With the connectors plugged output voltages will vary from about 0 6 volts at FULL to about 8 6 volts at EMPTY about 8 6 volts at EMPTY for Jeep models and about 7 0 volts at EMPTY for Dodge Truck...

Page 1576: ...SYSTEM HOSES FITTINGS LINES OR MOST COMPO NENTS FUEL SYSTEM PRESSURE MUST BE RELEASED REFER TO THE FUEL SYSTEM PRES SURE RELEASE PROCEDURE The lines tubes hoses used on fuel injected vehicles are of a special construction This is due to the higher fuel pressures and the possibility of contami nated fuel in this system If it is necessary to replace these lines tubes hoses only those marked EFM EFI ...

Page 1577: ...f a special tool for disconnection DISCONNECTING WARNING THE FUEL SYSTEM IS UNDER A CON STANT PRESSURE EVEN WITH ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSE FITTING OR LINE FUEL SYSTEM PRESSURE MUST BE RELEASED REFER TO FUEL SYSTEM PRES SURE RELEASE PROCEDURE CAUTION The interior components o rings spac ers of some types of quick connect fitting are not serviced separately If service parts ar...

Page 1578: ... on compo nent being serviced after fitting is disconnected The o rings and spacer will remain in quick con nect fitting connector body 8 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full round plastic retainer ring Fig 11 usually black in color a To release fuel system component from quick connect fitting firmly push fitting towards compo nent being se...

Page 1579: ... or to join fuel lines together a Type 1 Pry up on latch clip with a screw driver Fig 12 b Type 2 Separate and unlatch 2 small arms on end of clip Fig 13 and swing away from fuel line c Slide latch clip toward fuel rail while lifting with screwdriver Fig 10 TYPICAL 2 TAB TYPE FITTING 1 TAB S 2 QUICK CONNECT FITTING Fig 11 PLASTIC RETAINER RING TYPE FITTING 1 FUEL TUBE 2 QUICK CONNECT FITTING 3 PUS...

Page 1580: ...N Voltage to operate the electric pump is supplied through the fuel pump relay Fuel is drawn in through a filter at the bottom of the module and pushed through the electric motor gearset to the pump outlet Check Valve Operation The bottom section of the fuel pump module contains a one way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure engine warm when...

Page 1581: ...16 to locknut 5 Tighten locknut Refer to Torque Specifications 6 Install fuel tank Refer to Fuel Tank Removal Installation FUEL RAIL DESCRIPTION The fuel injector rail is used to mount the fuel injectors to the engine OPERATION High pressure from the fuel pump is routed to the fuel rail The fuel rail then supplies the necessary fuel to each individual fuel injector A quick connect fitting with a s...

Page 1582: ...l injectors To remove connector refer to Fig 17 Push red colored slider away from injector 1 While push ing slider depress tab 2 and remove connector 3 from injector The factory fuel injection wiring har ness is numerically tagged INJ 1 INJ 2 etc for injector position identification If harness is not tagged note wiring location before removal 10 Disconnect electrical connectors at all throttle bod...

Page 1583: ...tion identification If harness is not tagged note wiring location before removal 10 Disconnect electrical connectors at all throttle body sensors 11 Remove 8 ignition coils Refer to Ignition Coil Removal Installation 12 Remove 4 fuel rail mounting bolts Fig 19 13 Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head Gently rock and pul...

Page 1584: ...le body sensors 12 Remove 4 fuel rail mounting bolts and hold own clamps Fig 20 13 Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes Repeat this procedure left right until all injectors have cleared machined holes 14 Remove fuel...

Page 1585: ...r head Be care ful not to tear injector o rings 6 Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder Push left fuel rail down until injectors have bot tomed on cylinder head shoulder 7 Install 4 fuel rail mounting bolts and tighten Refer to torque specifications 8 Install 8 ignition coils Refer to Ignition Coil Removal Installation 9 Connect electrical c...

Page 1586: ...e top of the fuel tank Refer to Fuel Tank Check Valve for additional information An evaporation control system is connected to the fuel tank to reduce emissions of fuel vapors into the atmosphere When fuel evaporates from the fuel tank vapors pass through vent hoses or tubes to a charcoal canister where they are temporarily held When the engine is running the vapors are drawn into the intake manif...

Page 1587: ...d colored tab to unlock Push on black colored tab while removing connector 5 Disconnect fuel line at fuel filter fuel pressure regulator Fig 25 by pressing on tabs at side of quick connect fitting 6 Disconnect EVAP line at top of tank Fig 1 7 Continue to lower tank for removal 8 If fuel tank is to be replaced remove fuel pump module from tank Refer to Fuel Pump Module Removal Installation procedur...

Page 1588: ...ct fuel pump module electrical connector Fig 25 at top of tank 7 Connect fuel line quick connect fitting to fuel filter fuel pressure regulator Fig 1 or Fig 25 8 Continue raising tank until positioned snug to body 9 Install and position both tank support straps Install 2 fuel tank strap nuts Fig 24 and tighten Tighten rear strap nut first Refer to Torque Spec ifications 10 Connect rubber fill and ...

Page 1589: ...f the fuel pump module Fig 27 The fuel pump module is located inside of fuel tank 1 Snap new filter to bottom of module Be sure o ring is in correct position 2 Install fuel pump module Refer to Fuel Pump Module Removal Installation 3 Install fuel tank Refer to Fuel Tank Removal Installation Fig 25 FUEL PUMP MODULE CONNECTIONS 1 TOP OF FUEL TANK 2 FUEL PUMP MODULE 3 FUEL FILTER FUEL PRESSURE REGULA...

Page 1590: ...RIPTION 41 OPERATION 41 REMOVAL 41 INSTALLATION 43 ACCELERATOR PEDAL REMOVAL The following procedure applies only to vehicles without the Adjustable Pedal Package code XAP The accelerator pedal is serviced as a complete assembly including the bracket The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer clip Fig 1 This plastic retainer snaps into t...

Page 1591: ... APPS assembly is located under the vehicle battery tray Fig 2 Access to APPS is gained from over top of left front tire 1 Disconnect negative battery cable at battery 2 Disconnect APPS cable at accelerator pedal Refer to Accelerator Pedal Removal Installation 3 Remove wheel house liner at left front wheel Refer to Body 4 Gain access to APPS electrical connector by opening swing down door Fig 3 Di...

Page 1592: ... is mounted into the right rear side of the cylinder block It is positioned and bolted into a machined hole 4 7L V 8 The Crankshaft Position CKP sensor is mounted into the right rear side of the cylinder block It is positioned and bolted into a machined hole 5 7L V 8 The Crankshaft Position CKP sensor is mounted into the right rear side of the cylinder block It is positioned and bolted into a mach...

Page 1593: ... the input to the PCM 5 7L V 8 Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the pow ertrain control module PCM The PCM interprets the sensor input to determine the crankshaft posi tion The PCM then uses this position along with other inputs to determine injector sequence and igni tion timing The sens...

Page 1594: ...e right rear side of the engine cylinder block Fig 10 It is positioned and bolted into a machined hole in the engine block 1 Raise vehicle 2 Disconnect CKP electrical connector at sensor Fig 10 3 Remove CKP mounting bolt Fig 10 4 Carefully twist sensor from cylinder block 5 Remove sensor from vehicle 6 Check condition of sensor o ring INSTALLATION 3 7L V 6 1 Clean out machined hole in engine block...

Page 1595: ... 3 Install sensor into engine block with a slight rocking and twisting action CAUTION Before tightening sensor mounting bolt be sure sensor is completely flush to cylinder block If sensor is not flush damage to sensor mounting tang may result 4 Install mounting bolt and tighten to 28 N m 21 ft lbs torque 5 Connect electrical connector to sensor 6 Lower vehicle FUEL INJECTOR DESCRIPTION An individu...

Page 1596: ...PCM will adjust injector pulse width based on various inputs it receives Battery voltage 12 volts is supplied to the injec tors through the ASD relay The ASD relay will shut down the 12 volt power source to the fuel injectors if the PCM senses the ignition is on but the engine is not running This occurs after the engine has not been running for approximately 1 8 seconds The PCM determines injector...

Page 1597: ... which increases RPM The PCM uses the IAC motor to control idle speed along with timing and to reach a desired MAP dur ing decel keep engine from stalling The IAC motor has 4 wires with 4 circuits Two of the wires are for 12 volts and ground to supply elec trical current to the motor windings to operate the stepper motor in one direction The other 2 wires are also for 12 volts and ground to supply...

Page 1598: ...ani cally limit the position of the throttle body throttle plate Never attempt to adjust the engine idle speed using this screw All idle speed functions are controlled by the IAC motor through the PCM REMOVAL 3 7L V 6 The Idle Air Control IAC motor is located on the side of the throttle body Fig 14 1 Remove air resonator box at throttle body 2 Disconnect electrical connector from IAC motor 3 Remov...

Page 1599: ... timing to help prevent spark knock with high intake manifold air charge temperatures The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature ECT sensor REMOVAL 3 7L V 6 The intake manifold air temperature IAT sensor is installed into the left side of intake manifold ple num Fig 16 1 Disconnect electrical connector from IAT sen sor 2 Clean dirt from intake manifol...

Page 1600: ...stalled into the left side of intake manifold ple num Fig 16 1 Check condition of sensor o ring 2 Clean sensor mounting hole in intake manifold 3 Position sensor into intake manifold and rotate clockwise until past release tab Fig 16 4 Install electrical connector 4 7L V 8 The intake manifold air temperature IAT sensor is installed into the left side of intake manifold ple num Fig 18 1 Check condi...

Page 1601: ...rough the low noise sensor return circuit at the PCM The MAP sensor input is the number one contrib utor to fuel injector pulse width The most important function of the MAP sensor is to determine baromet ric pressure The PCM needs to know if the vehicle is at sea level or at a higher altitude because the air density changes with altitude It will also help to cor rect for varying barometric pressur...

Page 1602: ...osphere upon an object At sea level on a standard day no storm barometric pressure is approximately 29 92 in Hg For every 100 feet of altitude barometric pressure drops 0 10 in Hg If a storm goes through it can change baromet ric pressure from what should be present for that altitude You should know what the average pressure and corresponding barometric pressure is for your area REMOVAL 3 7L V 6 T...

Page 1603: ...take manifold 2 Check MAP sensor o ring seal for cuts or tears 3 Position sensor into manifold 4 Install MAP sensor mounting bolts screws Refer to Torque Specifications 5 Connect electrical connector 4 7L V 8 The MAP sensor is located on the front of the intake manifold Fig 23 An o ring seals the sensor to the intake manifold Fig 22 1 Clean MAP sensor mounting hole at intake manifold 2 Check MAP s...

Page 1604: ... located in the right exhaust downpipe just before the mini catalytic convertor The left upstream sensor 1 1 is located in the left exhaust downpipe just before the mini cata lytic convertor The right downstream sensor 2 2 is located in the right exhaust downpipe just after the mini catalytic convertor and before the main cata lytic convertor The left downstream sensor 1 2 is located in the left e...

Page 1605: ...r pedal The Accelerator Pedal Position Sensor APPS along with inputs from other sensors sets the throttle blade to pre determined positions Except 5 7L V 8 Engine Certain sensors are attached to the throttle body The accelerator pedal cable speed control cable and transmission control cable when equipped are con nected to the throttle body linkage arm A factory adjusted set screw is used to mechan...

Page 1606: ...NSTALLATION 3 7L V 6 1 Check condition of throttle body to intake man ifold o ring Replace as necessary 2 Clean mating surfaces of throttle body and intake manifold 3 Install throttle body to intake manifold o ring 4 Install throttle body to intake manifold 5 Install 3 mounting bolts Tighten bolts to 12 N m 105 in lbs torque 6 Install control cables 7 Install electrical connectors 8 Install necess...

Page 1607: ... 7 If the throttle body has been changed the following procedure must be performed a Disconnect negative battery cable from bat tery Leave cable disconnected for approximately 90 seconds b Reconnect cable to battery c Turn ignition switch ON but do not crank engine d Leave ignition switch ON for a minimum of 10 seconds This will allow PCM to learn throttle body electrical parameters THROTTLE CONTR...

Page 1608: ...7 Using finger pressure only disconnect accelera tor cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle Fig 35 DO NOT try to pull connector off perpendicular to bellcrank pin Connector will be broken 8 Lift accelerator cable from top of cable cam Fig 35 9 Press tab Fig 36 to release plastic cable mount from bracket Press on tab only enoug...

Page 1609: ...aps in place 7 Install air resonator tube to throttle body 8 Before starting engine operate accelerator pedal to check for any binding 4 7L V 8 1 Slide accelerator cable plastic mount into bracket Continue sliding until tab Fig 36 is aligned to hole in mounting bracket 2 Route accelerator cable over top of cable cam 3 Connect cable end to throttle body bellcrank pin snaps on rearward 4 Slide rubbe...

Page 1610: ... the output voltage of the TPS changes The PCM supplies approximately 5 volts to the TPS The TPS output voltage input signal to the PCM represents the throttle blade position The PCM receives an input signal voltage from the TPS This will vary in an approximate range of from 26 volts at minimum throttle opening idle to 4 49 volts at wide open throttle Along with inputs from other sensors the PCM u...

Page 1611: ... Remove TPS from throttle body 5 7L V 8 The 5 7L V 8 engine does not use a separate Throt tle Position Sensor TPS on the throttle body Fig 38 TPS INSTALLATION 3 7 V 6 1 THROTTLE BODY 2 TPS 3 THROTTLE BODY SHAFT 4 SOCKET LOCATING TANGS Fig 39 TPS LOCATION 4 7L 1 THROTTLE BODY 2 TPS 3 IAC MOTOR 4 IAT SENSOR 5 MOUNTING SCREWS 14 42 FUEL INJECTION GAS DR THROTTLE POSITION SENSOR Continued ...

Page 1612: ...le body 4 7L V 8 The throttle shaft end of throttle body slides into a socket in TPS Fig 41 The TPS must be installed so that it can be rotated a few degrees If sensor will not rotate install sensor with throttle shaft on other side of socket tangs The TPS will be under slight tension when rotated 1 Install TPS and two retaining bolts 2 Tighten bolts to 7 N m 60 in lbs torque 3 Manually operate th...

Page 1613: ...53 OPERATION 53 DIAGNOSIS AND TESTING FUEL INJECTION PUMP TIMING 53 REMOVAL 54 INSTALLATION 55 FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION 57 OPERATION 57 REMOVAL REMOVAL INSTALLATION 57 FUEL LINES DESCRIPTION 57 OPERATION 57 DIAGNOSIS AND TESTING HIGH PRESSURE FUEL LINE LEAKS 58 REMOVAL 58 INSTALLATION 60 FUEL PRESSURE SENSOR DESCRIPTION 60 OPERATION 60 REMOVAL 60 INSTALLATION 61 FUEL PRESSURE LIM...

Page 1614: ...ch is attached to the fuel filter assembly Fuel is forced through the fuel filter ele ment and then enters the Fuel Pump Gear Pump which is attached to the rear of the fuel injection pump The Fuel Pump Gear Pump is a low pressure pump and produce pressures ranging from 551 5 kpa 80 psi to 1241 kpa 180 psi Fuel then enters the fuel injection pump Low pressure fuel is then sup plied to the FCA Fuel ...

Page 1615: ...SSURE SWITCH 5 FUEL PRESSURE LIMITING VALVE 18 ENGINE CONTROL MODULE ECM 6 HIGH PRESSURE FUEL LINES 19 FUEL INJECTION PUMP 7 FUEL HEATER 20 CRANKSHAFT POSITION ENGINE SPEED SENSOR 8 HIGH PRESSURE FUEL RAIL 21 CAMSHAFT POSITION SENSOR CMP 9 FUEL HEATER TEMPERATURE SENSOR THERMOSTAT 22 FUEL CONTROL ACTUATOR FCA 10 FUEL FILTER WATER SEPARATOR 23 CASCADE OVERFLOW VALVE 11 FUEL TRANSFER LIFT PUMP 12 FU...

Page 1616: ...imately 1 to 2 second and then shuts off The pump will also operate for up to 25 seconds after the starter is quickly engaged and then disengaged without allowing the engine to start The pump shuts off immediately if the key is on and the engine stops running 1 Turn key to CRANK position and quickly release key to ON position before engine starts This will operate fuel transfer pump for approximat...

Page 1617: ...s 1 5 14 Fuel Pump Module Lock Ring 54 40 Fuel Line Banjo Fitting Bolts 24 18 Fuel Line Fittings High Pressure Pump to Rail 37 27 Fuel Line Fittings High Pressure Cylinder head to Rail 30 22 Bracket Over 6 Fuel Line Bolts 43 32 Fuel Injector Solenoid Nuts 1 25 11 Fuel Injection Pump to Gear Shaft Nut 105 77 Fuel Injection Pump Mounting Nuts 24 18 Fuel Line Support Clamps High Pressure 24 18 Fuel P...

Page 1618: ...UEL PRESSURE TEST ADAPTER 9014 FUEL INJECTOR REMOVER 9010 PRESSURE CAP 9011 FUEL PRESSURE TEST ADAPTER 9013 FUEL INJECTOR TUBE CONNECTOR REMOVER 9015 SPANNER WRENCH FUEL TANK MODULE REMOVAL INSTALLATION 6856 DR FUEL DELIVERY DIESEL 14 49 FUEL DELIVERY DIESEL Continued ...

Page 1619: ...te drain valve handle counter clockwise rearward to OPEN DRAIN position Hold drain valve open until all water and contaminants have been removed and clean fuel exits 3 If drain valve fuel heater element or Water In Fuel WIF sensor is being replaced drain housing completely Dispose of mixture in drain pan according to applicable regulations 4 After draining operation rotate valve handle clockwise f...

Page 1620: ... 4 mounting screws and tighten to 1 1 5 N m 8 13 in lbs torque e Connect drain hose to drain valve 6 Start engine and check for leaks FUEL HEATER DESCRIPTION The fuel heater assembly is located on the side of the fuel filter housing Fig 3 The heater element assembly is equipped with a temperature sensor thermostat that senses fuel temperature This sensor is attached to the fuel heat er element ass...

Page 1621: ...to operate the fuel heater The resistance value of the heater ele ment is less than 1 ohm cold and up to 1000 ohms warm TESTING 1 Disconnect electrical connector from thermostat Fig 3 Ambient temperature must be below the circuit close temperature If necessary induce this ambient temperature by placing ice packs on thermostat to produce an effective ambient temperature below cir cuit close tempera...

Page 1622: ... pump and produce pressures ranging from 551 5 kpa 80 psi to 1241 kpa 180 psi Fuel then enters the fuel injection pump Low pressure fuel is then sup plied to the FCA Fuel Control Actuator The FCA is an electronically controlled solenoid valve The ECM controls the amount of fuel that enters the high pressure pumping chambers by open ing and closing the FCA based on a demanded fuel pressure The FPS ...

Page 1623: ...e same 3 lines at their attachment points 5 Disconnect Fuel Control Actuator FCA electri cal connector at rear of injection pump Fig 9 CAUTION Whenever a fuel line fitting is connected to a secondary fitting always use a back up wrench on the secondary fitting Do not allow the second ary fitting to rotate 6 Remove fuel line injection pump to fuel pres sure limiting valve 7 Remove fuel line injecti...

Page 1624: ... oil or clean diesel fuel only 1 Inspect pump mounting surfaces at pump and mounting flange for nicks cuts or damage Inspect o ring surfaces for nicks cuts or damage 2 Clean injection pump mounting flange at gear housing Also clean front of injection pump 3 Install new rubber o ring into machined groove Fig 12 at pump mounting area 4 Apply clean engine oil to injection pump o ring only The machine...

Page 1625: ...ft nut to 105 N m 77 ft lbs 9 Install drive gear access cover plate using a 3 8 drive ratchet Plate is threaded to timing gear cover Tighten to 8 N m 71 in lbs torque 10 Install fuel line injection pump to pressure limiting valve Tighten bolts to 24 N m 18 ft lbs torque 11 Install fuel line injection pump to fuel rail a Tighten fitting at fuel pump to 37 N m 27 ft lbs torque Use a back up wrench b...

Page 1626: ... reading Refer to Instrument Panel for additional information REMOVAL REMOVAL INSTALLATION For diesel removal and installation procedures refer to the gas section of Fuel System Fuel Delivery See Fuel Level Sending Unit Sensor Removal Instal lation FUEL LINES DESCRIPTION Low Pressure Lines Are the fuel supply line from fuel tank to fuel trans fer lift pump the fuel return line back to fuel tank th...

Page 1627: ...r nozzle tip holes This in turn could lead to possible engine misfire Always wash clean any fuel system component thoroughly before disassembly and then air dry Cap or cover any open part after disassembly Before assembly examine each part for dirt grease or other contaminants and clean if necessary When installing new parts lubricate them with clean engine oil or clean diesel fuel only 1 Disconne...

Page 1628: ...NECTOR TUBE RETAINER FITTING 7 CONNECTOR TUBE Fig 14 BRACKET 6 INJECTOR 1 BRACKET 2 REAR OF CYLINDER HEAD 3 FUEL DRAIN MANIFOLD LINE TO FUEL TANK 4 BANJO BOLT CHECK VALVE 5 SLOTTED HOLE 6 BRACKET BOLTS 2 Fig 15 FUEL INJECTOR RAIL 1 FUEL RAIL MOUNTING BOLTS 3 2 INSULATED CLAMPS 3 FUEL INJECTOR RAIL DR FUEL DELIVERY DIESEL 14 59 FUEL LINES Continued ...

Page 1629: ... Heater Removal Installation for procedures 8 If fuel line at 6 cylinder has been replaced tilt metal bracket upward and tighten 2 bolts at rear of cylinder head Refer to Torque Specifications 9 Install remaining fuel line support clamps and bracket bolts at intake manifold Refer to Torque Specifications 10 Connect both negative battery cables to both batteries 11 Prime fuel system Refer to Fuel S...

Page 1630: ...tight tolerances are used with these parts Dirt contamination could cause rapid part wear and pos sible plugging of fuel injector nozzle tip holes This in turn could lead to possible engine misfire Always wash clean any fuel system component thoroughly before disassembly and then air dry Cap or cover any open part after disassembly Before assembly examine each part for dirt grease or other contami...

Page 1631: ... at top of tank To disconnect electrical connector Push upward on red colored tab to unlock Push on black colored tab while removing connector 5 Disconnect fuel supply and return lines at fuel tank module Fig 19 Refer to Quick Connect Fit tings for procedures 6 Continue to lower tank for removal 7 If fuel tank is to be replaced remove fuel tank module from tank Refer to Fuel Tank Module Removal In...

Page 1632: ... Fuel return line connection Auxiliary non pressurized fitting OPERATION Refer to Fuel Gauge Sending Unit REMOVAL 1 Drain and remove fuel tank Refer to Fuel Tank Removal Installation 2 Thoroughly clean area around tank module at top of tank 3 The plastic fuel tank module locknut is threaded onto fuel tank Install Special Tool 6856 to locknut and remove locknut Fig 22 The fuel tank module will spri...

Page 1633: ...ection pump Here the low pressure is raised to a high pressure by the fuel injection pump for operation of the high pressure fuel injectors Check valves within the pump control direction of fuel flow and prevent fuel bleed back during engine shut down Maximum current flow to the pump is 5 amperes With the engine running the pump has a 100 per cent duty cycle The transfer pump is self priming When ...

Page 1634: ...pump inlet connector 3 Position fuel transfer pump onto fuel filter housing Do not use mounting bolts to draw transfer pump to filter housing 4 Be sure pump is positioned flat to fuel filter housing Install mounting bolts and evenly tighten to 7 N m 61 in lbs 5 Connect fuel line extension at fuel supply line 6 Connect electrical connector to pump 7 Prime System Cycle key to actuate transfer pump o...

Page 1635: ...the filter sep arator increases the resistance across the WIF sensor decreases This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value Once the value reaches 30 to 40 kilohms the ECM will activate the water in fuel warning lamp through CCD bus circuits This all takes place when the ignition key is initially put in the ON position The ECM continues to ...

Page 1636: ...lve sends some fuel to a lubrication passage The rest of the fuel is sent to a drain passage which connects to an external fuel line Fuel that travels through the FCA is pressurized by the fuel injection pump and sent through an external high pressure fuel line to the fuel rail At the fuel rail fuel is sent to the fuel injectors If fuel pressure in the fuel rail becomes excessive the pres sure lim...

Page 1637: ...N SENSOR DESCRIPTION Engine Mounted Sensor The APPS assembly is located at the top left front of the engine A plastic cover is used to cover the assembly The actual sen sor is located behind its mounting bracket Battery Tray Mounted Sensor The Accelerator Pedal Position Sensor APPS assembly is located under the vehicle battery tray A cable connects the assembly to the accelerator pedal A plastic c...

Page 1638: ...tle cable Fig 2 and pull cable rearward to remove from cable mount ing bracket 8 Refer to 21 Transmission for transmission con trol cable removal procedures 9 Disconnect wiring harness clip Fig 3 at bot tom of bracket 10 Remove 6 mounting bolts Fig 3 and par tially remove APPS assembly from engine After assembly is partially removed disconnect electrical connector from bottom of sensor by pushing ...

Page 1639: ...ATION SCREWS NO ADJUSTMENT 5 APPS ASSEMBLY Fig 4 APPS CONNECTOR ON ENGINE MOUNTING 1 APPS 2 TAB 3 PUSH FOR REMOVAL 4 APPS CONNECTOR Fig 5 APPS LOCATION OFF ENGINE MOUNTING 1 BATTERY TRAY 2 APPS LOCATION 3 APPS MOUNTING BOLTS Fig 6 APPS REMOVE INSTALL OFF ENGINE MOUNTING 1 BOTTOM OF BATTERY TRAY 2 ELECTRICAL CONNECTOR 3 APPS 4 SWING DOWN DOOR 5 CABLE TO PEDAL 6 CABLE RELEASE TAB 14 70 FUEL INJECTIO...

Page 1640: ...dure a Connect negative battery cables to both bat teries b Turn key switch ON but do not crank engine c Leave key switch ON for a minimum of 10 seconds This will allow ECM to learn electrical parameters 8 If necessary use DRB IIIt Scan Tool to erase any Diagnostic Trouble Codes DTC s from ECM CAMSHAFT POSITION SENSOR DESCRIPTION The Camshaft Position Sensor CMP on the 5 9L diesel engine is locate...

Page 1641: ...hten Refer to Torque Specifications 5 Connect electrical connector to sensor CRANKSHAFT POSITION SENSOR DESCRIPTION The Crankshaft Position Sensor CKP on the die sel engine is attached at the front left side of the engine next to the engine harmonic balancer crank shaft damper OPERATION The Crankshaft Position Sensor CKP is the pri mary engine speed indicator for the engine after the engine is run...

Page 1642: ...ses the CMP as a backup sensor for engine speed REMOVAL 1 Raise and support vehicle 2 Disconnect electrical connector at CKP sensor Fig 12 3 Remove 1 sensor mounting bolt 4 Remove CKP sensor INSTALLATION 1 Position and install CKP sensor to engine 2 Install 1 sensor mounting bolt and tighten to 9 N m 80 in lbs torque 3 Install electrical connector to CKP sensor Fig 12 Fig 10 5 9L DIESEL CKP 1 ENGI...

Page 1643: ...o a bored hole in the top of the cyl inder head This bored hole is located between the intake exhaust valves High pressure connectors Fig 15 mounted into the side of the cylinder head con nect each fuel injector to each high pressure fuel line OPERATION High pressure fuel is supplied from the injection pump through a high pressure fuel line into a fuel rail through high pressure lines through stee...

Page 1644: ...all contaminants before entering the fuel injector The edge filters are not a substitute for proper cleaning and covering of all fuel system components during repair The bottom of each fuel injector is sealed to the cylinder head with a 1 5mm thick copper shim gas ket The correct thickness shim must always be re installed after removing an injector Fuel pressure in the injector circuit decreases a...

Page 1645: ...was meant to temporarily replace a rocker housing mounting bolt Remove the necessary rocker housing mounting bolt These mounting bolts are located at the center of each of the 3 rocker housing support bridges c Install and tighten 2 piece mounting stud to rocker housing If removing the 6 fuel injector separate the 2 piece mounting stud Install lower half of mounting stud to center of rocker housin...

Page 1646: ...t thickness must always be re installed after removing injector Measure thickness of injector shim Fig 21 Shim Thickness 1 5 mm 060 4 Install new shim washer to bottom of injector Apply light coating of clean engine oil to washer This will keep washer in place during installation 5 Install new o ring to fuel injector Apply small amount of clean engine oil to o ring Fig 18 FUEL INJECTORS 1 SOLENOID...

Page 1647: ...ation could cause rapid part wear and pos sible plugging of fuel injector nozzle tip holes This in turn could lead to possible engine misfire Always wash clean any fuel system component thoroughly before disassembly and then air dry Cap or cover any open part after disassembly Before assembly examine each part for dirt grease or other contaminants and clean if necessary When installing new parts l...

Page 1648: ...rom this sensor REMOVAL The Inlet Air Temperature Pressure Sensor is located on the air cleaner cover Fig 23 1 Disconnect electrical connector at sensor Fig 24 2 Remove two Torx type mounting screws 3 Remove sensor from air cleaner cover 4 Check condition of sensor o ring Fig 25 INSTALLATION 1 Check condition of sensor o ring 2 Position sensor into top of air cleaner cover with a slight twisting a...

Page 1649: ...isolate ends of both cables 2 Remove both the intake manifold air intake tube above injection pump and its rubber connector hose Fig 26 3 Lift 2 rubber covers Fig 27 to gain access to 2 positive cable nuts Remove these 2 nuts Fig 28 and remove 2 cables from studs 4 Disconnect ground strap Fig 27 at heater ele ment stud 5 Remove wiring harness clips 6 Remove engine oil dipstick tube bracket from ai...

Page 1650: ...ONNECTING HOSE 1 MANIFOLD ABOVE HEATERS 2 RUBBER CONNECTING HOSE 3 METAL INTAKE TUBE 4 CLAMPS 2 Fig 27 AIR HEATER MANIFOLD 1 GROUND CABLE 2 MOUNTING BOLTS 4 3 RUBBER COVERS 4 OIL DIPSTICK TUBE 5 DIPSTICK MOUNTING BOLT 6 NUT GROUND CABLE Fig 28 AIR HEATER ELEMENTS 1 MOUNTING BOLTS 4 2 AIR HEATER MANIFOLD 3 INTAKE MANIFOLD 4 HEATER ELEMENTS 5 LOWER GASKET 6 NUTS 2 POSITIVE CABLES 7 UPER GASKET DR FU...

Page 1651: ... cables to both batteries INTAKE AIR TEMPERATURE SENSOR MAP SENSOR DESCRIPTION The combination dual function Intake Manifold Air Temperature Sensor MAP Sensor is installed into the top of the intake manifold OPERATION The combination dual function Intake Manifold Air Temperature Sensor MAP Sensor is installed into the top of the intake manifold with the sensor ele ment extending into the air strea...

Page 1652: ...oval 7 Using 2 screwdrivers pry cable connector socket from throttle lever ball Fig 34 Be very careful not to bend throttle lever arm If Equipped With Battery Tray Mounted Accelerator Pedal Position Sensor The Throttle Control Cable connects the accelera tor pedal to the Accelerator Pedal Position Sensor APPS A separate mechanical cable is not routed to the throttle body CAUTION Be careful not to ...

Page 1653: ...ble core wire and plastic cable retainer into and through upper end of pedal arm the plastic retainer is snapped into pedal arm When installing plastic retainer to accelerator pedal arm note index tab on pedal arm Fig 32 Align index slot on plastic cable retainer to this index tab 5 Connect negative battery cables to both batter ies 6 Before starting engine operate accelerator pedal to check for a...

Page 1654: ...or any binding 7 If necessary use DRB IIIt Scan Tool to erase any APPS Diagnostic Trouble Codes DTC s from Engine Control Module ECM PTO SWITCH DESCRIPTION This Engine Control Module ECM input is used only on models equipped with aftermarket Power Take Off PTO units OPERATION This input is used only to tell the PCM non die sel or ECM diesel that the aftermarket PTO Power Take Off unit has been eng...

Page 1655: ......

Page 1656: ...the power steering pump and system if any other fluid is used and do not overfill Power steering systems consist of Steering column Rack and pinion steering gear Belt driven hydraulic steering pump Pump pressure and return hoses Oil Cooler OPERATION The steering column shaft is attached to the gear pinion The rotation of the pinion moves the gear rack from side to side This lateral action of the r...

Page 1657: ...e 1 Tighten bolts to specification 2 Loose or damaged suspension components 2 Inspect and repair suspension 3 Internal gear noise 3 Replace steering gear 4 Pressure hose in contact with other components 4 Reposition hose 5 Loose or damaged intermediate shaft or column 5 Inspect and repair or replace CHIRP OR SQUEAL 1 Loose belt 1 Adjust or replace WHINE OR GROWL 1 Low fluid level 1 Fill to proper ...

Page 1658: ...nd repair as necessary 5 Internal gear leak 5 Replace gear STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Tire pressure 1 Adjust tire pressure 2 Wheel alignment 2 Align front end 3 Lack of lubrication 3 Inspect and lubricate suspension compnents 4 High friction in steering gear 4 Replace gear LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERIN...

Page 1659: ...s and repair as necessary The initial pressure reading should be in the range of 345 552 kPa 50 80 psi 11 Increase the engine speed to 1500 RPM and read the flow meter If the flow rate GPM is below specification refer to pump specification chart for GPM the pump should be replaced CAUTION The following test procedure involves testing maximum pump pressure output and flow control valve operation Do...

Page 1660: ...IAL TOOLS STEERING PULLER 8677 ADAPTERS POWER STEERING FLOW PRESSURE TESTER 6893 ANALYZER SET POWER STEERING FLOW PRESSURE 6815 ADAPTER POWER STEERING FLOW PRESSURE 6825A DR STEERING 19 5 STEERING Continued ...

Page 1661: ...witches shrouds steering wheel etc Most steering column components can be serviced without remov ing the steering column from the vehicle To service the steering wheel switches or airbag refer to Restraints and follow all WARNINGS and CAUTIONS WARNING THE AIRBAG SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MU...

Page 1662: ...ion to ensure proper operation of the steering column 1 Position the front wheels straight ahead 2 Disconnect the negative ground cable from the battery 3 Remove the two switches from the steering wheel 4 Remove the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 5 Remove the steering wheel with special tool CJ98 1 or an appropriate steering wheel puller CAUTION Ensure the puller bol...

Page 1663: ...g shaft coupler bolt and slide the shaft down Fig 4 Fig 5 15 Remove the brake light switch and discard Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH REMOVAL 16 Remove the four steering column mounting nuts Fig 6 Fig 3 SHIFT CABLE CONNECTOR 1 Shift lever 2 Cable Connection 3 Overdrive Electrical Wiring 4 Mounting Screws Fig 4 COUPLER SHAFT 1 MOUNTING HOLES 2 COUPLER BOLT HOLE Fig ...

Page 1664: ...r Refer to 23 BODY INSTRUMENT PANEL STEER ING COLUMN OPENING COVER INSTALLA TION 13 Align the spline on the wheel hub to shaft 14 Then install the steering wheel and install a new bolt Tighten the bolt to 61 N m 45 ft lbs 15 Install the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG INSTALLATION 16 Install the two steering wheel switches 17 Install the tilt lever handle 18 Install the negat...

Page 1665: ...T OF THE AIRBAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COAT INGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES ANYTIME A NEW FASTENER IS NEEDED REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS CAUTION Do not hamm...

Page 1666: ...Enable the airbag system Refer to 8 ELEC TRICAL RESTRAINTS DRIVER AIRBAG INSTAL LATION KEY IN IGNITION SWITCH DESCRIPTION The key in ignition switch is integral to the igni tion switch which is mounted on the left side of the steering column It closes a path to ground for the Central Timer Module CTM when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is ...

Page 1667: ...SHIFT LEVER REMOVAL 1 Remove the kneeblocker Refer to 23 BODY INSTRUMENT PANEL KNEE BLOCKER REMOVAL 2 Remove the upper and lower column shroud 3 Remove and discard the brake light switch 4 Loosen the column bolts and lower the column enough to allow clearance for the gear shift lever removal 5 Disconnect the overdrive switch harness if equipped 6 Disconnect the shift cable from the shift lever 7 R...

Page 1668: ...mn on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key Alternative meth ods of locking the steering wheel for service will have to be used 2 Lock the steering wheel with the tire in the straight position 3 Remove and discard the lower pinch bolt 4 Lower the steering coupler shaft from the col ...

Page 1669: ...emove the left front tire and wheel assembly 5 Mark both coupler connections for proper installation 6 Remove and discard the upper coupler pinch bolt 7 Remove and discard the lower coupler pinch bolt 8 Remove the lower steering shaft coupler Fig 18 REMOVAL 4X4 HD 1 Disconnect the negative battery cable 2 Raise and support the vehicle NOTE The steering column on vehicles with an automatic transmis...

Page 1670: ...negative battery cable 8 Unlock the steering wheel STEERING WHEEL REMOVAL 1 Disable and remove the driver s side air bag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 2 Partially remove the steering wheel bolt and leave the bolt in the column 3 Install puller CJ98 1 or equivalent using the top of the bolt to push on Fig 21 4 Remove and discard the steering wheel bolt 5 Remove the steering...

Page 1671: ... care not to pry on the clock spring electrical connector when removing or installing the mounting screw located next to the clockspring NOTE New screws should be used when installing the tilt lever release knob bracket to the column 3 Install the tilt lever release knob bracket to the column and install the two new mounting screws Fig 22 Tighten the two new screws to 4 5 N m 40 in lbs 4 Install t...

Page 1672: ...ked with the key Alternative meth ods of locking the steering wheel for service will have to be used 1 Lock the steering wheel 2 Drain and siphon the power steering fluid from the reservoir 3 Raise the vehicle 4 Remove and discard the steering coupler pinch bolt 5 Remove the power steering hoses from the rack pinion 6 Remove the tire and wheel assembly 7 Remove the tie rod end nuts and separate ti...

Page 1673: ...LATION 5 Install the pressure power steering hose to the steering gear and tighten to 32 N m 23 ft lbs Refer to 19 STEERING PUMP HOSES INSTAL LATION 6 Install the return power steering hose to the steering gear and tighten to 71 N m 52 ft lbs Refer to 19 STEERING PUMP HOSES INSTAL LATION 7 Install the front skid plate Refer to 13 FRAME BUMPERS FRAME FRONT SKID PLATE INSTALLATION 8 Install the tire...

Page 1674: ...using care not to strike the gear 3 Remove the front mounting bushings 4 Remove the rear mounting bushings 5 Remove the steering gear from the vise and place it on the bench INSTALLATION NOTE Coat all bushings with a thin rubber lubri cate oil prior to installation NOTE A rubber mallet can be used to assist in the installation of the bushings once lubricated 1 Coat the rear bushings with a thin ru...

Page 1675: ...ack piston The worm shaft is sup ported by a thrust bearing at the lower end and a bearing assembly at the upper end When the worm shaft is turned from input from the steering column the rack piston moves The rack piston teeth mesh with the pitman shaft Turning the worm shaft turns the pitman shaft which turns the steering linkage REMOVAL 1 Place the front wheels in a straight ahead posi tion NOTE...

Page 1676: ... man shaft Tighten the nut to 305 N m 225 ft lbs 5 Connect fluid hoses to steering gear Refer to 19 STEERING PUMP HOSES INSTALLATION tighten to 31 N m 23 ft lbs 6 Add fluid Refer to 19 STEERING PUMP STANDARD PROCEDURE 7 Reset the toe and center the steering wheel Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE ADJUSTMENTS ADJUSTMENT CAUTION Steering gear must be adjusted in the proper ord...

Page 1677: ...on center torque reading must be 5 9 in lbs higher than the previously measured preload torque without exceeding a total of 17 in lbs The value of the total on center minus the preload torque is defined as the meshload torque 6 If required adjust the on center torque by loos ening the adjuster screw lock nut and turning the adjuster screw until the total on center and meshload torque readings fall...

Page 1678: ...mp 37 27 Steering Gear Adjustment Screw Locknut 31 23 Steering Gear Pitman Shaft Nut 305 225 Steering Gear Pitman Shaft Cover Bolts 68 50 Steering Gear Valve Housing to Gear Bolts 54 40 Steering Gear Retainer Ring Screw 2 26 20 Steering Gear Retainer Ring 97 72 SPECIAL TOOLS POWER STEERING GEAR HANDLE C 4171 INPUT SHAFT SEAL INSTALLER 8987 PULLER SLIDE HAMMER C 3752 DR GEAR LINK COIL 19 23 GEAR LI...

Page 1679: ...SEAL REMOVER ADAPTER 8990 PITMAN SHAFT SEAL INSTALLER 8989 RETAINER RING WRENCH 8988 PITMAN SHAFT SEAL PROTECTOR 8993 INPUT SHAFT SEAL PROTECTOR 8986 19 24 GEAR LINK COIL DR GEAR LINK COIL Continued ...

Page 1680: ... remove 10 Remove oil seal from the housing with a spe cial tool 8990 with slide hammer C 3752 REMOVAL DIESEL 1 Seperate the pitman arm from the gear box Refer to 19 STEERING LINKAGE PITMAN ARM REMOVAL 2 Remove the steering gear box Refer to 19 STEERING GEAR REMOVAL 3 Install the steering gear in a soft jawed bench vise 4 Clean exposed end of pitman shaft and housing with a wire brush 5 Rotate the...

Page 1681: ...the bearing 9 Install the new cover bolts and tighten to 68 N m 50 ft lbs 10 Install the pitman arm Refer to 19 STEER ING LINKAGE PITMAN ARM INSTALLATION INSTALLATION DIESEL NOTE Generous amounts of the high temperature grease from the seal kit should be applied to areas between the pitman shaft bearing and oil seals and also between the dust seals and snap ring 1 Coat the oil seal and washer with...

Page 1682: ...om stop to stop and count the number of turns using a 12 point socket Fig 9 NOTE The pitman shaft will not clear the housing if it is not centered 6 Center the input shaft by rotating it from the stop back 1 1 2 turns to achieve center position Fig 9 7 Remove the pitman shaft Refer to 19 STEERING GEAR PITMAN SHAFT REMOVAL 8 Remove the four bolts securing the valve hous ing 9 Remove the valve housi...

Page 1683: ...Then remove the wormshaft assembly from the vise Fig 14 14 Remove the dust seal with a pick Fig 15 Fig 12 SET SCREW FOR THE RETAINER RING 1 SET SCREW 2 3 32 ALLEN HEAD SOCKET 3 RETAINER RING Fig 13 REATINER RING REMOVAL 1 SPECIAL TOOL 8988 2 RATCHET Fig 14 WORMSHAFT AND VALVE ASSEMBLY 1 PISTON TEFLON SEALS 2 RETAINER RING Fig 15 DUST SEAL REMOVAL 1 PICK 2 VALVE HOUSING 3 SEAL 19 28 GEAR LINK COIL ...

Page 1684: ...t lbs NOTE It is very important to make sure to compen sate for the added length of the torque wrench when torquing to proper specifications 4 Install the retainer ring set screw Tighten to 2 26 N m 20 in lbs 5 Clean the steering gear housing CAUTION Valve assembly must be centered to the housing Fig 19 6 Install the valve assembly into the steering gear Fig 19 Tighten the new bolts to 54 N m 40 f...

Page 1685: ...the steering gear to the vehicle Refer to 19 STEERING GEAR INSTALLATION 15 Perform a wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE PITMAN SHAFT REMOVAL REMOVAL GAS 1 Separate the pitman arm from the gear box Refer to 19 STEERING LINKAGE PITMAN ARM REMOVAL 2 Clean exposed end of pitman shaft and housing with a wire brush 3 Rotate the steering wheel from stop to stop and ...

Page 1686: ...TEERING GEAR ADJUSTMENTS 5 Install the pitman arm Refer to 19 STEER ING LINKAGE PITMAN ARM INSTALLATION 6 Perform a wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE INSTALLATION DIESEL 1 Coat the seal with power steering fluid 2 Install the pitman shaft into the steering gear until it fully seats into the bearing 3 Install the new cover bolts and tighten to 68 N m 50 ft lb...

Page 1687: ... then zero the dial indicator 4 Position indicator plunger on the topside of the outer tie rod end NOTE The dial indicator plunger must be perpen dicular to the machined surface of the outer tie rod end 5 Position a pry bar in order to pry downwards on the outer tie rod end 6 If the travel exceeds 0 5 mm 0 020 in replace the outer tie rod end Refer to 19 STEERING LINKAGE TIE ROD END REMOVAL 7 If t...

Page 1688: ...he outer tie rod end into the steering knuckle Fig 2 3 Tighten the ball stud nut on the ball stud to 61 N m 45 ft lbs then an additional 90 4 Set wheel toe pattern Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE 5 Tighten jam nut to 75 N m 55 ft lbs Fig 2 Fig 2 TIE ROD END 1 JAM NUT 2 TIE ROD INNER 3 TIE ROD END OUTER DR LINKAGE INDEPENDENT FRONT SUSPENSION 19 33 TIE ROD END Continued ...

Page 1689: ...are replaced or serviced an alignment must be performed NOTE To avoid damaging ball stud seals use Puller C 3894 A or an appropriate puller to remove tie rod ends Fig 2 STANDARD PROCEDURE LUBRICATION Periodic lubrication of the steering system compo nents is required Refer to Lubrication And Mainte nance for the recommended maintenance schedule The following components must be lubricated Tie rod T...

Page 1690: ...Rod 108 80 Drag Link Adjuster Clamp 61 45 Tie Rod End Knuckle 108 80 Tie Rod End Adjuster Clamp 61 45 Stabilizer Bar Link to Axle 68 50 Steering Damper Axle 95 70 Steering Damper Tie Rod 81 60 SPECIAL TOOLS STEERING LINKAGE Remover Ball Stud MB 991113 Puller Tie Rod C 3894 A Remover Ball Joint C 4150A DR LINKAGE LINK COIL 19 35 LINKAGE LINK COIL Continued ...

Page 1691: ... m 65 ft lbs 2 Install the drag link to the right steering knuckle Install the nut and tighten to 108 N m 80 ft lbs 3 Install tie rod to the left steering knuckle and drag link Install the nuts and tighten to 108 N m 80 ft lbs 4 Remove the supports and lower the vehicle to the surface Center steering wheel and adjust toe Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE 5 After adjustment t...

Page 1692: ...o retain ing bolt is located on the bottom side of the sleeve TIE ROD END REMOVAL 1 Remove tie rod nuts Fig 7 2 Remove tie rod from drag link and left knuckle with Puller C 4150A INSTALLATION 1 Install tie rod to the left steering knuckle and drag link Install the nuts and tighten to 108 N m 80 ft lbs 2 Remove the supports and lower the vehicle to the surface Center steering wheel and adjust toe R...

Page 1693: ... 3 Remove the track bar Fig 8 INSTALLATION 1 Install the track bar 2 Install the new bolts and nuts Tighten to 203 N m 150 ft lbs 3 Remove the supports under the axle and lower the vehicle to the ground Fig 8 TRACK BAR REMOVAL INSTALLATION 1 TRACK BAR 2 BOLT 3 NUT 19 38 LINKAGE LINK COIL DR ...

Page 1694: ...TO COOLER 45 REMOVAL PRESSURE HOSE 45 REMOVAL RETURN HOSE RESERVOIR TO COOLER 45 INSTALLATION INSTALLATION RETURN HOSE GEAR TO COOLER 45 INSTALLATION PRESSURE HOSE 45 INSTALLATION RETURN HOSE RESERVOIR TO COOLER 45 POWER STEERING PRESSURE SWITCH DESCRIPTION 46 OPERATION 46 REMOVAL 3 7L 5 7L 46 INSTALLATION 3 7L 5 7L 46 PULLEY REMOVAL 47 INSTALLATION 47 RESERVOIR REMOVAL 47 INSTALLATION 47 PUMP DES...

Page 1695: ...il coolers turn wheel 40 times 5 Start the engine With the engine idling main tain the fluid level 6 Lower the front wheels and let the engine idle for two minutes 7 Turn the steering wheel in both direction and verify power assist and quiet operation of the pump If the fluid is extremely foamy or milky looking allow the vehicle to stand a few minutes and repeat the procedure CAUTION Do not run a ...

Page 1696: ...securing the pump to the cylinder head can be gained thru the pulley holes Fig 2 REMOVAL DIESEL 1 Drain and siphon the power steering fluid from the reservoir 2 Remove the serpentine belt CAUTION Do not remove the fitting on the pump that the high pressure hose screws into The fitting may come loose unless it is backed up using another wrench If the fitting does come loose it must be retightened b...

Page 1697: ...5 Tighten the inner cooler tube clamp at the intake plenum 6 Install 3 pump mounting bolts through the pul ley access holes Tighten the bolts to 28 N m 21 ft lbs 7 Tighten the pump bracket to the block 8 Reconnect the pressure line and return hose to the pump and reservoir Tighten the pressure line to 37 N m 27 ft lbs 9 Install the serpentine drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BEL...

Page 1698: ...ed on the dipstick COLD and HOT Before opening power steering system wipe the reservoir filler cap free of dirt and debris Remove the cap and check the fluid level on its dipstick When the fluid is at normal ambient temperature approximately 21 C to 27 C 70 F to 80 F the fluid level should read between the minimum and maximum area of the cold range When the fluid is hot fluid level is allowed to r...

Page 1699: ...t the return hose at the cooler 3 Reconnect the return hose at the gear Tighten the hose to 71 N m 52 ft lbs Fig 6 4 Reattach the hose to the routing clip at the fan shroud 5 Remove the support and lower the vehicle 6 Refill the power steering system Refer to 19 STEERING PUMP STANDARD PROCEDURE INSTALLATION PRESSURE HOSE NOTE Be sure to align the pressure hose so it does not contact the fan shroud...

Page 1700: ... 2 Reconnect the return hose at the cooler 3 Reconnect the return hose at the gear Tighten the hose to 51 N m 38 ft lbs Fig 7 4 Reattach the hose to the routing clip at the fan shroud 5 Remove the support and lower the vehicle 6 Refill the power steering system Refer to 19 STEERING PUMP STANDARD PROCEDURE INSTALLATION PRESSURE HOSE NOTE Be sure to align the pressure hose so it does not contact the...

Page 1701: ...h will open and the PCM will increase the engine idle speed This will prevent the engine from stalling When pump pressure drops to approximately 1379 kPa 200 psi the switch circuit will re close and engine idle speed will return to its previous setting REMOVAL 3 7L 5 7L The power steering pressure switch is installed in the power steering high pressure hose Fig 9 1 Disconnect electrical connector ...

Page 1702: ...creases press on 1 0 mm 0 040 in Be careful that pulley does not contact mounting bolts RESERVOIR REMOVAL 1 Drain and siphon the power steering fluid from the reservoir 2 Remove the serpentine belt 3 Remove the power steering pump Refer to 19 STEERING PUMP REMOVAL 4 Remove the reservoir mounting bolts 5 Remove the reservoir 6 Remove the rear bracket to the pump mounting bolts INSTALLATION 1 Instal...

Page 1703: ......

Page 1704: ...ts consist of the forks shaft shift lever socket and detent components OPERATION The manual transmission receives power through the clutch assembly from the engine The clutch disc is splined to the transmission input shaft and is turned at engine speed at all times that the clutch is engaged The input shaft is connected to the transmission coun tershaft through the mesh of fourth speed gear on the...

Page 1705: ...Fig 1 NV3500 TRANSMISSION 21 2 MANUAL TRANSMISSION NV3500 DR MANUAL TRANSMISSION NV3500 Continued ...

Page 1706: ... hard shift ing and noise Shift component damage or damaged clutch pres sure plate or disc are additional probable causes of increased shift effort Worn damaged pressure plate or disc can cause incorrect release If clutch problem is advanced gear clash during shifts can result Worn or damaged synchro rings can cause gear clash when shifting into any forward gear In some new or rebuilt transmission...

Page 1707: ...engine 20 Move transmission rearward until input shaft is clear of clutch disc and pressure plate Then lower jack and remove transmission from under vehicle DISASSEMBLY FRONT HOUSING 1 Shift transmission into Neutral 2 If lubricant was not drained out of transmis sion during removal remove drain plug and drain lubricant 3 Inspect drain plug magnet for debris 4 Remove backup light switch located on...

Page 1708: ...detent plug from the side of the transmission with Remover 8117A Attach fin gers of the remover to the detent plug and push the cup down till it contacts the trans Then tighten the nut till it pulls the plug from the case 11 Remove shift shaft detent plunger and spring with a pencil magnet Fig 7 SHAFT LOCK BOLT 1 SHIFT SHAFT LOCK BOLT 2 SHAFT SOCKET Fig 8 BEARING RETAINER SEAL 1 PRY TOOL 2 INPUT S...

Page 1709: ...nt dowels with a plastic hammer 14 Remove input shaft bearing and countershaft front bearing race Fig 13 Fig 11 HOUSING BEARING RETAINER BOLT 1 RETAINER BOLTS 2 HOUSING BOLTS 3 RETAINER BOLT 4 HOUSING BOLT LOCATIONS Fig 12 FRONT HOUSING 1 FRONT HOUSING 2 REAR HOUSING 3 DOWELS 2 4 PLASTIC MALLET Fig 13 Input Shaft Bearing and Countershaft Front Bearing Race 1 INPUT SHAFT BEARING 2 FRONT HOUSING 3 C...

Page 1710: ...eated on the shift socket Fig 16 4 Tilt socket toward the side of the case to avoid trapping the pin between the gear teeth 5 Tighten remover to press the roll pin down ward and out of the shift socket Fig 16 NOTE Roll pin must only clear the shift shaft Do not push the pin into the geartrain Fig 14 GEARTRAIN AND SHIFT COMPONENT 1 SHIFT SHAFT 2 BUSHING 3 REAR HOUSING 4 REVERSE IDLER AND SUPPORT 5 ...

Page 1711: ...ynchro sleeve until fork clears shift arms on 1 2 and fifth reverse forks then remove 3 4 fork Fig 21 Fig 17 SHIFT SHAFT LEVER BUSHING ROLL PIN 1 PIN PUNCH 2 BUSHING AND LEVER 3 SHIFT SHAFT Fig 18 SHIFT SHAFT 1 SHIFT SHAFT 2 3 4 FORK 3 SHAFT DETENT NOTCHES Fig 19 SHIFT SOCKET ROLL PIN 1 SHAFT BORE 2 ROLL PIN 3 SHIFT SOCKET Fig 20 SHIFT SHAFT LEVER BUSHING 1 SHAFT LEVER AND BUSHING 2 3 4 FORK Fig 2...

Page 1712: ...l onto input shaft counter shaft and idler gear Fig 23 d Stand geartrain and rear housing upright on fixture Fig 24 Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position 14 Remove rear bolt holding reverse idler shaft in housing Fig 22 REVERSE IDLER SHAFT SUPPORT 1 SUPPORT BOLT 2 SHAFT BOLT Fig 23 FIXTURE ASSEMBLY 1 FIXTURE 6747 2 ADAPTER 6747 1A...

Page 1713: ...t bearing with a plastic rawhide hammer Fig 26 3 Lift rear housing up and off geartrain Fig 27 Fig 26 SEPARATE REAR HOUSING OUTPUT SHAFT BEARING 1 REAR HOUSING 2 MALLET 3 FIXTURE Fig 27 REAR HOUSING 2WD 1 REAR HOUSING 2 SHIFT FORKS AND GEARTRAIN Fig 25 OUTPUT SHAFT 1 OUTPUT SHAFT BEARING RETAINER BOLTS THIRD BOLT IS AT OPPOSITE SIDE OF CASE 21 10 MANUAL TRANSMISSION NV3500 DR MANUAL TRANSMISSION N...

Page 1714: ...remove rear bearing retainer and rear bearing Fig 33 Push or tap bearing out of housing with a hammer handle if needed Fig 28 COUNTERSHAFT REAR BEARING 1 COUNTERSHAFT REAR BEARING 2 OUTPUT SHAFT 3 COUNTER SHAFT Fig 29 REAR SEAL 1 SLIDE HAMMER 2 REMOVER TOOL 3 REAR SEAL Fig 30 REAR SEAL FACE 1 DIMPLES 2 SEAL FACE Fig 31 REAR BEARING SNAP RING 1 HEAVY DUTY SNAP RING PLIERS 2 REAR BEARING SNAP RING 3...

Page 1715: ... synchronizer unit as an assembly to avoid mixing parts Mark each synchro hub and sleeve with a scriber or paint for correct assembly reference 1 Remove snap ring that secures 3 4 synchro hub on output shaft 2 Position Bearing Splitter 1130 between second and third gears and press off 3 4 synchro assembly third gear synchro ring and third gear with a shop press 3 Remove third gear needle bearing F...

Page 1716: ...nd first gear from output shaft with shop press Fig 39 10 Remove first gear needle bearing Fig 40 Fig 36 TWO PIECE THRUST WASHER 1 SECOND GEAR 2 THRUST WASHER 2 PIECE 3 WASHER LOCATING LUG Fig 37 SECOND GEAR 1 SECOND GEAR 2 SECOND GEAR NEEDLE BEARING Fig 38 SECOND GEAR SYNCHRO RING CONES 1 1 2 SYNCHRO HUB AND SLEEVE 2 INTERM RING 3 SYNCHRO FRICTION CONE 4 SYNCHRO CONE 5 SYNCHRO RING Fig 39 HUB SLE...

Page 1717: ...ifth reverse synchro hub snap ring Fig 44 Fig 41 OUTPUT SHAFT BEARING SNAP RING 1 OUTPUT SHAFT BEARING 2 BEARING SNAP RING 3 SNAP RING PLIERS Fig 42 FIFTH GEAR 1 FIFTH GEAR AND SYNCHRO RING Fig 43 FIFTH GEAR NEEDLE BEARING 1 FIFTH GEAR NEEDLE BEARING Fig 44 FIFTH REVERSE SYNCHRO HUB SNAP RING 1 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 2 SYNCHRO HUB SNAP RING 3 SNAP RING PLIERS 21 14 MANUAL TRANSMISSIO...

Page 1718: ... compressed air Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent Gunk or similar sol vents Do not dry the bearings with compressed air Allow the bearings to either air dry or wipe them dry with clean shop towels Fig 45 FIFTH REVERSE SYNCHRO 1 PRESS 2 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 3 REVERSE GEAR 4 OUTPUT SHAFT Fig 46 REVERSE GEAR NEEDLE BEARING 1 REVERSE GEAR AND...

Page 1719: ...her part is deformed or worn Do not attempt to salvage these parts as shift fork binding will occur Replace the roll pin that secures the lever to the shaft FRONT REAR HOUSINGS AND BEARING RETAINERS Inspect the housings carefully Look for cracks stripped threads scored mating surfaces damaged bearing bores or worn dowel pin holes Minor nicks on mating surfaces can be dressed off with a fine file o...

Page 1720: ...ng assem bly The socket roll pin is approximately 33 mm 1 1 4 in long Output Shaft And Geartrain Inspect all gears for worn cracked chipped or bro ken teeth Also check condition of the bearing bore in each gear The bores should be smooth and free of surface damage Discoloration of the gear bores is a normal occurrence and is not a reason for replace ment Replace gears only when tooth damage has oc...

Page 1721: ...en seat synchro onto shaft with shop press and Remover 6310 1 Fig 53 CAUTION One side of the hub has shoulders around the hub bore this side faces the front of the shaft One side of the sleeve is tapered the tapered side faces the front of the shaft Fig 50 REVERSE GEAR BEARING 1 REVERSE GEAR BEARING 2 SHOULDER Fig 51 REVERSE GEAR 1 REVERSE GEAR Fig 52 REVERSE GEAR SYNCHRO 1 REVERSE GEAR 2 SYNCHRO ...

Page 1722: ...bearing is properly seated 8 Install fifth gear on shaft and onto bearing Fig 57 Fig 54 FIFTH REVERSE SYNCHRO HUB SNAP RING 1 FIFTH REVERSE SYNCHRO ASSEMBLY 2 SNAP RING 3 PRESS BED 4 PRESS BLOCKS Fig 55 FIFTH GEAR SYNCHRO RING 1 FIFTH SPEED SYNCHRO RING 2 FIFTH REVERSE SYNCHRO ASSEMBLY Fig 56 FIFTH GEAR BEARING 1 SHAFT SHOULDER 2 FIFTH GEAR BEARING Fig 57 FIFTH GEAR 1 FIFTH GEAR 2 BEARING DR MANUA...

Page 1723: ...ar synchro ring Fig 60 13 Start 1 2 synchro assembly on shaft by hand Fig 61 CAUTION One side of the synchro sleeve is marked First Gear Side this side must face first gear Fig 58 FIRST GEAR 1 FIRST GEAR BEARING 2 SHAFT SHOULDER 3 COLLAR 4 PRESS BLOCKS Fig 59 FIRST GEAR 1 FIRST GEAR 2 COLLAR 3 BEARING Fig 60 FIRST GEAR SYNCHRO RING 1 FIRST GEAR SYNCHRO RING 2 COLLAR 3 FIRST GEAR Fig 61 STARTING 1 ...

Page 1724: ...in shaft groove 17 Install second gear synchro ring in 1 2 syn chro hub and sleeve Fig 64 Verify synchro ring is seated in sleeve 18 Install synchro friction cone and synchro cone in synchro ring Fig 62 1 2 SYNCHRO ON OUTPUT SHAFT 1 PIPE TOOL 2 SYNCHRO RING 3 COLLAR 4 1 2 SYNCHRO ASSEMBLY 5 PRESS RAM Fig 63 1 2 SYNCHRO HUB SNAP RING 1 1 2 SYNCHRO 2 COLLAR 3 SYNCHRO SNAP RING Fig 64 SECOND GEAR SYN...

Page 1725: ...direction 22 Start retaining ring around two piece thrust washer Fig 68 Verify locating dimple is between thrust washer halves Fig 65 SECOND GEAR BEARING 1 SECOND GEAR BEARING 2 COLLAR Fig 66 SECOND GEAR 1 COLLAR 2 1 2 SYNCHRO ASSEMBLY 3 BEARING 4 SECOND GEAR Fig 67 TWO PIECE THRUST WASHER 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS 4 LUG BORE 5 LUG 6 WASHER HALF Fig 68 RETAINING RING...

Page 1726: ...e can be installed backwards if care is not exercised One side of the sleeve has grooves in it this side must faces the front of the shaft Fig 69 THRUST RETAINER 1 PLASTIC MALLET 2 THRUST WASHER RETAINING RING Fig 70 THIRD GEAR BEARING 1 THIRD GEAR BEARING Fig 71 THIRD GEAR 1 THIRD GEAR 2 BEARING Fig 72 THIRD GEAR SYNCHRO RING 1 THIRD SPEED SYNCHRO RING 2 THIRD GEAR Fig 73 3 4 SYNCHRO HUB ON OUTPU...

Page 1727: ...EVERSE IDLER ASSEMBLY 1 Lubricate idler components with gear lube 2 Slide idler gear bearing on shaft Fig 78 Bearing fits either way on shaft 3 Slide gear onto shaft Side of gear with recess goes to rear Fig 78 4 Place first lock ball in dimple at rear end of idler shaft Fig 78 Petroleum jelly can be used to hold ball in place if desired 5 Slide thrust rear thrust washer onto shaft and over lock b...

Page 1728: ... FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 78 IDLER GEAR BEARING 1 IDLER GEAR 2 BEARING 3 LOCK BALL 4 REAR OF SHAFT Fig 79 IDLER GEAR REAR THRUST WASHER 1 LOCK BALL 2 SNAP RING GROOVE 3 THRUST WASHER DR MANUAL TRANSMISSION NV3500 21 25 MANUAL TRANSMISSION NV3500 Continued ...

Page 1729: ...new bearing e Bearing is correctly installed if flush with the transmission case 4 Inspect detent plunger bushings for damage NOTE The detent plunger bushings are installed to a specific depth The space between the two bush ings when correctly installed contain an oil feed hole Do not attempt to install the bushings with anything other than the specified tool or this oil hole may become restricted...

Page 1730: ...er goes toward the input shaft 4 Install fourth gear synchro ring on input shaft Fig 83 5 Adjust height of idler gear pedestal on fixture Fig 84 Start with a basic height of 18 4 cm 7 1 4 in Final adjustment can be made after gear is posi tioned on pedestal Fig 81 FIXTURE FOR GEARTRAIN BUILD UP 1 ADAPTER 6747 2A 2 CUP 8115 3 ADAPTER 6747 1A 4 FIXTURE 6747 Fig 82 PILOT BEARING INPUT SHAFT 1 PILOT B...

Page 1731: ...xist This will not interfere with assembly If difference is greater than this the coun tershaft adapter tool is probably upside down 10 Position reverse idler in support cup of fixture Fig 87 Verify idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out from the geartrain Adjust pedestal up or down if necessary and verify short end of idler shaft is faci...

Page 1732: ...ts must be in Neutral position to prevent damaging the synchro and shift components when installing the housings 1 Drive adapter housing alignment dowels back into housing until dowels are flush with mounting surface Fig 91 Fig 88 ALIGN OUTPUT SHAFT BEARING RETAINER 1 ALIGNMENT PIN 2 OUTPUT SHAFT BEARING RETAINER Fig 89 1 2 FIFTH REVERSE SHIFT FORKS 1 1 2 FORK 2 1 2 FORK ARM 3 FIFTH REVERSE FORK F...

Page 1733: ...llation 7 Install rear housing onto geartrain Fig 94 and verify bearing retainer pilot stud is in correct bolt hole in housing Verify countershaft and output shaft bearings are aligned in housing and on counter shaft NOTE It may be necessary to lift upward on coun tershaft slightly to ensure that the countershaft rear bearing engages to the countershaft before the rear output shaft bearing engages...

Page 1734: ...nder hex heads of bearing retainer bolts Fig 95 4 Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race 5 Install countershaft rear bearing in bearing race Fig 93 NOTE Large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing Fig 93 6 Apply extra petroleum jelly to hold counter shaft rear bearing in pl...

Page 1735: ...osition to prevent damaging the housings shift forks and gears while installing the housings 2 Install 3 4 shift fork in synchro sleeve Fig 100 Verify groove in fork arm is aligned with grooves in 1 2 and fifth reverse fork arms as shown 3 Slide shift shaft through 3 4 shift fork Fig 101 Fig 98 REAR BEARING SNAP RING 1 SNAP RING PLIERS 2 SNAP RING 3 OUTPUT SHAFT Fig 99 ADAPTER HOUSING REAR SEAL 1 ...

Page 1736: ...using Fig 105 8 Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing CAUTION Both shaft roll pins can be installed when the shaft is 180 off If this occurs the trans mission will have to be disassembled again to cor rect shaft alignment Fig 102 SHIFT SHAFT LEVER AND BUSHING 1 SHAFT LEVER 2 LEVER BUSHING 3 BUSHING LOCK PIN SLOT Fig 103 SHIFT SHAFT LEVER AND B...

Page 1737: ...g will bind on the roll pin if the pin is not seated flush 12 Verify that lock pin slot in lever bushing is positioned as shown Fig 108 13 Align roll pin holes in shift socket and shift shaft Then start roll pin into shift shaft by hand Fig 109 Fig 106 ROLL PIN IDENTIFICATION 1 SHAFT LEVER ROLL PIN 2 SHIFT SOCKET ROLL PIN Fig 107 SHIFT SHAFT ROLL PIN 1 SHAFT LEVER ROLL PIN 2 LEVER AND BUSHING Fig ...

Page 1738: ... fork arms before proceeding FRONT HOUSING AND INPUT SHAFT BEARING RETAINER 1 If previously removed install input shaft bear ing in front housing bore Fig 113 Install snap ring and use plastic mallet to seat bearing Bearing goes in from front side of housing only Fig 110 SEAT SHIFT SOCKET 1 PIN PUNCH 2 SHIFT SOCKET 3 SEAT ROLL PIN FLUSH 4 SHIFT SOCKET Fig 111 SHIFT LEVER POSITION 1 SHIFT FORK ARMS...

Page 1739: ... onto geartrain until seated on rear housing CAUTION Front housings will not seat if shift com ponents are not in Neutral or one or more compo nents are misaligned Do not force the front housing into place 8 Tap rear housing alignment dowels back into place with hammer and pin punch Both dowels should be flush fit in each housing Have helper hold transmission upright while dowels are tapped back i...

Page 1740: ...nd compress spring until detent plug pilots in detent plunger bore Drive detent plug into transmission case until plug seats 16 Install backup light switch Fig 118 17 Install input shaft snap ring Fig 119 18 Install new oil seal in front bearing retainer with Installer 6448 Fig 120 19 Apply bead of Mopar silicone sealer or equiv alent to flange surface of front bearing retainer Fig 121 Fig 117 SHA...

Page 1741: ...e sure shift ball is seated in socket and the offset in the tower is toward the passenger side of the vehicle before installing tower bolts 4 Install shift tower bolts Fig 125 and tighten bolts to 8 5 N m 75 2 in lbs 5 Fill transmission to bottom edge of fill plug hole with lubricant 6 Install and tighten fill plug to 34 N m 25 ft lbs 7 Check transmission vent Be sure vent is open and not restrict...

Page 1742: ...bs 7 Install transmission rear mounting bolts and tighten to 68 N m 50 ft lbs 8 Install front dust shield tighten bolt to 4 5 N m 40 in lbs If cover was removed install onto the transmission and engine Refer to 9 ENGINE EN GINE BLOCK STRUCTURAL COVER INSTALLA TION 9 Install structural dust cover and tighten the bolts to 54 N m 40 ft lbs 10 Install starter motor 11 Install suspension crossmember an...

Page 1743: ...9 27 14 20 Front To Rear Housing Bolts 30 35 22 26 Front Bearing Retainer Bolts 7 10 5 7 62 88 Idler Shaft Bolts 19 25 14 18 Rear Bearing Retainer Bolts 30 35 22 26 Shift Tower Bolts 7 10 5 7 62 88 Slave Cylinder Nuts 23 17 Transfer Case Nuts 47 35 SPECIAL TOOLS REMOVER C 3985 B INSTALLER C 3972 A REMOVER 6957 INSTALLER 6951 HANDLE C 4171 21 40 MANUAL TRANSMISSION NV3500 DR MANUAL TRANSMISSION NV3...

Page 1744: ...58 FIXTURE 6747 ADAPTER 6747 1A ADAPTER 6747 2A CUP 8115 BEARING SPLITTER 1130 TUBE 6310 1 INSTALLER 8118 REMOVER INSTALLER 8119 ALIGNMENT STUD 8120 DR MANUAL TRANSMISSION NV3500 21 41 MANUAL TRANSMISSION NV3500 Continued ...

Page 1745: ...INSTALLER C 3860 A INSTALLER 8123 INSTALLER 6448 REMOVER 8117A 21 42 MANUAL TRANSMISSION NV3500 DR MANUAL TRANSMISSION NV3500 Continued ...

Page 1746: ...upported on caged type roller bearings Drive gear thrust reac tion is controlled by a needle type thrust bearing The bearing is located at the forward end of the mainshaft The transmission is a top loader style The shift lever is located in a shifter tower which is bolted to the shift cover and operates the shift forks and rails directly The shift forks and rails are all located within the aluminu...

Page 1747: ...nadequate sealer gaps in the sealer incorrect bolt tightening or use of a non recommended sealer A leak at the front of the transmission will be from either the front bearing retainer or retainer seal Lubricant may be seen drip ping from the clutch housing after extended opera tion If the leak is severe it may also contaminate the clutch disc causing the disc to slip grab and or chatter HARD SHIFT...

Page 1748: ...OUR WHEEL DRIVE 1 Disconnect transfer case shift linkage at trans fer case range lever Then remove transfer case shift mechanism from transmission Fig 4 2 Support and secure transfer case to transmis sion jack with safety chains 3 Remove transfer case mounting nuts 4 Move transfer case rearward until input gear clears transmission mainshaft 5 Lower transfer case assembly and move it from under veh...

Page 1749: ...SION ADAPTER HOUSING 1 Remove bolts attaching extension adapter hous ing to gear case Fig 7 2 Remove extension adapter housing Fig 8 There is one alignment dowel in the gear case and one in the extension adapter housing Fig 5 LOOSEN SHIFT MECHANISM 1 SHIFT MECHANISM COVER SLOT 2 PRY TOOL Fig 6 SHIFT MECHANISM COVER 1 SHIFT MECHANISM COVER 2 ALIGNMENT DOWELS Fig 7 EXTENSION ADAPTER HOUSING BOLTS 1 ...

Page 1750: ...osened 5 Remove fifth gear nut then remove belleville washer from mainshaft FIFTH GEAR 1 Remove fifth gear shift fork roll pins Fig 11 Drive roll pins out from the bottom of fork 2 Remove fifth gear clutch hub and gear snap ring from countershaft Fig 12 3 Remove countershaft fifth gear clutch gear and stop ring 4 Tap off fifth gear shift fork and gear assembly off rail with plastic mallet 5 Remove...

Page 1751: ...osition first Jaw on gear Fig 15 11 Assemble Puller Flange 6444 1and Puller Rods 6444 3 4X2 or 6444 4 4X4 Fig 16 Slide assembly onto output shaft and seat flange in notch of jaw Fig 13 COUNTERSHAFT FIFTH GEAR NEEDLE BEARING 1 NEEDLE BEARING 2 COUNTERSHAFT Fig 14 COUNTERSHAFT REAR BEARING THRUST WASHER 1 THRUST WASHER 2 THRUST WASHER PIN Fig 15 JAW ON MAINSHAFT FIFTH GEAR 1 MAINSHAFT FIFTH GEAR 2 J...

Page 1752: ...nd discard front bearing retainer bolts Fig 20 CAUTION Do not reuse retainer bolts 2 Lightly tap retainer back and forth with plastic mallet to work it out of gear case NOTE Retainer flange extends into transmission case and is a snug fit Fig 17 PULLER COLLAR 1 JAWS 2 COLLAR Fig 18 PULLER ASSEMBLY 1 COLLAR 2 JAWS 3 BOLT 4 WRENCH 5 MAINSHAFT 6 PULLER FLANGE Fig 19 FIFTH GEAR BEARING PLATE SHIMS AND...

Page 1753: ...ner Fig 23 with puller jaws seated under bearing cup Place Insert 6453 2 in center of puller jaws to hold puller jaws in place 7 Install Puller 6444 on puller rods Fig 24 and install retaining nuts on puller rods Tighten puller bolt to draw bearing cup out of retainer Fig 21 BEARING RETAINER SEAL 1 SEAL 2 FRONT BEARING RETAINER Fig 22 PULLER RODS FLANGE AND JAWS 1 RODS 2 FLANGE 3 JAWS Fig 23 INSER...

Page 1754: ...ler jaw 5 Position second Jaw 6447 on gear and in notch of puller flange Slide Collar 6444 8 over puller jaws to hold them in place 6 Install Puller 6444 on puller rods then install retaining nuts Tighten puller bolt to remove bearing cone from drive gear Fig 25 DRIVE GEAR 1 MAINSHAFT 2 DRIVE GEAR Fig 26 PILOT BEARING 1 DRIVE GEAR 2 MAINSHAFT PILOT BEARING Fig 27 FRONT BEARING PULLER 1 PULLER 2 RO...

Page 1755: ...ed from case NOTE Handling mainshaft carefully because gears are lose on the mainshaft REVERSE IDLER AND COUNTERSHAFT 1 Remove countershaft rear bearing plate Fig 31 2 Remove countershaft end play shim and rear bearing cup Fig 32 Fig 28 DRIVE GEAR THRUST BEARING 1 MAINSHAFT 2 DRIVE GEAR THRUST BEARING Fig 29 FOURTH GEAR CLUTCH GEAR STOP RING 1 FOURTH GEAR SYNCHRO STOP RING 2 FOURTH SPEED CLUTCH GE...

Page 1756: ...arings to keep them in place 7 Remove idler gear thrust washers from gear case Install washers on idler shaft to keep them together for cleaning and inspection Fig 33 REVERSE IDLER SHAFT 1 REVERSE IDLER SHAFT Fig 34 IDLER GEAR AND COUNTERSHAFT 1 REVERSE IDLER GEAR 2 COUNTERSHAFT Fig 35 REVERSE IDLER GEAR 1 REVERSE IDLER GEAR 2 DRIVE GEAR BORE Fig 36 IDLER GEAR COMPONENTS 1 BEARINGS 2 REVERSE IDLER...

Page 1757: ...coun tershaft out of gear case Fig 38 13 Remove countershaft front bearing with Puller Flange 6444 1 and Puller Bolts 6444 4 Fig 39 14 Position first Jaw 6451 on bearing and seat puller flange in notch of puller jaw 15 Install second Jaw 6451 on bearing and in notch of puller flange Slide Collar 6444 8 over puller jaws to hold them in place NOTE Retaining collar has small lip on one end and only f...

Page 1758: ...A small pin punch can be mod ified by putting a slight bend in it to drive pin com pletely out of shift rail Fig 42 4 Remove shift lug rail Fig 40 COUNTERSHAFT FRONT BEARING CAP 1 HAMMER 2 BEARING CAP Fig 41 COUNTERSHAFT FRONT BEARING CUP 1 REMOVER 2 HANDLE Fig 42 SHIFT LUG ROLL PIN 1 PUNCH 2 30 BEND 3 PIN PUNCH MODIFICATION 4 SHIFT LUG 5 SHIFT RAIL DR MANUAL TRANSMISSION NV4500 21 55 MANUAL TRANS...

Page 1759: ... gear stop ring and third gear as an assembly Fig 43 3 Remove third gear bearing from mainshaft Fig 44 4 Remove third gear bearing spacer Fig 45 5 Remove second gear thrust washer snap ring from mainshaft Fig 45 Fig 43 THIRD GEAR STOP RING AND 3 4 HUB 1 THIRD GEAR 2 THIRD GEAR STOP RING 3 3 4 SYNCHRO HUB Fig 44 THIRD GEAR BEARING 1 THIRD GEAR NEEDLE BEARING Fig 45 SNAP RING AND THIRD GEAR BEARING ...

Page 1760: ...nd gear Fig 48 9 Remove second gear bearing Fig 49 Fig 46 SECOND GEAR THRUST WASHER 1 SECOND GEAR 2 THRUST WASHER 3 SECOND GEAR BEARING Fig 47 THRUST WASHER LOCATING PIN 1 THRUST WASHER LOCATING PIN Fig 48 SECOND GEAR 1 SECOND GEAR Fig 49 SECOND GEAR BEARING 1 SECOND GEAR NEEDLE BEARING DR MANUAL TRANSMISSION NV4500 21 57 MANUAL TRANSMISSION NV4500 Continued ...

Page 1761: ...sleeve also goes toward front Do not disassemble synchro components unless worn or damaged Fig 50 SECOND GEAR CLUTCH CONE SNAP RING 1 1 2 SLEEVE 2 SNAP RING 3 SECOND GEAR CLUTCH CONE Fig 51 SECOND GEAR CLUTCH CONE AND RING 1 1 2 SLEEVE AND HUB 2 SYNCHRO STOP RING 3 CLUTCH RING 4 SECOND GEAR CLUTCH CONE Fig 52 1 2 SLEEVE AND HUB SNAP RING 1 1 2 HUB SNAP RING 2 1 2 SLEEVE AND HUB Fig 53 1 2 SYNCHRO ...

Page 1762: ...inshaft hub Fig 56 NOTE Do not remove this snap ring unless main shaft is being replaced Fig 54 FIRST GEAR STOP AND CLUTCH RING 1 FIRST GEAR CLUTCH RING 2 FIRST GEAR STOP RING Fig 55 FIRST GEAR CLUTCH GEAR FRONT SNAP RING 1 FIRST SPEED CLUTCH GEAR 2 CLUTCH GEAR SNAP RING FRONT Fig 56 FIRST GEAR CLUTCH GEAR 1 CLUTCH GEAR SNAP RING REAR 2 FIRST SPEED CLUTCH GEAR DR MANUAL TRANSMISSION NV4500 21 59 M...

Page 1763: ...7 20 Install second Jaw 6445 on the bearing cone and puller flange Slide Collar 6444 8 over jaws to hold them in place 21 Install Puller 6444 on the puller rods and secure with nuts Fig 58 Tighten puller bolt to the remove bearing Fig 57 MAINSHAFT REAR BEARING PULLER 1 REAR BEARING 2 FLANGE 3 JAW 4 COLLAR 5 MAINSHAFT 6 PULLER 7 RODS 8 JAW 21 60 MANUAL TRANSMISSION NV4500 DR MANUAL TRANSMISSION NV4...

Page 1764: ...ainshaft Fig 60 26 Remove reverse gear bearing spacer from mainshaft Fig 61 27 Remove reverse clutch gear snap ring Fig 61 Heavy duty snap ring pliers will be required to spread the ring far enough to remove it Fig 58 MAINSHAFT REAR BEARING 1 JAWS 2 COLLAR 3 FLANGE 4 MAINSHAFT 5 PULLER 6 TIGHTENING WRENCH 7 HOLDING WRENCH 8 RODS Fig 59 REVERSE GEAR THRUST WASHER 1 REVERSE GEAR 2 THRUST WASHER Fig ...

Page 1765: ...earing surfaces splines snap ring grooves and threads Replace the shaft if any surfaces exhibit considerable wear or damage Inspect the countershaft and bearings Replace the shaft if any surfaces exhibit considerable wear or damage Inspect shift forks for wear and distortion Check fit of the sleeve in the fork to be sure the two parts fit and work smoothly Replace the fork if the roll pin holes ar...

Page 1766: ...cone with petroleum jelly 4 Position gear case on end with rear of case fac ing up Fig 66 5 Install countershaft in gear case Fig 66 NOTE Do not install rear countershaft bearing on countershaft at this time 6 Lubricate reverse idler gear bearings with petroleum jelly and install first bearing and second bearing Fig 67 7 Install idler gear front thrust washer on boss in gear case Fig 67 Coat thrus...

Page 1767: ...d position wood block between front of shaft and case Fig 70 13 Install rear bearing cone on countershaft with Installer C 4040 Fig 71 Fig 68 IDLER GEAR 1 REAR THRUST WASHER 2 REVERSE IDLER GEAR 3 FRONT THRUST WASHER Fig 69 REVERSE IDLER SHAFT 1 COUNTERSHAFT 2 SHAFT NOTCH 3 REVERSE IDLER SHAFT Fig 70 SUPPORTING COUNTERSHAFT 1 COUNTERSHAFT 2 WOOD BLOCK Fig 71 COUNTERSHAFT REAR BEARING 1 INSTALLER 2...

Page 1768: ...p in gear case Fig 74 with Handle C 4171 and Installer C 3972 A COUNTERSHAFT END PLAY 1 Rotate countershaft 4 5 times to seat bearings 2 Mount dial indicator on case Then position indicator plunger on end of countershaft and zero dial indicator Fig 75 3 Raise countershaft with screwdriver and note end play reading on dial indicator End play should be 0 051 0 15 mm 0 002 0 006 in Fig 72 COUNTERSHAF...

Page 1769: ... rail Fig 77 MAINSHAFT AND GEARTRAIN CAUTION The reverse 1 2 and 3 4 synchro compo nents can be assembled and installed incorrectly Follow assembly procedures for component identi fication and location Lubricate mainshaft bearing surfaces and all bear ing assemblies with Castrolt Syntorq or with petro leum jelly 1 Install first snap ring in rear most groove of mainshaft hub Fig 78 This snap ring l...

Page 1770: ...that will raise hub about 3 5 cm 1 375 in above surface of workbench Then allow sleeve to drop down on hub Fig 82 c Install springs and struts in hub Fig 82 Use lots of petroleum jelly to hold them in place Then compress struts with your fingers and move sleeve upward until struts are started in sleeve Verify that struts are engaged in sleeve before proceeding d Turn synchro assembly upright Then ...

Page 1771: ... Verify snap ring is seated in groove in mainshaft hub 9 Assemble second gear clutch cone clutch ring and stop ring Fig 86 Fig 83 FIRST GEAR STOP RING IN SYNCHRO HUB Fig 84 1 2 SYNCHRO 1 MAINSHAFT HUB 2 1 2 SYNCHRO ASSEMBLY 3 TAPERED SIDE OF SLEEVE Fig 85 1 2 SYNCHRO SNAP RING 1 SYNCHRO SNAP RING 2 1 2 SYNCHRO ASSEMBLY 3 MAINSHAFT HUB Fig 86 SECOND GEAR CLUTCH CONE CLUTCH RING AND STOP RING 1 STOP...

Page 1772: ...all second gear bearing on mainshaft Fig 89 13 Install second gear on mainshaft and bearing Rotate gear until tabs of second gear clutch ring are seated in tab slots in gear Fig 90 Fig 87 SECOND GEAR CLUTCH CONE CLUTCH RING AND STOP RING 1 CLUTCH CONE 2 STOP RING 3 CLUTCH RING Fig 88 SECOND GEAR CLUTCH CONE SNAP RING 1 SCREWDRIVER 2 MAINSHAFT HUB 3 SNAP RING 4 SECOND GEAR CLUTCH CONE Fig 89 SECOND...

Page 1773: ...lush with mainshaft hub NOTE If bearing is not flush with hub the bearing spacer or snap ring was not installed 19 Install third gear over bearing and onto main shaft Fig 95 Fig 91 THRUST WASHER PIN 1 THRUST WASHER PIN 2 SECOND GEAR Fig 92 SECOND GEAR THRUST WASHER 1 SECOND GEAR 2 SECOND GEAR THRUST WASHER 3 LOCATING PIN IN WASHER NOTCH Fig 93 SNAP RING AND THIRD 1 SECOND GEAR THRUST WASHER 2 THRU...

Page 1774: ...taller C 4040 Fig 98 23 Verify 3 4 synchro hub is seated on shaft with approximately 3 mm 0 125 in of shaft spline visi ble NOTE If hub is not seated stop ring lugs are mis aligned Rotate ring until lugs are engaged in 3 4 hub slots 24 Verify that second and third gear rotate freely at this point If not determine the cause and correct 25 Invert mainshaft in case or bench 26 Install first gear bear...

Page 1775: ...as follows CAUTION The reverse sleeve will fit either way on the hub Verify tapered side of the sleeve faces rearward a Position sleeve on hub so tapered side of sleeve faces rearward Fig 102 b Rotate sleeve to align teeth on sleeve and hub Sleeve will slide easily into place on hub when properly aligned c Install springs in gear hub Fig 102 Use petroleum jelly to hold springs in place if desired ...

Page 1776: ...drops into seated position 35 Install reverse gear thrust washer Fig 104 36 Install rear bearing on mainshaft with Installer 6446 Seat bearing on output shaft and against thrust washer Fig 105 37 Install fourth gear stop ring in 3 4 synchro sleeve Fig 106 38 Install fourth gear clutch gear in stop ring Fig 107 Fig 103 REVERSE GEAR 1 REVERSE GEAR AND SYNCHRO ASSEMBLY Fig 104 REVERSE GEAR THRUST WAS...

Page 1777: ... and realign shaft and gears in case DRIVE GEAR AND RETAINER 1 Install bearing on drive gear with Installer 6448 Fig 110 2 Lubricate pilot bearing with petroleum jelly and install it in drive gear bore 3 Install drive gear on mainshaft Work gear rearward until mainshaft hub is seated in pilot bear ing 4 Install bearing cup in front retainer with Han dle C 4171 and Installer C 4308 Fig 111 Fig 108 ...

Page 1778: ...ly 4 Place gear case in upright position on bench Either cut hole in bench to accept drive gear and front retainer or use C clamps to secure transmission on bench NOTE Do not leave transmission unsupported 5 Install Extension Rod 8161 into a suitable threaded hole in rear of case 6 Mount dial indicator on extension rod and posi tion indicator plunger against end of mainshaft 7 Move mainshaft forwa...

Page 1779: ...d cone side faces the front 3 Lubricate and install fifth gear bearing on countershaft Fig 119 Fig 115 REAR BEARING PLATE 1 BEARING PLATE OIL HOLE AT TOP 2 MAINSHAFT REAR BEARING PLATE Fig 116 MAINSHAFT FIFTH GEAR 1 MAINSHAFT FIFTH GEAR 2 INSTALLER Fig 117 FIFTH GEAR THRUST WASHER PIN 1 THRUST WASHER PIN 2 COUNTERSHAFT Fig 118 FIFTH GEAR THRUST WASHER 1 PIN 2 THRUST WASHER Fig 119 COUNTERSHAFT FIF...

Page 1780: ... and fork into place with plastic or rawhide mallet 7 Install fifth gear synchro struts and springs Fig 123 Fig 120 SYNCHRO SLEEVE ON COUNTERSHAFT FIFTH 1 GEAR HUB 2 SYNCHRO SLEEVE 3 COUNTERSHAFT FIFTH GEAR Fig 121 FIFTH GEAR SHIFT FORK IN SYNCHRO SLEEVE 1 SYNCHRO SLEEVE 2 SHIFT FORK Fig 122 COUNTERSHAFT FIFTH GEAR SHIFT FORK AND SYNCHRO SLEEVE 1 SHIFT FORK AND SLEEVE 2 FIFTH GEAR HUB 3 SHIFT FORK...

Page 1781: ...n 5 Place 10 15 drops of Loctite 272 onto the main shaft threads where the fifth gear nut will be engaged 6 Install fifth gear nut on mainshaft Fig 126 7 Hold mainshaft Socket 6993 4X2 or Socket 6984 4X4 while installing the fifth gear nut 8 Tighten fifth gear nut as much as possible with Wrench 6743 long handle ratchet breaker bar and applicable socket wrench Fig 127 9 Lock mainshaft gears by shi...

Page 1782: ...ealer or equivalent to sealing surface of shift cover CAUTION Do not over apply an excesive amount sealer Excess can squeezed into gear case and could block lubricant feed holes in time 3 Lubricate synchro sleeves with Castrolt Syn torq gear lubricant or equivalent Then apply light coat of petroleum jelly to shift fork contact surfaces 4 Verify shift fork pads Fig 129 are secure 5 Verify 1 2 and 3...

Page 1783: ...he isolator plate 8 Verify that the shift tower isolator plate and the shift tower bushings are properly aligned 9 Install the bolts to hold the shift tower to the isolator plate and the shift cover Tighten the shift tower bolts to 10 2 11 25 N m 7 5 8 3 ft lbs 10 Install the shift lever extension onto the shift tower and lever assembly 11 Install shift boot and bezel 12 Connect battery negative c...

Page 1784: ... 35 Front Bearing Retainer Bolts 27 34 20 25 235 305 Mainshaft Bearing Plate Bolts 19 26 14 19 170 230 PTO Cover Bolts 27 54 20 40 Extension Adapter Housing Bolts 41 68 30 50 Shift Mechanism Cover Bolts 27 31 20 23 Transmission Bolts 108 80 SPECIAL TOOLS REMOVER C 3985 B BUSHING REMOVER 6957 REMOVER BUSHING 8155 INSTALLER BUSHING 6951 INSTALLER BUSHING 8156 HANDLE C 4171 DR MANUAL TRANSMISSION NV4...

Page 1785: ...EAL C 3972 A INSTALLER SEAL 8154 INSTALLER SEAL C 3860 A WRENCH 6443 WRENCH 6743 SOCKET 6441 SOCKET 6442 SOCKET 6993 SOCKET 6984 PULLER 6444 21 82 MANUAL TRANSMISSION NV4500 DR MANUAL TRANSMISSION NV4500 Continued ...

Page 1786: ...JAWS 6459 JAWS 6820 JAWS INSERT 6453 JAWS 6447 JAWS 6449 JAWS 6451 REMOVER 6454 INSTALLER 6061 INSTALLER C 4340 DR MANUAL TRANSMISSION NV4500 21 83 MANUAL TRANSMISSION NV4500 Continued ...

Page 1787: ...INSTALLER C 4040 INSTALLER 6448 INSTALLER C 4308 INSTALLER 6052 ROD EXTENSION 8161 INSTALLER 6446 JAWS 6445 21 84 MANUAL TRANSMISSION NV4500 DR MANUAL TRANSMISSION NV4500 Continued ...

Page 1788: ...L 1 Mark the propeller shaft and yoke for installa tion reference 2 Remove the propeller shaft 3 Remove extension housing seal Fig 131 using Remover C 3985 B 4 On heavy duty 4X2 vehicles remove extension housing seal with a pry tool or a slide hammer mounted screw 5 On light duty transmissions remove the exten sion housing bushing with Remover 6957 6 On heavy duty transmissions remove the extensio...

Page 1789: ...e held in place by tension and a small locating tang Fig 136 To remove the pads grasp a pad with hand and tilt it out and off the fork If pad is difficult to remove by hand insert a screwdriver blade between the pad and fork and pry the pad off EXPANSION PLUG The expansion plugs at the rear of the shift rail bores Fig 137 can be replaced if loose leaking 1 Drill 6 mm 1 4 in diameter hole in center...

Page 1790: ...ism bolts and tighten to 27 31 N m 216 276 in lbs 9 Apply sealer to backup lamp switch Install switch into cover and tighten to 22 34 N m 193 265 in lbs 10 Install vent assembly if removed Apply an adhesive sealer to vent tube to help secure it in cover 11 Install transmission SHIFT COVER REMOVAL 1 Shift transmission into Neutral 2 Unscrew and remove the shift lever extension from the shift 3 Remo...

Page 1791: ...esh manual transmission Fig 1 All gear ranges including reverse are synchronized First and second gears uti lize dual cone synchronizers in order to aid shifting Sixth gear is an overdrive range The transmission uses cast iron for the gear case and extension adapter housing and aluminum for the clutch hous ing To drain the trans remove the bottom PTO cover bolt Fill the trans through the plug to t...

Page 1792: ...Fig 1 NV5600 MANUAL TRANSMISSION DR MANUAL TRANSMISSION NV5600 21 89 MANUAL TRANSMISSION NV5600 Continued ...

Page 1793: ...ult of an overfill condition Leaks at the rear of the extension or adapter housing will be from the hous ing oil seals Leaks at component mating surfaces will probably be the result of inadequate sealer gaps in the sealer incorrect bolt tightening or use of a non recommended sealer A leak at the front of the transmission will be from either the front bearing retainer or retainer seal Lubricant may...

Page 1794: ...lts at the engine block 5 Slide transmission and jack rearward until input shaft clears clutch disc and pressure plate 6 Lower transmission jack and remove transmis sion from under vehicle FOUR WHEEL DRIVE 1 Disconnect transfer case shift linkage at trans fer case range lever 2 Support and secure transfer case with safety chains to a transmission jack 3 Remove transfer case mounting nuts 4 Move tr...

Page 1795: ...t plug Fig 7 5 Remove primary shift rail detent spring Fig 8 Fig 5 REMOVE SHIFT TOWER 1 SHIFT TOWER 2 TRANSMISSION Fig 6 SHIFT TOWER ISOLATOR PLATE 1 ISOLATOR PLATE 2 TRANSMISSION Fig 7 PRIMARY SHIFT RAIL DETENT PLUG 1 DETENT PLUG Fig 8 PRIMARY SHIFT RAIL DETENT SPRING 1 DETENT SPRING 21 92 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSION NV5600 Continued ...

Page 1796: ...e extension adapter housing from the transmission gear case with Puller 8244 Fig 12 NOTE It may be necessary to straighten the housing during removal due to the tendency for the reverse idler shaft to bind into one side of the housing Fig 9 PRIMARY SHIFT RAIL DETENT PLUNGER 1 DETENT PLUNGER Fig 10 CLUTCH HOUSING BOLTS 1 BOLTS 10 Fig 11 SHIFT RAIL BLOCKER BOLT 1 BLOCKER BOLT Fig 12 TRANSMISSION CAS...

Page 1797: ...om between the bearing race and the housing Fig 16 8 Remove crossover cam bushing from the exten sion adapter housing with Remover 8240 9 On 4X2 vehicles remove extension housing seal with a pry tool or a slide hammer and screw 10 On 4X4 vehicles remove adapter housing seal with a pry tool or a slide hammer and screw Fig 13 CROSSOVER CAM DETENT PLUG 1 DETENT PLUG 2 EXTENSION HOUSING Fig 14 CROSSOV...

Page 1798: ...eperate countershaft reverse gear and sleeve 7 Remove output shaft nut with Wrench 8226 on the shaft nut and Socket 6993 or 6984 to hold the shaft Fig 20 Discard output shaft nut from the output shaft NOTE If necessary strike the flat side area of Wrench 8226 with a hammer to break the nut loose Fig 17 CROSSOVER CAM ROLLERS AND PIN 1 CROSSOVER CAM PIN 2 CROSSOVER CAM ROLLERS Fig 18 REVERSE IDLER A...

Page 1799: ...y with a heat gun Do not use a torch to heat the sleeve or damage to the output shaft may occur 11 Remove roll pin securing the reverse shift fork to the reverse shift rail with a 6 mm 7 32 in punch and hammer Fig 21 OUTPUT SHAFT BEARING AND THRUST WASHER 1 OUTPUT SHAFT BALL BEARING 2 THRUST WASHER Fig 22 REVERSE GEAR COMPONENTS 1 REVERSE GEAR 2 REVERSE BEARING 3 BLOCKER RING 4 FRICTION CONE Fig 2...

Page 1800: ...case 5 Attach an engine crane or equivalent to Fixture 8232 and remove the transmission gear case from the clutch housing Fig 25 6 Remove rear output shaft and countershaft bearing races from the transmission gear case with a brass drift and hammer GEARTRAIN 1 Remove bolts holding the 5 6 crossover bracket to the clutch housing Fig 26 Fig 24 REVERSE SHIFT FORK AND SYNCHRO 1 REVERSE SYNCHRO 2 REVER...

Page 1801: ...e 5 6 syn chro together during the removal operation NOTE Note the order of the shift fork arms at the primary shift rail while in the Neutral position 7 Raise geartrain and shift rails until all the shift rails clear the clutch housing 8 Remove shift rails from the rest of the geartrain Fig 29 9 Raise the geartrain until the input shaft is clear of the clutch housing Fig 27 FIXTURE OUTPUT SHAFT 1...

Page 1802: ... from the synchro hub COUNTERSHAFT BEARINGS 1 Remove snap ring holding the front counter shaft bearing onto the countershaft 2 Remove front countershaft bearing with Collar 6444 8 Jaws 6451 Puller Rods 6444 4 and Puller 6444 Fig 31 3 Remove rear countershaft bearing with Collar 6444 8 Jaws 6447 Puller Rods 6444 4 Puller 6444 and suitable press button Fig 32 Fig 30 GEARTRAIN FIXTURE 1 FIXTURE 2 SUP...

Page 1803: ...r Rods 6444 4 for 4X4 vehicles with the remainder of Puller 6444 to remove the rear output shaft bearing from the output shaft 5 Remove rear output shaft thrust washer from the output shaft INPUT SHAFT 1 Remove fifth gear blocker ring from the input shaft Fig 34 2 Remove fifth gear friction cone from the input shaft Fig 35 Fig 33 OUTPUT SHAFT POCKET BEARING 1 PULLER 2 JAWS Fig 34 FIFTH GEAR BLOCKE...

Page 1804: ...he gears clutch gears synchro hubs and sleeves for installation reference during disassembly Use paint or a scribe for mark ing purposes Then stack the geartrain parts in order of removal 1 Remove first gear from the output shaft 2 Remove first gear bearing from the output shaft Fig 38 Fig 36 OUTPUT SHAFT POCKET BEARING RACE 1 PULLER 2 INPUT SHAFT Fig 37 INPUT SHAFT BEARING 1 PULLER 2 JAWS Fig 38 ...

Page 1805: ... Remove second gear bearing from the output shaft 8 Reverse output shaft in the Fixture 8227 with press blocks positioned under the 5 6 synchro assem bly 9 Press the 5 6 synchro assembly from the out put shaft Fig 39 FIRST GEAR BLOCKER RINGS AND FRICTION CONE 1 OUTPUT SHAFT 2 FIRST GEAR BLOCKER RINGS 3 FIRST GEAR FRICTION CONE Fig 40 SECOND GEAR 1 2 SYNCHRO FIRST GEAR BEARING SLEEVE 1 OUTPUT SHAFT...

Page 1806: ...ace countershaft in Fixture 8227 with press blocks placed under the sixth countershaft gear 5 Use Guide 8235 on end of countershaft and press the countershaft sixth gear from the counter shaft Fig 43 Fig 41 SIXTH GEAR COMPONENTS 1 SIXTH GEAR FRICTION CONE 2 SIXTH GEAR 3 OUTPUT SHAFT 4 SIXTH GEAR BLOCKER RING 5 5 6 SYNCHRO Fig 42 FIFTH COUNTERSHAFT GEAR 1 GUIDE 2 FIFTH COUNTER SHAFT GEAR 3 FIXTURE ...

Page 1807: ...27 11 Remove third countershaft gear bearing from the countershaft Fig 46 12 The 2 3 thrust washer should not normally need to be removed from the countershaft If neces sary slide 2 3 thrust washer off countershaft Fig 44 FOURTH COUNTERSHAFT GEAR COMPONENTS 1 FOURTH GEAR BLOCKER RING 2 FOURTH GEAR BEARING 3 COUNTERSHAFT 4 FOURTH GEAR FRICTION CONE 5 FOURTH COUNTERSHAFT GEAR Fig 45 THIRD COUNTERSHA...

Page 1808: ... shims and spacer from the clutch housing with Remover 6061 1 and Handle C 4171 Fig 49 4 Remove input shaft bearing race with Remover Installer 8237 and Handle C 4171 Fig 47 INPUT SHAFT RETAINER 1 INPUT SHAFT RETAINER 2 CLUTCH HOUSING Fig 48 COUNTERSHAFT OIL GUIDE 1 CLUTCH HOUSING 2 COUNTERSHAFT OIL GUIDE Fig 49 FRONT COUNTERSHAFT BEARING RACE 1 CLUTCH HOUSING 2 HANDLE 3 REMOVER DR MANUAL TRANSMIS...

Page 1809: ... the fork if the roll pin holes are worn oversize or damaged Do not attempt to salvage a worn fork Replace shift fork roll pins if necessary or if doubt exists about their condition The all bearings for wear roughness flat spots pitting or other damage Replace the bearings if nec essary Inspect the blocker rings and fiction cones replace either part if worn or damaged in any way Replace if the fri...

Page 1810: ... ring Fig 53 5 Install 1 2 synchro assembly onto the second gear assembly Fig 54 6 Reverse assembly on the bench 7 Lubricate and install second gear bearing into second gear Fig 55 Fig 52 FRICTION CONE 1 GEAR 2 FRICTION CONE Fig 53 OUTER BLOCKER RING 1 OUTER BLOCKER RING 2 LUG 3 GEAR Fig 54 3 4 SYNCHRO ASSEMBLY 1 SYNCHRO 2 GEAR Fig 55 SECOND GEAR AND BEARING 1 BEARING 2 GEAR DR MANUAL TRANSMISSION...

Page 1811: ...nchro friction cone Align one of the lugs on the outer ring with a lug on the inner ring Fig 53 15 Reverse the output shaft in the press 16 Install first gear bearing sleeve onto the out put shaft 17 Install first gear bearing sleeve the remainder of the way onto the output shaft using Installer 8228 and a shop press Fig 57 18 Install first gear and blocker assembly onto the output shaft Fig 58 19...

Page 1812: ...n the Fixture 8227 and support the shaft with press blocks under first gear 24 Install sixth gear bearing onto the output shaft 25 Install sixth gear onto the output shaft and over the sixth gear bearing Fig 61 26 Install the sixth gear friction cone onto sixth gear Fig 59 OUTPUT SHAFT THRUST WASHER 1 OUTPUT SHAFT 2 OUTPUT SHAFT THRUST WASHER Fig 60 REAR OUTPUT SHAFT BEARING 1 INSTALLER 2 REAR OUT...

Page 1813: ...de 8235 and onto the output shaft 30 Press 5 6 synchro Fig 64 onto the output shaft with Installer 8156 and a shop press Fig 62 SIXTH GEAR BLOCKER RING 1 SIXTH GEAR BLOCKER RING 2 SIXTH GEAR FRICTION CONE Fig 63 OUTPUT SHAFT GUIDE 1 GUIDE 2 OUTPUT SHAFT Fig 64 5 6 SYNCHRO 1 INSTALLER 2 5 6 SYNCHRO 21 110 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSION NV5600 Continued ...

Page 1814: ...ountershaft gear on the bench with the synchro clutch ring up 2 Install third countershaft gear friction cone onto third gear Fig 66 3 Install third countershaft gear blocker ring onto the friction cone Fig 67 Fig 65 OUTPUT SHAFT POCKET BEARING 1 GUIDE 2 POCKET BEARING Fig 66 FRICTION CONE AND THIRD GEAR 1 FRICTION CONE 2 GEAR 3 CLUTCH RING Fig 67 BLOCKER RING ONTO FRICTION CONE 1 BLOCKER RING 2 G...

Page 1815: ...Place fourth countershaft gear on the bench with the synchro clutch ring up 14 Install fourth countershaft gear friction cone onto fourth countershaft gear Fig 66 15 Install fourth countershaft gear blocker ring onto the friction cone Fig 67 16 Install fourth countershaft gear bearing into the fourth countershaft gear 17 Place sixth countershaft gear in the shop press 18 Position fourth countersha...

Page 1816: ...e aligned while pressing or the gear will bind on the shaft 23 Place front countershaft bearing onto the countershaft 24 Install front countershaft bearing onto the countershaft with Installer 8236 and Handle C 4171 25 Install a new snap ring to hold the front countershaft bearing onto the countershaft 26 Place rear countershaft bearing onto the coun tershaft Fig 71 COUNTERSHAFT INTO SIXTH GEAR 1 ...

Page 1817: ...98805 5 Place the output shaft pocket bearing race in the input shaft 6 Install output shaft pocket bearing race into the input shaft with Installer C 4628 and Handle C 4171 Fig 75 Fig 73 INPUT SHAFT BEARING 1 INSTALLER 2 INPUT SHAFT BEARING Fig 74 INPUT SHAFT OIL GUIDE 1 INPUT SHAFT 2 INPUT SHAFT OIL GUIDE Fig 75 OUTPUT SHAFT POCKET BEARING RACE 1 HANDLE 2 INPUT SHAFT 3 INSTALLER 21 114 MANUAL TR...

Page 1818: ...t this time New sealer will be applied after all the preload measurements are made and end play shims are installed NOTE Do not replace the input shaft seal at this time A new seal will be installed after all the pre load measurements are made and endplay shims are installed 5 Install input shaft retainer onto the clutch housing and install bolts to hold the input shaft retainer GEARTRAIN 1 Instal...

Page 1819: ...all shift forks and rails onto the geartrain Fig 80 NOTE The closest shift arm to the geartrain is for Reverse The next is 5 6 then 3 4 and then 1 2 when moving out from the geartrain 10 Install geartrain and shift rails into the clutch housing Lower the geartrain and rails into the hous ing slowly while guiding input shaft through input shaft seal Avoid any binds on the shift rails forks and sync...

Page 1820: ... 8153 and Han dle C 4171 3 Install Fixture 8232 to the transmission gear case NOTE Shift socket must be loose on the shift shaft and is rotated a minimum of 90 from its normal position This will ensure enough clearance to install the transmission gear case 4 Apply sealant to the clutch housing 5 Attach an engine crane or equivalent to Fixture 8232 and install the transmission gear case onto the cl...

Page 1821: ...r 6 Install a new input shaft seal into the input shaft retainer with Installer C 4965 7 Install input shaft oil guide with C 3972 A and Handle C 4171 8 Apply sealer to the input shaft retainer and install retainer onto the clutch housing Install bolts and tighten to 28 N m 20 ft lbs REVERSE GEAR 1 Install reverse shift fork and synchronizer as an assembly onto the reverse shift rail and output sh...

Page 1822: ...ces away from the reverse gear 6 Install a new output shaft nut onto the output shaft 7 With Wrench 8226 on the output shaft nut and Socket 6993 or 6984 holding the output shaft tighten the nut to 339 N m 250 ft lbs 8 Stake nut into the slot in the output shaft with a 9 mm 5 16 in punch 9 Press countershaft reverse gear into the sleeve with a shop press Fig 87 REVERSE BEARING SLEEVE 1 REVERSE GEAR...

Page 1823: ...tion of the seal must face downward toward the ground when installed 3 On 4X4 vehicles install adapter housing seal with Installer C 3860 A and Handle C 4171 4 Install the crossover cam bushing into the extension adapter housing with Installer 8239 and Handle C 4171 5 Clean the rear of the transmission case of all sealer 6 Install reverse countershaft gear bearing race onto the reverse countershaf...

Page 1824: ...ion adapter housing Tighten the plug to 47 5 N m 35 ft lbs Fig 95 19 Apply sealer to the surface of the transmis sion case 20 Install extension adapter housing onto the transmission case 21 Install bolts to hold the extension adapter housing onto the transmission gear case Tighten bolts to 48 N m 35 ft lbs 22 Install shift rail blocker bolt and tighten bolt to 55 N m 41 ft lbs 23 Install primary s...

Page 1825: ...he isolator plate No sealant is necessary between the shift tower and top of isolator plate 9 Verify shift tower isolator plate and the shift socket are properly aligned 10 Install bolts to hold the shift tower to the iso lator plate and the transmission case Tighten bolts to 10 2 11 25 N m 7 5 8 3 ft lbs 11 Install shift boot and bezel FOUR WHEEL DRIVE 1 Install and secure transfer case on the tr...

Page 1826: ...ousing 48 35 Bolt Extension Adapter Housing 48 35 Bolt Shift Tower 9 7 80 Switch Back up Lamp 28 20 Bolt Shift Blocker 55 41 Bolt PTO Cover 40 30 Pivot Clutch Release Lever 22 16 Plug Fill 30 22 Nut Output Shaft 339 250 SPECIAL TOOLS REMOVER 8155 INSTALLER 8156 HANDLE C 4171 INSTALLER C 3972 A INSTALLER 8154 DR MANUAL TRANSMISSION NV5600 21 123 MANUAL TRANSMISSION NV5600 Continued ...

Page 1827: ...NCH 8226 SOCKET 6984 SOCKET 6984 PULLER 6444 JAWS 6447 JAWS 6451 INSTALLER 6061 INSTALLER 6448 INSTALLER C 4308 ROD EXTENSION 8161 21 124 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSION NV5600 Continued ...

Page 1828: ...FIXTURE 8227 INSTALLER 8228 FIXTURE 8230 FIXTURE 8232 REMOVER 8233 REMOVER 8234 GUIDE 8235 INSTALLER 8236 DR MANUAL TRANSMISSION NV5600 21 125 MANUAL TRANSMISSION NV5600 Continued ...

Page 1829: ...INSTALLER REMOVER 8237 INSTALLER REMOVE 8238 INSTALLER 8239 REMOVER 8240 FIXTURE 8241 HOLDING 8242 REMOVER 8243 PULLER 8244 21 126 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSION NV5600 Continued ...

Page 1830: ...RT STAND 8246 REMOVER 8262 REMOVER 8271 DIAL INDICATOR C 3339 INSTALLER C 4965 REMOVER L 4418 PULLER C 293 PA ADAPTERS C 293 52 INSTALLER MD998805 DR MANUAL TRANSMISSION NV5600 21 127 MANUAL TRANSMISSION NV5600 Continued ...

Page 1831: ...ler shaft and pinion yoke for installation reference and remove the propeller shaft 2 Remove extension housing seal with a pry tool or a slide hammer and screw 3 Remove extension housing bushing with Remover 8155 Fig 97 INSTALLATION 1 Install extension housing bushing with Installer 8156 and Handle C 4171 Fig 98 2 Install extension housing seal with Installer 8154 and Handle C 4171 Fig 99 3 Instal...

Page 1832: ... gear case with suitable wax and grease remover 3 Apply Mopar Gasket Maker or equivalent to the sealing surface of the transmission Do not over apply sealant 4 Install isolator plate onto the transmission metal side down 5 Install shift tower onto the isolator plate No sealant is necessary between the shift tower and iso lator plate 6 Verify shift tower isolator plate and shift tower bushings are ...

Page 1833: ... SHIFT INTERLOCK SYSTEM DESCRIPTION 196 OPERATION 196 DIAGNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK 196 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 196 ELECTRONIC GOVERNOR DESCRIPTION 197 OPERATION 198 REMOVAL 199 INSTALLATION 200 EXTENSION HOUSING SEAL REMOVAL 201 INSTALLATION 201 FLUID AND FILTER DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL 201 DIAGN...

Page 1834: ...T MECHANISM DESCRIPTION 252 OPERATION 252 SOLENOID DESCRIPTION 252 OPERATION 252 SPEED SENSOR DESCRIPTION 253 OPERATION 253 THROTTLE VALVE CABLE DESCRIPTION 253 ADJUSTMENTS THROTTLE VALVE CABLE 254 TORQUE CONVERTER DESCRIPTION 255 OPERATION 259 REMOVAL 260 INSTALLATION 260 TORQUE CONVERTER DRAINBACK VALVE DESCRIPTION 261 OPERATION 261 STANDARD PROCEDURE TORQUE CONVERTER DRAINBACK VALVE 261 TOW HAU...

Page 1835: ...lso contains the kickdown front and the low reverse rear bands which along with the over running clutch and overdrive clutch serve as the holding components The driving and holding compo nents combine to select the necessary planetary gear components in the front rear or overdrive planetary gear set transfer the engine power from the input shaft through to the output shaft The valve body is mounte...

Page 1836: ...Fig 1 48RE Transmission DR AUTOMATIC TRANSMISSION 48RE 21 133 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1837: ...r under various conditions such as when the O D switch is OFF when the vehicle is cruising on a level surface after the vehicle has warmed up The torque converter clutch can also be engaged in the MANUAL SECOND gear position if high trans mission temperatures are sensed by the PCM The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM such as wh...

Page 1838: ...ub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the park ing sprag Fig 3 which locks the parking gear on the output shaft to the transmission case NEUTRAL POWERFLOW With the gear selector in the NEUTRAL position Fig 4 the power flow of the transmission is essen...

Page 1839: ...transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear out put The entire transmission of torque is applied to the rear planetary gearset only Although there is torque input to the front gearset through the sun gear no other member of the gearset is being held During the ...

Page 1840: ...in a clockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direction The rear planet carrier is splined into the low reverse drum and the low reverse drum is splined to the inner race of the over running clutch With the over running clutch locked the planet car rier is held and the resu...

Page 1841: ...ry the annulus rotation causes the front planets to rotate in a clockwise direction The front carrier is then also made to rotate in a clockwise direction but at a reduced speed This will transmit the torque to the output shaft which is directly connected to the front planet carrier The rear planetary annulus gear will also be turning because it is directly splined to the output shaft All power fl...

Page 1842: ... trolled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and closes a vent port in the 3 4 shift valve feed passage The overdrive solenoid and check ball are not ener gized in first second third or reverse gear The vent port remains open diverting line p...

Page 1843: ...tch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into gear and note following a If propeller shaft turns but wheels do not problem is with differential o...

Page 1844: ...n fourth gear the overdrive clutch is slipping Simi larly if the direct clutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the transmission will not shift to fourth gear the control switch overdrive solenoid or related wiring may also be the problem cause This process of elimination can be used to identify a slipping unit and ...

Page 1845: ... one detent rear ward from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range Third Gear This test checks pressure regul...

Page 1846: ... pressure at the overdrive clutch in fourth gear range Use 300 psi Test Gauge C 3293 SP for this test The test should be performed on the road or on a chassis dyno 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug 3 Lower vehicle 4 Turn OD switch on 5 Secure test gauge so it can be vi...

Page 1847: ...the servo when air pressure is removed DIAGNOSIS AND TESTING CONVERTER HOUSING FLUID LEAK When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter ...

Page 1848: ... 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatext No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install transmission and converter housing dust shield 10 Lower vehicle DIAGNOSIS AND TESTING DIAGNOSIS CHARTS The diagnos...

Page 1849: ...sh Incorrect 5 Check per Service Manual Correct as needed 6 Hydraulic Pressure Incorrect 6 Check pressure Remove overhaul or adjust valve body as needed 7 Band Mis adjusted 7 Adjust rear band 8 Valve Body Check Balls Missing 8 Inspect valve body for proper check ball installation 9 Axle Pinion Flange Loose 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if thre...

Page 1850: ...ve transmission and repair as needed 10 Reaction Shaft Seal Rings Worn Broken 10 Remove transmission remove oil pump and replace seal rings 11 Rear Clutch Input Shaft Rear Clutch Seal Rings Damaged 11 Remove and disassemble transmission and repair as necessary 12 Regulator Valve Stuck 12 Clean 13 Cooler Plugged 13 Transfer case failure can plug cooler NO DRIVE RANGE REVERSE OK 1 Fluid Level Low 1 ...

Page 1851: ...n Repair or replace failed components as needed 8 Park Sprag not Releasing Check Stall Speed Worn Damaged Stuck 8 Remove disassemble repair 9 Torque Converter Damage 9 Inspect and replace as required SHIFTS DELAYED OR ERRATIC SHIFTS ALSO HARSH AT TIMES 1 Fluid Level Low High 1 Correct fluid level and check for leaks if low 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutc...

Page 1852: ...T REVERSE ONLY NO 1 2 OR 2 3 UPSHIFT 1 Governor Circuit Electrical Fault 1 Test using DRBT scan tool and repair as required 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band Damaged Burned 3 Repair replace MOVES IN 2ND OR 3RD GEAR ABRUPTLY DOWNSHIFTS TO LOW 1 Valve Body Malfunction 1 Remove clean and inspect Look for stuck 1 2 valve or governor pl...

Page 1853: ...nction 7 Check with DRBT scan tool and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR WILL NOT UPSHIFT 1 Throttle Linkage Mis adjusted Stuck 1 Adjust linkage and repair linkage if worn or damaged Check for binding cable or missing return spring 2 Gearshift Linkage Mis adjusted 2 Adju...

Page 1854: ...rmine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Mis a...

Page 1855: ...ges in case 5 Servo Band or Linkage Malfunction 5 Air pressure check servo operation and repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch Dragging 8 Check for plugged cooler Perform flow check Inspect pump for excessive side clearance Replace pum...

Page 1856: ...URS IMMEDIATELY AFTER 2 3 SHIFT 1 Overdrive Solenoid Connector or Wiring Shorted 1 Test connector and wiring for loose connections shorts or ground and repair as needed 2 TPS Malfunction 2 Test TPS and replace as necessary Check with DRBT scan tool 3 PCM Malfunction 3 Test PCM with DRBT scan tool and replace controller if faulty 4 Overdrive Solenoid Malfunction 4 Replace solenoid 5 Valve Body Malf...

Page 1857: ...gine no start 7 PCM Malfunction 7 Check with DRBT scan tool and replace if necessary 8 Overdrive Solenoid Shorted Open 8 Replace solenoid if shorted or open and repair loose or damaged wires DRBT scan tool 9 Solenoid Feed Orifice in Valve Body Blocked 9 Remove disassemble and clean valve body thoroughly Check feed orifice 10 Overdrive Clutch Failed 10 Disassemble overdrive and repair as needed 11 ...

Page 1858: ... shaft 7 O D Check Valve Bleed Orifice Failure 7 Check for function secure orifice insert in O D piston retainer DELAYED 3 4 UPSHIFT SLOW TO ENGAGE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Throttle Valve Cable Mis adjusted 2 Adjust throttle valve cable 3 Overdrive Clutch Pack Worn Burnt 3 Remove unit and rebuild clutch pack 4 TPS Faulty 4 Test with DRBT scan tool and replace as necessar...

Page 1859: ...pair 5 Valve Body Manual Lever Assembly Bent Worn Broken 5 Inspect lever assembly and replace if damaged NO REVERSE OR SLIPS IN REVERSE 1 Direct Clutch Pack front clutch Worn 1 Disassemble unit and rebuild clutch pack 2 Rear Band Mis adjusted 2 Adjust band 3 Front Clutch Malfunctioned Burned 3 Air pressure test clutch operation Remove and rebuild if necessary 4 Overdrive Thrust Bearing Failure 4 D...

Page 1860: ...ks 10 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn Damaged 11 Replace seal 12 Torque Converter Weld...

Page 1861: ...CAL STARTING STARTER MOTOR REMOVAL 7 Disconnect and remove the crankshaft position sensor Refer to 14 FUEL SYSTEM FUEL INJEC TION CRANKSHAFT POSITION SENSOR REMOVAL Retain the sensor attaching bolts 8 If transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 9 Remove torque converter access cover 10 Rotate crankshaft in clockwise direction until conver...

Page 1862: ...out of transmission Retain fill tube seal On 4X4 models it will also be necessary to remove bolt attaching transfer case vent tube to converter hous ing Fig 16 23 Remove all converter housing bolts 24 Carefully work transmission and torque con verter assembly rearward off engine block dowels 25 Lower transmission and remove assembly from under the vehicle 26 To remove torque converter remove C cla...

Page 1863: ... install Alignment Shaft 6227 2 into the over drive unit to prevent misalignment of the overdrive clutches during service of main transmission compo nents 5 Remove throttle and shift levers from valve body manual shaft and throttle lever shaft 6 Remove transmission oil pan and gasket 7 Remove filter from valve body Fig 18 Keep filter screws separate from other valve body screws Filter screws are l...

Page 1864: ...n shaft support assembly as follows a Tighten front band adjusting screw until band is tight around front clutch retainer Fig 23 This will prevent retainer from coming out with pump and possibly damaging clutch or pump com ponents Fig 23 Tightening Front Band To Hold Front Clutch In Place 1 LOCK NUT 2 FRONT BAND ADJUSTER Fig 20 Valve Body Removal 1 GOVERNOR PRESSURE SENSOR 2 VALVE BODY 3 PARK ROD ...

Page 1865: ...osition in case for assembly reference 16 Loosen front band adjusting screw until band is completely loose 17 Remove front band strut and anchor Fig 27 Fig 24 Oil Pump Removal Tools 1 PUMP HOUSING 2 SLIDE HAMMER TOOLS THREAD INTO PUMP HOUSING Fig 25 Oil Pump Removal 1 OIL PUMP AND REACTION SHAFT SUPPORT Fig 26 Oil Pump Gasket 1 OIL PUMP GASKET Fig 27 Front Band Linkage 1 LEVER 2 STRUT 3 ANCHOR 4 F...

Page 1866: ...0 21 Remove intermediate shaft thrust washer Tri angular shaped washer will either be on shaft pilot hub or in rear clutch retainer Fig 31 Fig 29 Removing Front Rear Clutch Assemblies 1 FRONT AND REAR CLUTCH ASSEMBLIES Fig 30 Front Band Lever And Pin 1 BAND LEVER 2 USE PENCIL MAGNET TO REMOVE REACTION PIN Fig 31 Intermediate Shaft Thrust Washer 1 THRUST WASHER 2 INTERMEDIATE SHAFT PILOT HUB Fig 28...

Page 1867: ...ust washer off piston retainer hub and out of rear band Fig 35 Fig 35 Low Reverse Drum And Thrust Washer 1 LOW REVERSE DRUM 2 SPOTFACE FOR WASHER 3 THRUST WASHER Fig 32 Intermediate Shaft Thrust Plate 1 SHAFT THRUST PLATE 2 INTERMEDIATE SHAFT PILOT HUB Fig 33 Intermediate Shaft And Planetary Geartrain 1 INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN ASSEMBLY Fig 34 Low Reverse Drum Snap Ring 1 LOW RE...

Page 1868: ... Tool C 4470 or Compressor Tool C 3422 B Fig 38 Compress guide only enough to permit snap ring removal about 1 8 in 32 Remove servo piston snap ring Fig 38 Unseat one end of ring Then carefully work removal tool around back of ring until free of ring groove Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised Fig 38 Front Servo Retaining Snap Ring...

Page 1869: ...ored bush ings contribute to low pressures clutch slip and accelerated wear of other components However do not replace bushings as a matter of course Replace bushings only when they are actually worn or scored The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital ...

Page 1870: ...Install rear servo spring and retainer in case bore Fig 41 Be sure spring is seated on piston 4 Compress rear servo piston with C clamp or Valve Spring Compressor C 3422 B and install servo piston snap ring Fig 42 5 Lubricate front servo piston components and servo bore in case with transmission fluid 6 Install front servo piston in bore Carefully run small suitable tool around piston ring to pres...

Page 1871: ...iston retainer hub and into engage ment with overrunning clutch and race 4 Install thrust washer in low reverse drum spot face Fig 45 Use petroleum jelly to hold washer in place 5 Install snap ring that secures low reverse drum to piston retainer hub Fig 45 6 Insert the rear band pivot pin part way into the case 7 Install rear band adjusting lever and pivot pin Be sure lever and the single lug on ...

Page 1872: ...onal cut ends of front seal rings are firmly seated against each other as shown Lubricate seal rings with petro leum jelly after checking them 5 Assemble front and rear clutches Fig 49 Align lugs on front clutch discs Mount front clutch on rear clutch Turn front clutch retainer back and forth until front clutch discs are fully seated on rear clutch splined hub Fig 46 Intermediate Shaft And Planeta...

Page 1873: ...1 Turn clutch retainers back and forth until both clutches are seated 9 Position front band lever in case and over servo rod guide Then install front band lever pin in case and slide it through lever 10 Coat threads of front band pin access plug with sealer and install it in case Tighten plug to 17 N m 13 ft lbs torque Fig 50 Intermediate Shaft Thrust Washer 1 BE SURE WASHER GROOVES FACE OUT AS SH...

Page 1874: ...53 3 Coat the reaction shaft thrust washer with petroleum jelly to hold it in place Then install washer over reaction shaft hub and seat it on pump Fig 54 CAUTION The thrust washer bore I D is cham fered on one side Make sure the chamfered side is installed so it faces the pump Fig 53 Oil Pump Gasket And Pilot Studs 1 OIL PUMP GASKET 2 PILOT STUDS C 3288 B Fig 54 Front Clutch Thrust Washer Install...

Page 1875: ...E If end play is incorrect transmission is incorrectly assembled or reaction shaft thrust washer is incorrect The reaction shaft thrust washer is selective a Attach Adapter 8266 5 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 5 to secure it to the input shaft d P...

Page 1876: ... fiber contamination in the fluid replace the torque converter and reverse flush the cooler s and cooler lines Fluid contamination and transmis sion failure can result if not done 6 Move the transmission manual shaft lever to the manual LOW position 7 Install the TRS mounting bracket into the transmission case Using Adapter 8581 Fig 60 tighten the mounting bracket to 34 N m 300 in lbs 8 Install th...

Page 1877: ...must be smooth to avoid damaging pump seal at installation 2 Lubricate pocket in the rear oil pump seal lip with transmission fluid 3 Lubricate converter pilot hub of the crankshaft with a light coating of Mopart High Temp Grease 4 Align and install converter in oil pump 5 Carefully insert converter in oil pump Then rotate converter back and forth until fully seated in pump gears 6 Check converter...

Page 1878: ...rface inside the converter 22 Install torque converter to driveplate bolts 23 Install converter housing access cover 24 Install starter motor and cooler line bracket Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 25 Connect cooler lines Fig 65 to transmission 26 Install transmission fill tube Install new seal on tube before installation 27 Install any exhaust components previously remov...

Page 1879: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK 21 176 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1880: ...HYDRAULIC FLOW IN NEUTRAL DR AUTOMATIC TRANSMISSION 48RE 21 177 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1881: ...HYDRAULIC FLOW IN REVERSE 21 178 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1882: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR DR AUTOMATIC TRANSMISSION 48RE 21 179 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1883: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR CONVERTER CLUTCH NOT APPLIED 21 180 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1884: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 181 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1885: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED 21 182 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1886: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 183 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1887: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 184 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1888: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 185 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1889: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 186 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1890: ...HYDRAULIC FLOW IN MANUAL SECOND 2 DR AUTOMATIC TRANSMISSION 48RE 21 187 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1891: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING GEAR 21 188 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1892: ... DIMENSIONS Component Metric Inch Front clutch thrust washer reaction shaft support hub 1 55 mm 0 061 in 2 15 mm 0 084 in 2 59 mm 0 102 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Intermediate shaft thrust plate shaft hub pilot 1 5 1 6 mm 0 060 0 063 in Output shaft thrust washer rear clutch hub 1 3 1 4 mm 0 052 0 054 in 1 75 1 8 mm 0 068 0 070 in 2 1 2 2 mm 0 083 0 085 in Rear c...

Page 1893: ...ansmission from downshifting TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fitting cooler line at trans 18 13 Bolt torque convertor 47 35 Bolt clevis bracket to crossmember 47 35 Bolt clevis bracket to rear support 68 50 Bolt driveplate to crankshaft 75 55 Plug front band reaction 17 13 Locknut front band adj 34 25 Bolt fluid pan 13 6 120 Screws fluid filter 4 35 Bolt oil pump 20 15 Bolt ove...

Page 1894: ...sure Gauge C 3293SP Dial Indicator C 3339 Valve Spring Compressor C 3422 B Adapter Band Adjuster C 3705 Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer C 3860 A Spring Compressor C 3863 A DR AUTOMATIC TRANSMISSION 48RE 21 191 AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1895: ...4962 Spring Compressor and Alignment Shaft 6227 Gauge Bar 6311 Gauge 6312 Retainer 6583 Installer 8114 Socket TRS Mounting Bracket 8581 Installer Seal 9037 21 192 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued ...

Page 1896: ...on and then to the kickdown servo As the line pressure reaches the accumulator the com bination of spring pressure and line pressure forces the piston away from the accumulator plate This causes a balanced pressure situation which results in a cushioned band application After the kickdown servo has become immovable line pressure will fin ish pushing the accumulator up into its bore When the large ...

Page 1897: ...n appearance and operation to the front band The rear band is slightly different in that it does not use a link bar but is acted directly on by the apply lever This is referred to as a double wrap band design the drum is completely encompassed wrapped by the band The double wrap band pro vides a greater holding power in comparison to the single wrap design OPERATION KICKDOWN FRONT BAND The kickdow...

Page 1898: ...g screw 1 3 4 turns 5 Hold adjuster screw in position and tighten locknut to 41 N m 30 ft lbs torque 6 Lower vehicle REAR BAND The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehicle 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Be sure adjusting screw turns freely in lever 4 Tighten adjusting screw to 8 N...

Page 1899: ...2 inch 12mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi tions ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK Correct cable adjustment is important to proper interlock operation The gearshif...

Page 1900: ...ssure Engine starts must be possible PARK position Apply downward force on the shift arm and remove pressure Engine starts must be possible NEUTRAL position Normal position Engine starts must be possible NEUTRAL position Engine running and brakes applied apply upward force on the shift arm Trans mission shall not be able to shift from neutral to reverse ELECTRONIC GOVERNOR DESCRIPTION Governor pre...

Page 1901: ... Averaging of the transducer signal is necessary to reject electrical noise Under cold conditions below 50 degrees F sump the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 0 5 second calibration pulse Calibration pulses are continued during this period however the transducer output valves are discarded Transducer offset must be read at key on under conditi...

Page 1902: ...e ini tial setting for the WOT upshift is below the opti mum engine speed As WOT shifts are repeated the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed After each shift the PCM adjusts the shift point until the optimum speed is reached The PCM also considers vehicle loading grade and engine performance changes due to hig...

Page 1903: ...olts to hold governor body to valve body 4 Lubricate o ring on pressure sensor with trans mission fluid 5 Align pressure sensor to bore in governor body 6 Push pressure sensor into governor body 7 Lubricate o ring on pressure solenoid with transmission fluid 8 Align pressure solenoid to bore in governor body Fig 83 9 Push solenoid into governor body Fig 80 Pressure Solenoid and O ring 1 PRESSURE S...

Page 1904: ... develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve and clutch operation Foaming also causes fluid expansion which can result in fluid overflow from the transmiss...

Page 1905: ...e fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the fluid level too high When the transmssion has too much fluid the geartrain churns up foam and cause the same condi tions which occur with a low fluid level In either case air bubbles can cause overheating and or fluid oxidation and varnishing ...

Page 1906: ... fully drain from the fill tube into the transmission before rechecking the fluid level 10 Check transmission for leaks STANDARD PROCEDURE FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICA TION MAINTENANCE MAINTENANCE SCHED ULES DESCRIPTION The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts REMOVAL 1 Hoist and support vehicle on safety stan...

Page 1907: ... a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert clean funnel in transmission fill tube 2 Add following initial quantity of Mopart ATF 4 to transmission a If only fluid and filter were changed add 3 pints 1 1 2 quarts of ATF 4 to transmission b If transmission was completely overhauled torque converter was replaced or drained and cooler was flushed add 12 pi...

Page 1908: ...clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack When pressure is released from the piston the spring returns the piston to its fully released position and disengages the clutch The release spring also helps to cushion the application of the clutch assem bly When the clutch is in the process of being r...

Page 1909: ... be bent cracked or damaged in any way Replace the piston springs and spring retainer if either are distorted warped or broken Check the lug grooves in the clutch piston retainer The steel plates should slide freely in the slots Replace the piston retainer if the grooves are worn or damaged Also check action of the check ball in the piston retainer The ball must move freely and not stick Replace t...

Page 1910: ...t 0 015 0 020 in thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or score the seals 6 Install and position nine clutch piston springs Fig 94 7 Install spring retainer ...

Page 1911: ...h its guide against the apply lever Release of the servo at the 2 3 upshift is accom plished by a combination of spring and line pressure acting on the bottom of the larger land of the piston The small piston is used to cushion the application of the band by bleeding oil through a small orifice in the larger piston The release timing of the kickdown servo is very important to obtain a smooth but f...

Page 1912: ...red or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse suspect parts ASSEMBLY Clean and inspect front servo components 1 Lubricate new o ring and seal rings with petro leum jelly and install them on piston guide and rod Fig 98 Front Servo 1 PISTON RINGS 2 SERVO PISTON 3 O RING 4 SNAP RING 5 PISTON ROD GUIDE 6 SEAL RING 7 SNA...

Page 1913: ...ion Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply upward force on the shift arm Transmission shall not be able to shift from neutral to reverse REMOVAL 1 Shift transmission into PARK 2 Raise vehicle 3 Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket Fig 102 or Fig 103 Fig 101 Front Servo 1 PISTON RINGS 2 ...

Page 1914: ...anel opening 3 Snap the cable into the steering column bracket so the retaining ears Fig 107 are engaged and snap the cable eyelet onto the shift lever ball stud 4 Raise the vehicle 5 Place the transmission manual shift lever in the PARK detent rearmost position and rotate prop shaft to ensure transmission is in PARK Fig 104 Gearshift Cable at the Dash Panel 1 GEARSHIFT CABLE 2 GROMMET Fig 105 Gea...

Page 1915: ... in any position other than PARK or NEUTRAL or if the engine will not start at all the transmission range sensor may be faulty Gearshift Adjustment Procedure 1 Shift transmission into PARK 2 Release cable adjuster lock tab underneath the steering column Fig 108 to unlock cable 3 Raise vehicle 4 Disengage the cable eyelet from the transmis sion manual shift lever 5 Verify transmission shift lever i...

Page 1916: ...r teeth increases in the crescent area and creates a suction at the inlet side of the pump This suction draws fluid through the pump inlet from the oil pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body Fig 109 Oil Pump Assembly 1 OIL SEAL 7 BOLTS 6 2 VENT BAFFLE 8 1 THRUST WASHER SELECTIVE 3 OIL PUMP BO...

Page 1917: ... tion shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both clearances can be mea sured at the same time by installing the gears in the pump body and measure pump component clearances as follows 1 Position an appropriate piece of Plastigage across both gears 2 Align the plastigage to a flat area on the reac tion shaft housing 3 Install the reaction shaft to the pump housing 4 Separate...

Page 1918: ...erwise the rings will either prevent pump installation or break during installation Fig 112 Oil Pump Assembly 1 OIL SEAL 7 BOLTS 6 2 VENT BAFFLE 8 1 THRUST WASHER SELECTIVE 3 OIL PUMP BODY 9 INNER GEAR 4 GASKET 10 OUTER GEAR 5 REACTION SHAFT SUPPORT 11 O RING 6 SEAL RINGS 12 TORQUE CONVERTER SEAL RING Fig 113 Checking Pump Gear Tip Clearance 1 FEELER GAUGE 2 INNER GEAR 3 OUTER GEAR DR AUTOMATIC TR...

Page 1919: ... locating retainer groove toward the rear 2 Push bearing onto shaft until the snap ring groove is visible 3 Install snap ring to hold bearing onto output shaft 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive unit from the vehicle Refer to 21 TRANSMISSION AUTOMATIC OVERDRIVE REMOVAL 2 Remove overdrive geartrain from...

Page 1920: ...through the control valves and passageways and enters the clutch through passages at the lower rear portion of the valve body area With pressure applied between the piston retainer and piston the piston moves away from the piston retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the intermediate shaft into the overdrive planetary gear set T...

Page 1921: ...ermediate shaft Do not tilt unit during removal Keep it as level as possible 11 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment If misalign ment occurs overdrive unit will have to be disassem bled in order to realign splines 12 Remove and retain overdrive piston...

Page 1922: ...tainer Fig 123 Fig 120 Overdrive Piston Thrust Bearing Removal Installation 1 THRUST BEARING 2 OVERDRIVE PISTON 3 THRUST PLATE Fig 121 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PISTON 2 OVERDRIVE PISTON SPACER SELECT FIT Fig 122 Intermediate Shaft Spacer Location 1 INTERMEDIATE SHAFT 2 INTERMEDIATE SHAFT SPACER SELECT FIT Fig 123 Overdrive Piston Removal 1 PISTON RETAINER 2 OV...

Page 1923: ...nap ring is located in same groove as wave spring Fig 124 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig 125 Overdrive Clutch Pack Removal 1 OVERDRIVE CLUTCH PACK Fig 126 Overdrive Clutch Component Position Typical 1 REACTION PLATE 2 CLUTCH PLATES 3 PRESSURE PLATE 4 CLUTCH DISCS Fig 127 Overdrive Clutch Wave Spring Removal 5 Disc Clutch Only 1 WAVE SPRING ...

Page 1924: ...e snap ring that retains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 133 Fig 129 Access Cover Screw Removal 1 TORX SCREWDRIVER T25 2 ACCESS COVER SCREWS Fig 130 Access Cover And Gasket Removal 1 ACCESS COVER AND GASKET Fig 131 Releasing Bearing From Locating Ring 1 EXPAND BEARING LOCATING RING WITH SNAP RING PLIERS 2 ACCESS HOLE Fig 132 Removing Geartrain 1 GEARTRAIN A...

Page 1925: ...ft flange with steel press plates as shown and center assembly under press ram 3 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 134 4 Remove direct clutch pack snap ring Fig 135 5 Remove direct clutch hub retaining ring Fig 136 Fig 134 Geartrain Mounted In Shop Press 1 PRESS RAM 2 SPECIAL T...

Page 1926: ...d spring Fig 138 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 139 Fig 137 Direct Clutch Pack Removal 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH HUB 3 DIRECT CLUTCH PACK Fig 138 Direct Clutch Hub And Spring Removal 1 DIRECT CLUTCH SPRING 2 DIRECT CLUTCH HUB Fig 139 Removing Sun Gear Thrust Bearing And Planetary Gear 1 PLANETARY GEAR 2 PLANETARY THRUST BE...

Page 1927: ...r punch or scriber to make alignment marks 7 Remove direct clutch drum rear retaining ring Fig 142 8 Remove direct clutch drum outer retaining ring Fig 143 Fig 142 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2 DIRECT CLUTCH DRUM 3 ANNULUS GEAR Fig 143 Clutch Drum Outer Retaining Ring Removal 1 OUTER RETAINING RING Fig 140 Overrunning Clutch Assembly Removal Installation 1 OVERR...

Page 1928: ...luid pas sages Discard the old case gasket and seals Do not attempt to salvage these parts They are not reus able Replace any of the overdrive unit snap rings if distorted or damaged Minor nicks or scratches on components can be smoothed with crocus cloth However do not attempt to reduce severe scoring on any components with abrasive materials Replace severely scored compo nents do not try to salv...

Page 1929: ...he race if either assembly is worn or damaged in any way Replace the shaft pilot bushing and inner bushing if damaged Replace either shaft bearing if rough or noisy Replace the bearing snap rings if distorted or cracked Check the machined surfaces on the output shaft These surfaces should clean and smooth Very minor nicks or scratches can be smoothed with crocus cloth Replace the shaft if worn sco...

Page 1930: ...tall bearing if it does not seat squarely 9 Install overrunning clutch in output shaft Fig 152 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with coun terclockwise twisting motion Fig 152 Overrunning Clutch Installation 1 CLUTCH DRUM 2 OVERRUNNING CLUTCH ASSEMBLY 3 EXPANDING TYPE SNAP RING PLIERS 4 CLUTCH DRUM 5 ANNULUS GEAR 6 OVERRUNNING CLUTCH ASSEMBLY SE...

Page 1931: ... are fully seated before proceeding 14 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assem bly mounted in press 15 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 156 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully se...

Page 1932: ...r bore in plate fits over raised splines Plate should be flush with this end of hub Fig 158 b Install first clutch disc with internal splines friction side up followed by a disc with external lugs friction side up Continue alternating internal and external discs until all discs have been installed Fig 158 Correct Position Of Direct Clutch Reaction Plate 1 REACTION PLATE COUNTERBORE 2 DIRECT CLUTCH...

Page 1933: ...LY TO AVOID PERSONAL INJURY 19 Position Compressor Tool 6227 1 on clutch hub 20 Compress clutch hub and spring just enough to place tension on hub and hold it in place 21 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 22 Realign clutch pack on hub and seat clutch discs and plates in clutch dr...

Page 1934: ... ring 4 Install reaction plug snap ring Fig 164 Com press snap ring only enough for installation do not distort it 5 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 165 6 Support geartrain on Tool 6227 1 Fig 166 Be sure tool is securely seated in clutch hub Fig 165 Correct Rear Bearing Locating Ring Position 1 CASE ACCESS HOLE 2 TAB ENDS OF LOCATING RING...

Page 1935: ... Fig 170 Reac tion ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ensure that the ends of the two rings are offset from each other 3 Assemble overdrive clutch pack 4 Install overdrive clutch reaction plate first Fig 166 Overdrive Gear Case Installation 1 GEARTRAIN ASSEMBLY 2 GEAR CASE Fig 167 Seating Locating Ring In Rear Bearing 1 EXPAND ...

Page 1936: ...netary gear and into pilot bushing in output shaft Be sure tool bottoms against planetary shoulder b Position Gauge Tool 6311 across face of over drive case Fig 172 Then position Dial Caliper C 4962 over gauge tool c Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312 Lock scale in place Remove dial caliper tool and note dista...

Page 1937: ...nsor not be installed until after overdrive unit is secured to transmission OVERDRIVE PISTON 1 Install new seals on overdrive piston 2 Stand transmission case upright on bellhous ing 3 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 4 Position Seal Guide 8114 3 on inner edge of overdrive piston retainer 5 Install overdrive piston in overdrive piston retainer by a Aligning loc...

Page 1938: ...227 2 Overdrive unit cannot be installed if splines are not aligned If splines have rotated out of alignment unit will have to be disassembled to realign splines 9 Carefully slide Alignment Tool 6227 2 out of overdrive planetary gear and overrunning clutch splines 10 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reaction plug at same ti...

Page 1939: ... in the same direction as the inner race they are wedged between the inner and outer races due to the design of the cam In this condition the clutch is locked and acts as one unit DISASSEMBLY 1 Remove the overdrive piston Fig 179 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Tap old cam out of case with pin punch Insert punch through bolt ho...

Page 1940: ...on retainer in case Use 3 4 bolts to secure retainer 2 Align and start new clutch cam in the trans mission case Be sure serrations on cam and in case are aligned Fig 181 Then tap cam into case just enough to hold it in place 3 Verify that cam is correctly positioned before proceeding any further Narrow ends of cam ramps should be to left when cam is viewed from front end of case Fig 181 4 Insert A...

Page 1941: ...ing cam installation are removed from case 13 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to align governor feed holes in gasket with feed passages in case Fig 186 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer Fig 186 Installing Aligning Case Gasket 1 ...

Page 1942: ...of pistons used in an automatic transmission Some pistons are used to apply clutches while others are used to apply bands They all have in common the fact that they are round or circular in shape located within a smooth walled cylinder which is closed at one end and con verts fluid pressure into mechanical movement The fluid pressure exerted on the piston is contained within the system through the...

Page 1943: ...ation of Pascal s Law is that regardless of container shape or size the pressure will be maintained throughout as long as the fluid is confined In other words the pressure in the fluid is the same everywhere within the container FORCE MULTIPLICATION Using the 10 PSI example used in the illustration Fig 190 a force of 1000 lbs can be moved with a force of only 100 lbs The secret of force multiplica...

Page 1944: ...ve planetary gear assem blies and located in such order A simple planetary gearset consists of three main members The sun gear which is at the center of the sys tem The planet carrier with planet pinion gears which are free to rotate on their own shafts and are in mesh with the sun gear The annulus gear which rotates around and is in mesh with the planet pinion gears NOTE The number of pinion gear...

Page 1945: ...m driving shell Fig 196 Note washer position for assembly reference Fig 193 Removing Planetary Snap Ring 1 PLANETARY SNAP RING Fig 194 Removing Front Planetary And Annulus Gears 1 DRIVING SHELL 2 FRONT ANNULUS GEAR 3 FRONT PLANETARY GEAR Fig 195 Disassembling Front Planetary And Annulus Gears 1 FRONT PLANETARY GEAR 2 TABBED THRUST WASHER 3 FRONT ANNULUS GEAR 4 TORLON BUSHING Fig 196 Driving Shell ...

Page 1946: ...haft Be sure the oil passages are open and clear Replace the shaft if scored pitted or damaged Inspect the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then replace the necessary component Replace the sun gear as an assembly if the gear teeth are chipped or worn Also repla...

Page 1947: ...in driving shell Note that the large ID chamfer on the sun gear goes forward 3 Install rear annulus gear on intermediate shaft Fig 202 4 Install thrust washer to rear planetary gear Fig 203 using petroleum jelly Be sure washer is seated against corner witht teh tabs completely in the locating holes 5 Install rear planetary gear in rear annulus gear Fig 204 Be sure planetary carrier is seated again...

Page 1948: ...m jelly to hold washer in place if desired 10 Install tabbed thrust washer on front plane tary gear Fig 208 Seat washer tabs in matching slots in face of gear carrier Use extra petroleum jelly to hold washer in place if desired 11 Install the torlon bushing onto the front plan etary carrier hub Fig 205 Installing Rear Planetary Thrust Washer 1 REAR PLANETARY GEAR 2 TABBED THRUST WASHER Fig 206 Ins...

Page 1949: ...mponents are assembled correctly 15 Install new planetary snap ring in groove at end of intermediate shaft Fig 211 16 Turn planetary geartrain over Position wood block under front end of intermediate shaft and sup port geartrain on shaft Be sure all geartrain parts have moved forward against planetary snap ring This is important for accurate end play check Fig 209 Assembling Front Planetary And An...

Page 1950: ...he front clutch pack is needed to hold against the greater torque load imposed onto the rear pack The rear clutch is directly behind the front clutch and is considered a driving component NOTE The number of discs and plates may vary with each engine and vehicle combination Fig 212 Checking Planetary Geartrain End Play 1 OUTPUT SHAFT 2 REAR ANNULUS GEAR 3 FEELER GAUGE Fig 213 Rear Clutch Components...

Page 1951: ...ng ring 8 Press input shaft out of retainer with shop press and suitable size press tool Use a suitably sized press tool to support the retainer as close to the input shaft as possible CLEANING Clean the clutch components with solvent and dry them with compressed air Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to component surfaces and could r...

Page 1952: ... of transmission fluid 8 Install clutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 0209 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into...

Page 1953: ...ndicator d Lift the pressure plate until it contacts the snap ring and record the dial indicator reading Clearance should be 0 635 0 914 mm 0 025 0 036 in If clearance is incorrect steel plates discs selective snap ring and pressure plates may have to be changed The selective snap ring thicknesses are 0 107 0 109 in 0 098 0 100 in 0 095 0 097 in 0 083 0 085 in 0 076 0 078 in 0 071 0 073 in 0 060 0...

Page 1954: ... from servo piston Fig 218 2 Remove and discard servo piston seal ring CLEANING Remove and discard the servo piston seal ring Fig 219 Then clean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use new ones at assembly ASSEMBLY 1 Lubricate piston ...

Page 1955: ...solenoids operate the valves directly which means that the solenoids must have very high outputs to close the valves against the siz able flow areas and line pressures found in current transmissions Fast response time is also necessary to ensure accurate control of the transmission The strength of the magnetic field is the primary force that determines the speed of operation in a par ticular solen...

Page 1956: ...hifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 223 The cable is attached to an arm mounted on the throttle lever shaft A retaining clip at the engine end of the cable...

Page 1957: ...throttle body lever Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction Fig 226 If cable end and attachment stud are misaligned off center cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure Fig 225 Throttle Valve Cable at Transmission 1 TRANSMISSION SHIFTER CABLE 2 THROTTLE VALVE CABLE 3 TRANS...

Page 1958: ... push the T V cable lock A into the down position Fig 226 This will lock the present T V cable adjustment NOTE Be sure that as the cable is pulled forward and centered on the throttle lever stud the cable housing moves smoothly with the cable Due to the angle at which the cable housing enters the spring housing the cable housing may bind slightly and create an incorrect adjustment 8 Reconnect the ...

Page 1959: ... the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 228 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 ENGINE ROTATION 3 IMPELLER VANES AND COVER ARE INTEGRAL 21 256 AUTOMATIC TRANSMISSION 48RE DR TORQUE CONVERTER Continued ...

Page 1960: ... through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 229 Turbine 1 TURBINE VANE 4 PORTION OF TORQUE CONVERTER COVER 2 ENGINE ROTATION 5 ENGINE ROTATION 3 INPUT SHAFT 6 OIL FLOW WITHIN TURBINE SECTION DR AUTOMATIC TRANSMISSION 48RE 21 257 TORQUE CONVERTER Contin...

Page 1961: ...is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impeller and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of the front cover to pro vide this me...

Page 1962: ...ce is transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a clockwise direction following the impeller As the fluid is leav ing the trailing edges of the turbine s blades it con tinues in a hindering direction back toward the impeller If the fluid is not redirected before it strikes the impeller it will strike the impeller in a direction t...

Page 1963: ...ed by the PCM The torque converter clutch may disengage momentarily when an increase in engine load is sensed by the PCM such as when the vehicle begins to go uphill or the throttle pressure is increased REMOVAL 1 Remove transmission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the l...

Page 1964: ...iods The valve check ball is spring loaded and has an opening pressure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do not clean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates significant amounts of sludge and or clutch par ticles and metal shavings the valve must be replaced...

Page 1965: ... component when diagnosis indicates this is necessary Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range REMOVAL 1 Using a plastic trim tool remove the tow haul overdrive off switch retainer from the shift lever Fig 237 2 Pull the switch outwards to release it from the connector in the lever Fig 238 INSTALLATION NOTE There is enough sla...

Page 1966: ...he TRS signal The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL providing a ground for the sig nal from the starter relay and the JTEC engine con troller OPERATION As the switch moves through its linear motion Fig 241 contacts slide across a circuit board which changes th...

Page 1967: ... suitable hoist 2 Disconnect the vehicle s shift cable from the manual lever 3 With the manual lever in the PARK position the PARK position is with the manual lever moved to the full rearward position measure the resistance between the Park Neutral Position Sense pin of the TRS and the transmission case The resistance should be less than 5 ohms 4 With the manual lever in the NEUTRAL posi tion the ...

Page 1968: ...ce should be 59 9 ohms If the resistance is not correct replace the TRS 11 With the manual lever in the SECOND posi tion the SECOND position is with the manual lever moved one detent rearward of the full forward posi tion measure the resistance between the Transmis sion Range Sensor MUX and the Back up Lamp feed pins of the TRS The resistance should be 31 9 ohms If the resistance is not correct re...

Page 1969: ...operation Fig 247 6 Move the transmission manual shaft lever to the PARK position 7 Connect TRS wiring connector to the TRS and lower vehicle 8 Refill the transmission fluid to the correct level Fig 244 Remove TRS Mounting Bracket 1 SOLENOID CASE CONNECTOR 2 TRS MOUNTING BRACKET Fig 245 Tighten the TRS Mounting Bracket 1 SOLENOID CASE CONNECTOR 2 TRS MOUNTING BRACKET 3 ADAPTER 8581 Fig 246 Remove ...

Page 1970: ...t allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and transfer plate The valve body contains valves and check balls that control fluid delivery to the torque converter clutch bands and frictional clutches The valve body contains the following components Fig 249 ...

Page 1971: ...ATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING 21 268 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 1972: ...INER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER DR AUTOMATIC TRANSMISSION 48RE 21 269 VALVE BODY Continued ...

Page 1973: ...G 2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG 21 270 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 1974: ...R 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CONVERTER CLUTCH SOLENOID 19 SOLENOID GASKET 10 OVERDRIVE SOLENOID 20 HARNESS DR AUTOMATIC TRANSMISSION 48RE 21 271 VALVE BODY Continued ...

Page 1975: ...er Manual Low or Manual 2nd forcing the downshift to 2nd gear regardless of governor pressure 6 Provides a by pass around the front servo orifice so that the servo can release quickly 7 Provides a by pass around the rear clutch orifice so that the clutch can release quickly 8 Directs reverse line pressure through an orifice to the throttle valve eliminating the extra leakage and insuring that Reve...

Page 1976: ...o increase Oil pressure on the opposite end of the valve pushes the valve to the right opening the dump and lowering oil pressure The result is spring pressure working against oil pressure to maintain the oil at specific pressures With the engine run ning fluid flows from the pump to the pressure reg ulator valve manual valve and the interconnected circuits As fluid is sent through passages to the...

Page 1977: ... spring decreases the size of the metering passage When the size of the metering passage is reduced the pressure rises again and the size of the land is increased again Pressure is regulated by this con stant balance of hydraulic and spring pressure The metering at land 2 establishes the line pres sure throughout the transmission It is varied accord ing to changes in throttle position and the tran...

Page 1978: ...Fig 255 Regulator Valve in Drive Position Fig 256 Regulator Valve in Reverse Position DR AUTOMATIC TRANSMISSION 48RE 21 275 VALVE BODY Continued ...

Page 1979: ...right After passing the annular groove the fluid is routed to the spring end of the 2 3 shift valve Fluid pressure reacting on the area of land 1 overcomes governor pressure downshifting the 2 3 shift valve into the kickdown or second gear stage of operation The valve is held in the kickdown position by throttle pressure routed from a seated check ball 2 Again if vehicle speed is low enough thrott...

Page 1980: ...bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore This pushes the valve upward against the spring and bot toms the valve against the top of the housing With the valve bottomed against the housing the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve When the supply of throttle pressure ha...

Page 1981: ...o the right the middle land of the valve will close off the circuit supplying the throttle pres sure to the right side of the valve When the throttle pressure is closed off the valve will move even far ther to the right allowing line pressure to enter another circuit and energize the front servo applying the front band Fig 261 The governor plug serves a dual purpose It allows the shift valves to m...

Page 1982: ...tor piston by the 1 2 shift control valve During the 1 2 upshift this pressure is used to control the kick down servo apply pressure that is needed to apply the kickdown and accumulator pistons Thus the 1 2 shift point is cushioned and the quality is improved During a WOT kickdown kickdown pres sure is applied between the kickdown valve and the 1 2 shift control valve This additional pressure is d...

Page 1983: ... pressure to the front clutch After the shift Fig 264 line pressure is directed to the release side of the kickdown servo This releases the front band and applies the front clutch shifting into third gear or direct drive The rear clutch remains applied as it has been in the other gears During a manual 1 or manual 2 gear selec tion line pressure is sent between the two lands of the 2 3 governor plu...

Page 1984: ...Fig 264 2 3 Shift Valve After Shift Fig 265 3 4 Shift Valve Before Shift Fig 266 3 4 Shift Valve After Shift DR AUTOMATIC TRANSMISSION 48RE 21 281 VALVE BODY Continued ...

Page 1985: ...peed increases pump output The increase in pressure and volume must be regu lated to maintain the balance within the transmis sion To do this throttle pressure is routed to the reaction area on the right side of the throttle pres sure plug in the regulator valve The higher engine speed and line pressure would open the vent too far and reduce line pressure too much Throttle pressure which increases...

Page 1986: ...n occurs Fig 268 the pressure regulator valve is supplying torque converter pres sure to the switch valve The switch valve directs this pressure through the transmission input shaft into the converter through the converter back out between the input shaft and the reaction shaft and back up to the switch valve From the switch valve the fluid pressure is directed to the transmission cooler and lubri...

Page 1987: ...pply side of the torque converter piston This pressure differential causes the piston to apply against the friction material cutting off any further flow of line pressure oil After the switch valve is shuttled right allowing line pressure to engage the TCC torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits Fig 269 Switch Valve Torque C...

Page 1988: ...4 3 downshift until the TCC is completely unlocked and the clutch is disen gaged SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves When the manual valve is positioned in the Drive range throttle pressure acts on the throttle plug of the shuttle valve Fig 262 to move it against a spring increasing the spring force on the shuttle valve During a part or full t...

Page 1989: ...mission temperature thermistor Converter clutch overdrive solenoid assembly and harness Governor housing gasket Solenoid case connector O rings 1 Shift transmission into NEUTRAL 2 Raise vehicle 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 273 5 Remove the transmission range sensor Refer to 21 TRANSMISSION AUTOMATIC T...

Page 1990: ... transfer plate 3 Remove retainer plate governor body and gas ket from transfer plate 4 Remove governor pressure sensor from gover nor body 5 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and discard solenoid O rings if worn cut or torn 6 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 275 Retai...

Page 1991: ...OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 278 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLENOID 3 SOLENOID SCREWS 4 GOVERNOR SENSOR WIRES 5 OVERDRIVE SOLENOID 6 HARNESS 7 CASE CONNECTOR Fig 279 Boost Valve Cover Location 1 BOOST VALVE HOUSING AND COVER 2 BOOST VALVE TUBE Fig 280 Boost Valve Components 1 SPRING AND VALVE RETAINER 2 COVER SCREWS 3 BOOST VALVE C...

Page 1992: ...gnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 285 Fig 281 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 282 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD Fig 283 Throttle Lever E Clip And Washer 1 THROTTLE LEVER SHAFT 2 E CLIP AND WASHER 3 MANUAL SHAFT Fig 284 Manual And Throttle Le...

Page 1993: ...g 288 20 Remove kickdown detent kickdown valve and throttle valve and spring Fig 288 21 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right side housing attaching screws Fig 289 22 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 290 Fig 287 Adjusting Screw Bracket ...

Page 1994: ...OVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 289 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW 2 REMOVE THESE SCREWS 3 3 4 ACCUMULATOR HOUSING Fig 290 3 4 Shift And Converter Clutch Valve Springs and Plug 1 ACCUMULATOR HOUSING 2 CONVERTER CLUTCH VALVE SPRING 3 CLUTCH VALVE PLUG 4 3 4 SHIFT VALVE SPRING DR AUTOMATIC TRANSMISSION 48RE 21 29...

Page 1995: ...t fall out when lower housing and separator plate are removed 27 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 294 Note position of boost valve tube brace for assembly reference 28 Remove lower housing and overdrive separa tor plate from transfer plate Fig 294 Fig 293 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4...

Page 1996: ...or plate for assembly reference 33 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 298 Fig 295 Number 10 Check Ball 1 NUMBER 10 CHECK BALL 3 169 Fig 296 Transfer Plate 1 UPPER HOUSING 2 TRANSFER PLATE Fig 297 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PLATE 3 FILTER SCREEN 4 BRACE Fig 298 Rear Clutc...

Page 1997: ...Turn upper housing around and remove limit valve and shift valve covers Fig 302 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 302 9 Remove 1 2 shift control valve and spring Fig 302 10 Remove 1 2 shift valve and spring Fig 302 11 Remove 2 3 shift valve and spring from valve body Fig 302 12 Remove pressure plug cover Fig 302 ...

Page 1998: ...INER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER DR AUTOMATIC TRANSMISSION 48RE 21 295 VALVE BODY Continued ...

Page 1999: ...G 2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG 21 296 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 2000: ...prings 1 3 4 ACCUMULATOR HOUSING 11 TIMING VALVE COVER 2 3 4 SHIFT VALVE AND SPRING 12 PLUG 3 PLUG 13 3 4 TIMING VALVE AND SPRING 4 SPRING RETAINER 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CO...

Page 2001: ...ten a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks 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 be corrected by smoothing th...

Page 2002: ...oulder bolt switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E clip fluid filter and screws detent ball and spring valve body screws governor pressure solenoid governor pressure sensor and retaining clip park lock rod and E clip ASSEMBLY CAUTION Do not force valves or plugs into place during reasse...

Page 2003: ...R 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CONVERTER CLUTCH SOLENOID 19 SOLENOID GASKET 10 OVERDRIVE SOLENOID 20 HARNESS 21 300 AUTOMATIC TRANSMISSION 48RE DR VALVE BODY Continued ...

Page 2004: ...9 4 Install brace plate Fig 309 Tighten brace attaching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in lbs torque Fig 306 3 4 Accumulator and Housing 1 ACCUMULATOR PISTON 2 3 4 ACCUMULATOR HOUSING 3 TEFLON SEALS 4 PISTON SPRING 5 COVER PLATE AND SCREWS Fig 307 Rear Clutch And Rear Servo Check Ball Locations 1 REAR CLUTCH CHECK BA...

Page 2005: ... screen is seated in proper housing recess 3 Install the Number 10 check ball into the transfer plate Fig 312 The check ball is approxi mately 4 8 mm 3 16 in in diameter 4 Position lower housing separator plate on transfer plate Fig 313 Fig 310 Check Ball Locations In Upper Housing 1 SMALL DIAMETER CHECK BALLS 5 2 LARGE DIAMETER CHECK BALL 1 Fig 311 Installing Transfer Plate On Upper Housing 1 FIL...

Page 2006: ... pressure sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring Fig 314 Installing Lower Housing On Transfer Plate And Upper Housing 1 VALVE BODY SCREWS 13 2 LOWER HOUSING 3 UPPER HOUSING 4 TRANSFER PLATE Fig 315 Shuttle...

Page 2007: ...y seated before proceeding 8 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install shuttle valve primary spring and throttle plug 11 Align and install governor plug cover Tighten cover screws to 4 N m 35 in lbs torque Fig 316 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 RE...

Page 2008: ...G 2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG DR AUTOMATIC TRANSMISSION 48RE 21 305 VALVE BODY Continued ...

Page 2009: ...d finger tighten three screws that secure tube brace to valve body housings Fig 319 7 Bend tube brace tabs up and against tube to hold it in position Fig 320 8 Tighten all valve body housing screws to 4 N m 35 in lbs torque after tube and brace are installed Tighten screws in diagonal pattern starting at center and working outward Fig 318 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISEN...

Page 2010: ...ainer and cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 2 Insert manual lever detent spring in upper housing 3 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Retainer Tool 6583 Fig 323 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 5 Align manual lever with...

Page 2011: ...SION TRANS AXLE AUTOMATIC VALVE BODY ADJUST MENTS 18 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 19 Attach solenoid case connector to 3 4 accumu lator with shoulder type screw Connector has small locating tang that fits in dimple at top of accumula tor housing Fig 325 Seat tang in dimple before tightening connector screw 20 Install solenoi...

Page 2012: ...shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly 7 Position valve body in case and work end of park lock rod into and through pawl sprag Turn pro peller shaft to align sprag and park lock teeth if nec essary The rod will click as it enters pawl Move rod to check engagement CAUTION It is possible for the park rod to displace into a cavity just ...

Page 2013: ...usting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between the throttle lever cam and the kickdown valve stem Fig 330 Push the gauge tool inward to compress the kick down valve against the spring and bottom the thro...

Page 2014: ...IFT INTERLOCK 364 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 365 FLUID AND FILTER DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL 366 DIAGNOSIS AND TESTING CAUSES OF BURNT FLUID 366 DIAGNOSIS AND TESTING FLUID CONTAMINATION 366 STANDARD PROCEDURE STANDARD PROCEDURE FLUID LEVEL CHECK 366 STANDARD PROCEDURE FLUID AND FILTER REPLACEMENT 367 STANDARD PROCEDURE TRANSMIS...

Page 2015: ...efficiency features and low NVH Other features include driver adaptive shifting and three planetary gear sets to provide wide ratio capability with precise ratio steps for optimum driveability The three planetary gear sets also make available a unique alternate second gear ratio The primary 2nd gear ratio fits between 1st and 3rd gears for normal through gear accelera tions The alternate second ge...

Page 2016: ... system also monitors input and output speed and if incipi ent clutch slip is observed the pressure control sole noid duty cycle is varied increasing pressure in proportion to demand A high travel torque converter damper assembly allows earlier torque converter clutch engagement to reduce slippage Needle type thrust bearings reduce internal friction The 45RFE 545RFE is packaged in a one piece die ...

Page 2017: ...k for broken or disconnected gearshift cable 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into gear and note following a If propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remov...

Page 2018: ...n only with the output shaft speed below 150 rpm 545RFE CLUTCH APPLICATION CHART SLP UD OD R 2C 4C L R OVERRUNNING P PARK ON R REVERSE ON ON N NEUTRAL ON D OVERDRIVE FIRST ON ON ON SECOND ON ON SECOND PRIME ON ON THIRD ON ON FOURTH ON ON FIFTH ON ON LIMP IN ON ON 2 FIRST ON ON ON SECOND ON ON LIMP IN ON ON 1 LOW ON ON ON L R clutch is on only with the output shaft speed below 150 rpm DR AUTOMATIC ...

Page 2019: ...ns the transmission oil pan must be removed the pres sure port plugs removed and Valve Body Pressure Tap Adapter 8258 A Fig 5 installed The extensions supplied with Adapter 8258 A will allow the installa tion of pressure gauges to the valve body Refer to Fig 3 for correct pressure tap location identifica tion TEST PROCEDURE All pressure readings should be taken with the transmission fluid level fu...

Page 2020: ... 120 120 120 120 120 130 DOWNSHIFT PRESSURES ENG INE 5 4 5 3 5 2 4 3 4 2 prime 3 2 3 2 prime 2 prime 1 2 1 3 1 5 7L 135 135 135 135 135 135 135 135 135 135 3 7L 4 7L 120 120 120 120 120 120 120 120 120 120 IN GEAR PRESSURES ENGINE 1 2 2 prime 3 4 5 NEUT RAL REV ERSE 5 7L 160 135 135 135 135 135 120 250 3 7L 4 7L 135 120 120 120 120 120 120 220 DIAGNOSIS AND TESTING AIR CHECKING TRANSMISSION CLUTCH...

Page 2021: ...meter weld Fig 7 2 Leaks at the converter hub weld Fig 7 STANDARD PROCEDURE ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and valve body can be repaired by the use of Heli Coils or equivalent This repair con sists of drilling out the worn out damaged threads Then tap the hole with a special Heli Coil tap or equivalent and installing a Heli Coil insert or equival...

Page 2022: ... solenoid TRS assembly connector from the transmission solenoid TRS assembly Fig 11 15 Disengage the line pressure sensor connector from the line pressure sensor Fig 12 Fig 9 Disconnect Output Speed Sensor 1 TRANSMISSION 2 OUTPUT SPEED SENSOR Fig 10 Disconnect Input Speed Sensor 1 TRANSMISSION 2 INPUT SPEED SENSOR Fig 11 Disconnect Transmission Solenoid TRS Assembly 1 TRANSMISSION 2 TRANSMISSION S...

Page 2023: ...ce during trans mission removal 26 Lower transmission and remove Fig 14 assembly from under the vehicle 27 To remove torque converter carefully slide torque converter out of the transmission DISASSEMBLY 1 Drain fluid from transmission 2 Clean exterior of transmission with suitable solvent or pressure washer 3 Remove the torque converter from the trans mission 4 Remove the manual shift lever from t...

Page 2024: ...housing hub This value should not be included in the end play measured value and there fore must be recorded and subtracted from the dial indicator reading 9 Remove the bolts holding the transmission extension adapter housing to the transmission case 10 Remove the extension adapter housing from the transmission case 11 Using Alignment Plate 8261 Adapter 8266 17 from End Play Tool Set 8266 and Dial...

Page 2025: ...case 18 Remove the outer snap ring securing the transmission front cover into the transmission case Fig 21 19 Remove the inner snap ring securing the transmission front cover to the oil pump Fig 21 Fig 19 Remove Primary Oil and Cooler Filters 1 PRIMARY OIL FILTER 2 COOLER RETURN FILTER 3 COOLER RETURN FILTER BYPASS VALVE 4 VALVE BODY Fig 20 Remove Valve Body Assembly 1 VALVE BODY TO CASE BOLT 6 Fi...

Page 2026: ... number 1 bearing from the input clutch assembly Fig 23 24 Remove the input clutch assembly from the transmission case Fig 23 25 Remove the number 5 bearing and selective thrust plate from the input clutch assembly Fig 23 or the 4C clutch retainer bulkhead 26 Remove the 4C clutch retainer bulkhead tapered snap ring from the transmission case Fig 24 27 Remove the 4C clutch retainer bulkhead from th...

Page 2027: ...8 bearing from the reac tion planetary carrier Fig 26 35 Remove the reaction planetary carrier Fig 26 Note that this planetary gear set has three pin ion gears 36 Remove the number 9 bearing from the reverse planetary gear set Fig 26 Fig 25 Remove 2C Clutch Pack 1 SNAP RING 2 PLATE 3 DISC 4 REACTION PLATE Fig 26 Remove Reaction Annulus and Carrier 1 BEARING NUMBER 8 5 BEARING NUMBER 7 2 BEARING NU...

Page 2028: ...utch retainer into the transmission case Fig 30 42 Remove the low reverse clutch retainer from the transmission case Fig 30 Fig 27 Remove Park Sprag Snap Ring 1 SNAP RING Fig 28 Remove Park Sprag Gear 1 PARK SPRAG GEAR Fig 29 Remove Input Reverse Planetary Assembly 1 INPUT REVERSE PLANETARY ASSEMBLY 2 BEARING NUMBER 9 3 BEARING NUMBER 12 Fig 30 Remove Low Reverse Clutch Retainer 1 LOW REVERSE OVER...

Page 2029: ...se and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quant...

Page 2030: ... pointing toward the valve body area 14 Install the 4C retainer bulkhead tapered snap ring into the transmission case Make sure that the open ends of the snap ring are located in the case opening toward the valve body area 15 Using a feeler gauge through the opening in the rear of the transmission case measure the 2C clutch pack clearance between the 2C reaction plate and the transmission case at ...

Page 2031: ...g groove 19 Air check the low reverse clutch and verify correct overrunning clutch operation 20 Install the number 12 bearing over the output shaft and against the rear planetary gear set The flat side of the bearing goes toward the planetary gearset and the raised tabs on the inner race should face the rear of the transmission 21 Install the reverse input planetary assembly through the low revers...

Page 2032: ...ace against the reaction planetary carrier into the transmission case Fig 41 28 Install the flat 2C clutch snap ring into the transmission case Fig 40 29 Install the reaction sun gear into the reaction planetary gear set Make sure the small shoulder is facing the front of the transmission Fig 41 30 Install the number 7 bearing onto the reaction sun gear with the inner race against the sun gear Fig...

Page 2033: ...ING NUMBER 8 5 BEARING NUMBER 7 2 BEARING NUMBER 9 6 THRUST PLATE SELECT 3 REACTION PLANETARY CARRIER 7 BEARING NUMBER 6 4 REACTION SUN GEAR 8 REACTION ANNULUS 21 330 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2034: ...ignment Plate 8261 Adapter 8266 17 from End Play Tool Set 8266 and Dial Indicator C 3339 measure and record the output shaft end play Fig 44 The correct output shaft end play is 0 22 0 55 mm 0 009 0 021 in Adjust as necessary Install the chosen output shaft selective thrust plate and re measure end play to verify selection 38 Apply a bead of RTV silicone and install the extension adapter housing o...

Page 2035: ...y Install the chosen thrust plate on the number 5 bearing and re measure end play to verify selec tion NOTE When measuring the input shaft end play two stops will be felt When the input shaft is pushed inward and the dial indicator zeroed the first stop felt when the input shaft is pulled out ward is the movement of the input shaft in the input clutch housing hub This value should not be included ...

Page 2036: ... other suitable tool 52 Install the primary oil filter and the oil cooler return filter Fig 51 Tighten the screw to hold the primary oil filter to the valve body to 4 5 N m 40 in lbs Using Oil Filter Wrench 8321 tighten the cooler return oil filter to the transmission case to 14 N m 125 in lbs 53 Apply RTV silicone to the oil pan and install the transmission oil pan Tighten the bolts to 12 N m 105...

Page 2037: ...n alignment 10 Apply a light coating of Mopart High Temp Grease to the torque converter hub pocket in the rear pocket of the engine s crankshaft 11 Raise transmission Fig 54 and align the torque converter with the drive plate and transmis sion converter housing with the engine block 12 Move transmission forward Then raise lower or tilt transmission to align the converter housing with engine block ...

Page 2038: ...switch assembly Fig 55 connector input Fig 56 and out put Fig 57 speed sensors and line pressure sensor Fig 58 Be sure transmission harnesses are prop erly routed CAUTION It is essential that correct length bolts be used to attach the converter to the driveplate Bolts that are too long will damage the clutch surface inside the converter Fig 54 Install Transmission 1 ENGINE 2 TRANSMISSION Fig 55 Co...

Page 2039: ...nto the trans mission and the engine 28 Align and connect propeller shaft s 29 Adjust gearshift cable if necessary 30 Install any skid plates removed previously Refer to 13 FRAMES BUMPERS FRAME TRANSFER CASE SKID PLATE INSTALLATION 31 Lower vehicle 32 Fill transmission with Mopart ATF 4 Auto matic Transmission Fluid Fig 58 Connect Line Pressure Sensor 1 TRANSMISSION 2 LINE PRESSURE SENSOR Fig 59 T...

Page 2040: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK NEUTRAL DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 337 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2041: ...HYDRAULIC FLOW IN NEUTRAL OVER 8MPH 21 338 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2042: ...HYDRAULIC FLOW IN REVERSE DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 339 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2043: ...HYDRAULIC FLOW IN REVERSE BLOCK 21 340 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2044: ...HYDRAULIC FLOW IN FIRST GEAR FROM N OR OD DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 341 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2045: ...HYDRAULIC FLOW IN FIRST GEAR AFTER LAUNCH FROM REST 21 342 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2046: ...HYDRAULIC FLOW IN FIRST GEAR FROM K D DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 343 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2047: ...HYDRAULIC FLOW IN SECOND GEAR 21 344 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2048: ...HYDRAULIC FLOW IN SECOND GEAR EMCC DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 345 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2049: ...HYDRAULIC FLOW IN SECOND PRIME GEAR 21 346 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2050: ...HYDRAULIC FLOW IN SECOND PRIME GEAR EMCC DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 347 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2051: ...HYDRAULIC FLOW IN DIRECT GEAR 21 348 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2052: ...HYDRAULIC FLOW IN DIRECT GEAR FAILSAFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 349 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2053: ...HYDRAULIC FLOW IN DIRECT GEAR EMCC 21 350 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2054: ...HYDRAULIC FLOW IN FOURTH DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 351 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2055: ...HYDRAULIC FLOW IN FOURTH EMCC 21 352 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2056: ...HYDRAULIC FLOW IN FIFTH DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 353 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2057: ...HYDRAULIC FLOW IN FIFTH EMCC 21 354 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2058: ...HYDRAULIC FLOW IN MANUAL LOW OR AUTOSTICK 1ST DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 355 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2059: ...HYDRAULIC FLOW IN MANUAL SECOND 21 356 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2060: ...HYDRAULIC FLOW IN MANUAL SECOND FAILSAFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 357 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2061: ...N m Ft Lbs In Lbs Fitting cooler line at trans 17 5 155 Bolt torque convertor 31 23 Bolt nut crossmember 68 50 Bolt driveplate to crankshaft 75 55 Bolt oil pan 11 8 105 Screw primary fluid filter 4 5 40 Bolt oil pump 28 2 250 Bolt oil pump body to cover 4 5 40 Screw plate to oil pump body 4 5 40 Bolt valve body to case 11 8 105 Plug pressure test port 5 1 45 Bolt reaction shaft support 11 8 105 Sc...

Page 2062: ... Gauge Oil Pressure C 3293SP Dial Indicator C 3339 Installer Seal C 3860 A Compressor Spring 8249 Compressor Spring 8250 Compressor Spring 8251 Installer Piston 8252 DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 359 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2063: ...staller Snap ring 8255 Stand Support 8257 Adapter Pressure Tap 8258 A Adapter Line Pressure 8259 Fixture Input Clutch Pressure 8260 Plate Alignment 8261 21 360 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2064: ...End Play Set 8266 Compressor Spring 8285 Installer Bearing 8320 Wrench Filter 8321 Installer Piston 8504 DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 361 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued ...

Page 2065: ...the 4C clutch pack from the retainer bulkhead Fig 60 6 Using Spring Compressor 8250 and a suitable shop press compress the 4C piston return spring and remove the snap ring Fig 60 7 Remove the 4C piston return spring and piston from the retainer bulkhead Fig 60 Use 20 psi of air pressure to remove the piston if necessary Fig 60 4C Retainer Bulkhead Components 1 SEAL 8 REACTION PLATE 2 2C PISTON 9 S...

Page 2066: ... retainer bulkhead Fig 60 The 4C reaction plate is non directional 9 Measure the 4C clutch clearance The correct clutch clearance is 0 77 1 39 mm 0 030 0 055 in The snap ring is selectable Install the chosen snap ring and re measure to verify the selection 10 Install the 2C piston into the retainer bulk head Fig 60 11 Position the 2C Belleville spring onto the 2C piston 12 Position the 2C Bellevil...

Page 2067: ...ll move into any position The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is fully locked into the PARK position DIAGNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OUT position ...

Page 2068: ...lowed in PARK position only 2 When the shift lever is in PARK the ignition key cylinder should rotate freely from off to lock When the shifter is in any other position the ignition key should not rotate from off to lock 3 Shifting out of PARK should be possible when the ignition key cylinder is in the off position 4 Shifting out of PARK should not be possible while applying normal force and igniti...

Page 2069: ...ntual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped clean before checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in t...

Page 2070: ...efore rechecking the fluid level 10 Check transmission for leaks STANDARD PROCEDURE FLUID AND FILTER REPLACEMENT For proper service intervals Refer to LUBRICA TION MAINTENANCE MAINTENANCE SCHED ULES DESCRIPTION REMOVAL 1 Hoist and support vehicle on safety stands 2 Place a large diameter shallow drain pan beneath the transmission pan 3 Remove bolts holding front and sides of pan to transmission 4 ...

Page 2071: ...on case sealing surface 6 Place pan in position on transmission 7 Install bolts to hold pan to transmission Tighten bolts to 11 8 N m 105 in lbs torque 8 Lower vehicle and fill transmission with Mopart ATF 4 STANDARD PROCEDURE TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert clean funnel in transmissio...

Page 2072: ...ctor 9 Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle Fig 71 10 Remove gearshift cable from vehicle Fig 68 Gearshift Cable at Transmission RFE 1 GEARSHIFT CABLE 2 RFE TRANSMISSION 3 MANUAL LEVER Fig 69 Gearshift Cable at Transmission RE 1 GEARSHIFT CABLE 2 RE TRANSMISSION 3 MANUAL LEVER Fig 70 Gearshift Cable at the D...

Page 2073: ... SYS TEM ADJUSTMENTS as necessary ADJUSTMENTS GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL Adjustment is CORRECT if the engine starts only in these positions Adjustment is INCORRECT if the engine starts in one but not both positions If the engine starts in any position other than PARK or NEUTRAL or if the engine will not start at all the transmission range sensor may...

Page 2074: ...dered holding clutches The 2C and 4C clutches are located in the 4C retainer bulkhead Fig 75 while the Low Reverse clutch is located at the rear of the transmis sion case Fig 76 Fig 74 Gearshift Cable at Steering Column 1 STEERING COLUMN 2 GEARSHIFT CABLE 3 GEARSHIFT CABLE LOCK TAB 4 BTSI SOLENOID LOCK TAB 5 BTSI CONNECTOR Fig 75 2C and 4C Clutches 1 SEAL 8 REACTION PLATE 2 2C PISTON 9 SNAP RING 3...

Page 2075: ...he reaction annulus gear is held or grounded to the transmission case LOW REVERSE CLUTCH The Low Reverse clutch is hydraulically applied in park reverse neutral and first gear only at low speeds by pressurized fluid against the Low Reverse clutch piston When the Low Reverse clutch is applied the input annulus assembly is held or grounded to the transmission case Fig 76 Low Reverse Clutch 1 SNAP RI...

Page 2076: ...different components of the planetary geartrain UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first second second prime and third direct gears by pressurized fluid against the underdrive piston When the underdrive clutch is applied the under drive hub drives the input sun gear Fig 77 Input Clutch Assembly Part 1 1 INPUT CLUTCH HUB 11 UD CLUTCH 2 O RING SEALS 12 PLATE 3 SEAL 1...

Page 2077: ...from the input clutch retainer Fig 79 2 Remove the reverse reaction plate from the input clutch retainer 3 Remove the reverse hub and reverse clutch pack from the input clutch retainer 4 Remove the number 4 bearing from the over drive hub 5 Remove the overdrive hub from the input clutch retainer Fig 79 Fig 78 Input Clutch Assembly Part 2 1 BEARING NUMBER 3 10 SNAP RING SELECT 2 OD HUB SHAFT 11 PLA...

Page 2078: ...D reaction plate tapered snap ring from the input clutch retainer 12 Remove the UD OD reaction plate from the input clutch retainer 13 Remove the UD OD reaction plate flat snap ring from the input clutch retainer Fig 79 14 Remove the underdrive clutch pack from the input clutch retainer Fig 81 Fig 79 Input Clutch Assembly Part 2 1 BEARING NUMBER 3 10 SNAP RING SELECT 2 OD HUB SHAFT 11 PLATE 3 SNAP...

Page 2079: ...tempt to install a new seal onto the piston The piston seal must be replaced as an assembly 18 Remove the input clutch retainer tapered snap ring 19 Separate input clutch retainer from input clutch hub 20 Separate OD reverse piston from input clutch hub retainer Fig 81 21 Remove all seals and o rings from the input shaft and input hub The o rings on the input hub are color coded Be sure to make no...

Page 2080: ...UTCH RETAINER 4 SNAP RING 14 SEAL 5 SNAP RING 15 OD REV PISTON 6 UD BALANCE PISTON 16 BELLEVILLE SPRING 7 SNAP RING 17 SNAP RING 8 UD PISTON 18 SEAL RINGS 9 SPRING 19 INPUT SHAFT 10 DISC 20 LUBRICATION CHECK VALVE AND SNAP RING DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 377 INPUT CLUTCH ASSEMBLY Continued ...

Page 2081: ...c Transmission Fluid prior to installation 4 Assemble the OD reverse piston onto the input clutch hub Fig 82 5 Assemble the input clutch retainer onto the input clutch hub 6 Install the input clutch retainer tapered snap ring with tapered side up onto the input clutch hub Fig 82 Input Clutch Assembly Part I 1 INPUT CLUTCH HUB 11 UD CLUTCH 2 O RING SEALS 12 PLATE 3 SEAL 13 CLUTCH RETAINER 4 SNAP RI...

Page 2082: ...ate is to be installed with the big step down 16 Install the UD OD reaction plate upper tapered snap ring with tapered side up 17 Install the input clutch assembly into Input Clutch Pressure Fixture 8260 Fig 87 Mount a dial indicator to the assembly push down on the clutch discs and zero the indicator against the underdrive clutch discs Fig 88 Apply 20 psi of air pressure to the underdrive clutch ...

Page 2083: ...n four 4 places 90 apart Take average of four measurements and compare with OD clutch pack clearance specification Verify that the clutch clearance is 1 103 1 856 mm 0 043 0 073 in The reaction plate is not selective If the clutch clearance is not within specification replace the reaction plate along with all the friction and steel discs 23 Install the reverse clutch pack into the input clutch ret...

Page 2084: ... places 90 apart Take average of four measurements and compare with Reverse clutch pack clearance specification The correct clutch clearance is 0 58 1 47 mm 0 023 0 058 in Adjust as necessary Install the chosen snap ring and re measure to verify selection 27 Remove the reverse clutch pack from the input clutch retainer Fig 87 Input Clutch Assembly Mounted on Tool 8260 1 INPUT CLUTCH ASSEMBLY 2 TOO...

Page 2085: ...speed signals to determine the following Transmission gear ratio Speed ratio error detection CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following Torque converter clutch slippage Torque converter element speed ratio REMOVAL 1 Raise vehicle 2 Place a suitable fluid catch pan under the transmission 3 Remove the wiring connector from the ...

Page 2086: ...st ments are made to the pressure control solenoid duty cycle REMOVAL 1 Raise vehicle 2 Place a suitable fluid catch pan under the transmission 3 Remove the wiring connector from the line pressure sensor Fig 92 4 Remove the bolt holding the line pressure sen sor to the transmission case 5 Remove the line pressure sensor from the transmission case INSTALLATION 1 Install the line pressure sensor int...

Page 2087: ...e clutch and the over running clutch from the low reverse clutch retainer as an assembly Fig 93 4 Separate the low reverse clutch from the over running clutch Fig 93 Low Reverse Clutch Assembly 1 SNAP RING SELECT 8 SEAL 2 REACTION PLATE 9 BELLEVILLE SPRING 3 DISC 10 RETAINER 4 PLATE 11 SNAP RING 5 L R CLUTCH RETAINER 12 OVERRUNNING CLUTCH 6 SEAL 13 SNAP RING 7 PISTON 21 384 AUTOMATIC TRANSMISSION ...

Page 2088: ...ll a new seal on the low reverse piston Lubricate the seal with Mopart ATF 4 Automatic Transmission Fluid prior to installation 3 Install the low reverse piston into the low re verse clutch retainer 4 Position the low reverse piston Belleville spring on the low reverse piston 5 Using Spring Compressor 8285 and a suitable shop press Fig 95 compress the low reverse piston Belleville spring and insta...

Page 2089: ...ion draws fluid through the pump inlet from the oil pan As the gear teeth come back into mesh pressurized fluid is forced into the pump outlet and to the oil pump valves At low speeds both sides of the pump supply fluid to the transmission As the speed of the torque con verter increases the flow from both sides increases until the flow from the primary side alone is suffi cient to meet system dema...

Page 2090: ...the proper level Refer to the Fluid Level Check procedure in this section If necessary fill the transmission to the proper level with Mopart ATF 4 Automatic Trans mission Fluid 1 Disconnect the To cooler line at the cooler inlet and place a collecting container under the dis connected line CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage...

Page 2091: ...ction shaft support from the oil pump Fig 100 3 Remove all bolts holding the oil pump halves together Fig 100 4 Using suitable prying tools separate the oil pump sections by inserting the tools in the supplied areas and prying the halves apart NOTE The oil pump halves are aligned to each other through the use of two dowels Be sure to pry upward evenly to prevent damage to the oil pump components 5...

Page 2092: ...rs must be returned to their original locations 8 Remove the oil pump gears from the oil pump case Fig 101 Fig 101 Oil Pump Housing and Gears 1 SEPARATOR PLATE 5 DOWEL 2 2 DRIVEN GEAR 2 6 DRIVE GEAR 3 CHECK VALVE 7 SCREW 4 PUMP HOUSING DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 389 OIL PUMP Continued ...

Page 2093: ...arpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the oil pump cover Use a penlight to view the bore interi ors Replace the oil pump if any bores are distorted or scored Inspect all of the valve springs The springs must be free of distortion warpage or broken coils Trial fit ea...

Page 2094: ...ors are two wire magnetic pickup devices that generate AC signals as rotation occurs They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module TCM OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating As the teeth of the input clutch hub pass by the sensor coil an AC voltage is generated a...

Page 2095: ...be illu minated Pressing the switch a second time causes normal overdrive operation to be restored and the tow haul lamp to be turned off The tow haul over drive OFF mode defaults to ON after the ignition switch is cycled OFF and ON The normal position for the control switch is the ON position The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control switch i...

Page 2096: ...ave in common the fact that they are round or circular in shape located within a smooth walled cylinder which is closed at one end and con verts fluid pressure into mechanical movement The fluid pressure exerted on the piston is contained within the system through the use of piston rings or seals OPERATION The principal which makes this operation possible is known as Pascal s Law Pascal s Law can ...

Page 2097: ...on of Pascal s Law is that regardless of container shape or size the pressure will be maintained throughout as long as the fluid is confined In other words the pressure in the fluid is the same everywhere within the container FORCE MULTIPLICATION Using the 10 PSI example used in the illustration Fig 112 a force of 1000 lbs can be moved with a force of only 100 lbs The secret of force multiplica ti...

Page 2098: ...d example To raise a car weigh ing 2000 lbs an effort of only 100 lbs may be required For every inch the car moves upward the input piston at the jack handle must move 20 inches downward PLANETARY GEARTRAIN DESCRIPTION The planetary geartrain is located behind the 4C retainer bulkhead toward the rear of the transmis sion The planetary geartrain consists of three pri mary assemblies Reaction Fig 11...

Page 2099: ...NPUT PLANETARY GEARTRAIN The input sun gear of the input planetary geartrain is driven by the underdrive clutch DISASSEMBLY 1 Remove the snap ring holding the input annu lus into the input carrier Fig 116 2 Remove the input annulus from the input car rier Fig 116 3 Remove the number 9 bearing from the reverse planetary carrier Note that this planetary carrier has four pinion gears 4 Remove the rev...

Page 2100: ...carrier so that the inner race will be toward the front of the transmission Fig 116 3 Install the input sun gear into the input carrier Fig 116 4 Install the number 10 bearing onto the rear of the reverse planetary carrier with the inner race toward the carrier Fig 116 5 Install the number 9 bearing onto the front of the reverse planetary carrier with the outer race toward the carrier and the inne...

Page 2101: ... will be set after three unsuccessful attempts are made to get into 1st gear in one given key start SOLENOIDS DESCRIPTION The typical electrical solenoid used in automotive applications is a linear actuator It is a device that produces motion in a straight line This straight line motion can be either forward or backward in direc tion and short or long distance A solenoid is an electromechanical de...

Page 2102: ...rial and accomplishes this movement by providing a path for the magnetic field to flow By keeping the air gap between the plunger and the coil to the minimum necessary to allow free movement of the plunger the magnetic field is maximized TORQUE CONVERTER DESCRIPTION The torque converter Fig 117 is a hydraulic device that couples the engine crankshaft to the transmission The torque converter consis...

Page 2103: ... converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 118 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 ENGINE ROTATION 3 IMPELLER VANES AND COVER ARE INTEGRAL 21 400 AUTOMATIC TRANSMISSION 45RFE 545RFE DR TORQUE CONVERTER Continued ...

Page 2104: ...ough the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 119 Turbine 1 TURBINE VANE 4 PORTION OF TORQUE CONVERTER COVER 2 ENGINE ROTATION 5 ENGINE ROTATION 3 INPUT SHAFT 6 OIL FLOW WITHIN TURBINE SECTION DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 401 TORQUE CONVERTER Co...

Page 2105: ...lippage condition could be obtained A hydraulic piston with friction material was added to the tur bine assembly to provide this mechanical lock up In order to reduce heat build up in the transmis sion and buffer the powertrain against torsional vibrations the TCM can duty cycle the L R CC Sole noid to achieve a smooth application of the torque converter clutch This function referred to as Elec tr...

Page 2106: ... from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine begins to match the speed of the impeller the fluid that was hitting the stator in such as...

Page 2107: ...evice or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATI...

Page 2108: ...re sen sor thermistor that communicates transmission temperature to the TCM and PCM OPERATION The Transmission Range Sensor TRS communi cates shift lever position to the TCM as a combina tion of open and closed switches Each shift lever position has an assigned combination of switch states open closed that the TCM receives from four sense circuits The TCM interprets this information and determines...

Page 2109: ...ids receive electrical power from the Transmission Control Relay through a single wire The TCM energizes or operates the solenoids individ ually by grounding the return wire of the solenoid as necessary When a solenoid is energized the solenoid valve shifts and a fluid passage is opened or closed vented or applied depending on its default operat ing state The result is an apply or release of a fri...

Page 2110: ... if output speed is below 100 rpm in Drive and Manual 2 L R is open in Manual 1 545RFE PRESSURE SWITCH STATES GEAR L R 2C 4C UD OD R OP OP OP OP OP P N CL OP OP OP OP 1ST CL OP OP CL OP 2ND OP CL OP CL OP 2ND PRIME OP OP CL CL OP D OP OP OP CL CL 4TH OP OP CL OP CL 5TH OP CL OP OP CL L R is closed if output speed is below 100 rpm in Drive and Manual 2 L R is open in Manual 1 A Diagnostic Trouble C...

Page 2111: ...PTION The valve body consists of a cast aluminum valve body a separator plate and a transfer plate The valve body contains valves and check balls that con trol fluid delivery to the torque converter clutch bands and frictional clutches The valve body con tains the following components Fig 129 and Fig 130 Solenoid switch valve Manual valve Low reverse switch valve 5 Accumulators 7 check balls OPERA...

Page 2112: ...DERDRIVE ACCUMULATOR 3 UPPER VALVE BODY 8 4C ACCUMULATOR 4 MANUAL VALVE 9 2C ACCUMULATOR 5 SOLENOID SWITCH VALVE Fig 130 Check Ball Locations Fig 131 TRS Selector Plate and Detent Spring 1 TRS SELECTOR PLATE 2 DETENT SPRING 3 CLUTCH PASSAGE SEALS DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 409 VALVE BODY Continued ...

Page 2113: ...ary oil filter from valve body Fig 132 7 Remove bolts attaching valve body to transmis sion case Fig 133 8 Lower the valve body and work the electrical connector out of transmission case 9 Separate the valve body from the transmission DISASSEMBLY 1 Remove the screws holding the solenoid and pressure switch assembly to the valve body Fig 134 Do not remove the screws on the top of the sole noid and ...

Page 2114: ...dy on the bench with the transfer plate upward NOTE The valve body contains seven check balls The transfer plate must be placed upward to pre vent losing the check balls when the transfer plate is removed from the valve body 10 Remove the screws holding the valve body to the valve body transfer plate Fig 135 Valve Body External Components 1 TRS SELECTOR PLATE 2 DETENT SPRING 3 CLUTCH PASSAGE SEALS...

Page 2115: ... Do not immerse any of the electrical components in cleaning solution Clean the electrical components by wiping them off with dry shop towels only Dry all except the electrical parts with compressed air Make sure all passages are clean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere...

Page 2116: ...y springs The springs must be free of distortion warpage or broken coils Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should no...

Page 2117: ...screw to 4 5 N m 40 in lbs 15 Install new clutch passage seals onto the valve body if necessary INSTALLATION 1 Check condition of seals on valve body and the solenoid and pressure switch assembly Replace seals if cut or worn 2 Place TRS selector plate in the PARK position 3 Place the transmission in the PARK position 4 Lubricate seal on the solenoid and pressure switch assembly connector with petr...

Page 2118: ...ncreased low speed torque capability The gear cases and extension are all of aluminum Fig 1 Drive sprockets and an interconnecting drive chain are used to transmit engine torque to the front rear propeller shafts The mainshaft input gear and front output shaft are supported by ball and needle bearings IDENTIFICATION An identification tag Fig 2 is attached to the rear case of every transfer case Th...

Page 2119: ...ng properly refer to the Diagnosis Chart for further information DIAGNOSIS CHART Condition Possible Cause Correction Transfer Case difficult to shift or will not shift into desired range 1 Vehicle speed too great to permit shifting 1 Stop vehicle and shift into desired range Or reduce speed to below 3 4 km h 2 3 mph before attempting the shift 2 If vehicle was operated for an extended period in 4H...

Page 2120: ...rd dry surfaces in the 4H position 1 Operate vehicle in the 2H position on hard dry surfaces REMOVAL 1 Raise and support vehicle 2 Remove skid plate if equipped Refer to 13 FRAMES BUMPERS FRAME TRANSFER CASE SKID PLATE REMOVAL 3 Position drain oil container under transfer case 4 Remove transfer case drain plug and drain lubricant into container 5 Disconnect vent hose and transfer case position sen...

Page 2121: ...g Fig 6 the slinger ears away from the transfer case 6 Using a suitable pry tool Fig 7 remove the slinger from the output shaft using care not to dam age the shaft 7 Using a screw and a slide hammer remove the front output shaft seal Fig 3 Remove Range Lever Nut 1 RANGE LEVER Fig 4 Remove Boot Clamp 1 SEAL BOOT 2 BOOT CLAMP Fig 5 Remove Seal Boot 1 SEAL BOOT 2 SEAL SLINGER Fig 6 Bend Slinger Ears ...

Page 2122: ... PUMP AND REAR CASE 1 Remove rear case to front case bolts Fig 11 Fig 8 Remove Rear Extension Bolts 1 EXTENSION HOUSING 2 TRANSFER CASE Fig 9 Remove Rear Extension 1 EXTENSION HOUSING 2 TRANSFER CASE 3 PRY SLOT Fig 10 Remove Output Shaft Retaining Ring 1 REAR OUTPUT SHAFT 2 OUTPUT SHAFT BEARING 3 RETAINING RING 4 TRANSFER CASE Fig 11 Remove Case Bolts 1 REAR CASE 2 FRONT CASE 3 BOLT DR TRANSFER CA...

Page 2123: ... transfer case failure has gener ated any debris which may have become trapped in the oil pump the rear case and oil pump assembly MUST be replaced FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Remove shift rail cup and spring Fig 14 2 Remove front sprocket retaining ring Fig 15 Fig 12 Loosen Case Halves 1 REAR CASE 2 FRONT CASE 3 PRY SLOTS Fig 13 Remove Rear Case 1 REAR CASE 2 FRONT CASE Fig 14 Shift Rail...

Page 2124: ...g 18 Note that the plug has an O ring seal Remove and discard this seal 4 Remove the front output shaft snap ring Fig 19 Fig 16 Remove Front Sprocket and Drive Chain 1 FRONT DRIVE SPROCKET 2 DRIVE CHAIN 3 MAINSHAFT Fig 17 Remove Position Sensor 1 FRONT CASE 2 POSITION SENSOR Fig 18 Remove Detent Plug Spring and Plunger 1 FRONT CASE 2 DETENT PLUG 3 DETENT SPRING 4 DETENT PLUNGER Fig 19 Remove Front...

Page 2125: ...to front 8 Remove range fork retaining ring 9 Remove range fork and hub as an assembly Fig 23 Note fork position for installation reference Fig 23 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 20 Remove Front Output Shaft 1 FRONT CASE 2 FRONT OUTPUT SHAFT Fig 21 Remove Mainshaft 1 FRONT CASE 2 MAINSHAFT Fig 22 Remove Mode Fork and Shift Rail 1 MODE FORK 2 SHIFT RAIL 3 MODE SLEEVE 21 422 ...

Page 2126: ... 27 from the output shaft Fig 24 Remove Sector Support 1 SECTOR SUPPORT 2 FRONT CASE 3 SECTOR SHAFT Fig 25 Remove Shift Sector 1 SHIFT SECTOR Fig 26 Remove The Drive Sprocket Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 DRIVE SPROCKET Fig 27 Remove Drive Sprocket Thrust Washer 1 OUTPUT SHAFT 2 THRUST WASHER 3 DRIVE SPROCKET DR TRANSFER CASE NV241 GENII 21 423 TRANSFER CASE NV241 GENII Continue...

Page 2127: ...ng Fig 31 from the output shaft Fig 31 Remove Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 MODE HUB Fig 28 Remove Drive Sprocket 1 OUTPUT SHAFT 2 DRIVE SPROCKET Fig 29 Remove Clutch Gear 1 OUTPUT SHAFT 2 CLUTCH GEAR 3 MODE HUB Fig 30 Remove Sprocket Hub 1 OUTPUT SHAFT 2 SPROCKET HUB 21 424 TRANSFER CASE NV241 GENII DR TRANSFER CASE NV241 GENII Continued ...

Page 2128: ...s an assem bly Fig 34 Tap gear out of bearing with plastic mallet if necessary INPUT AND PLANETARY GEAR 1 Remove snap ring that retains input gear in low range gear Fig 35 Fig 35 Input Gear Snap Ring Removal 1 INPUT GEAR SNAP RING Fig 32 Remove Mode Hub 1 OUTPUT SHAFT 2 MODE HUB Fig 33 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 34 Remove Input Planetary Assembly 1 FRONT CAS...

Page 2129: ...e hub and shaft and the teeth on the sprocket Minor nicks and scratches can be smoothed with an oilstone however replace any part that is damaged Check the contact surfaces in the sprocket bore and on the mainshaft Minor nicks and scratches can be smoothed with 320 400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe Fig 36 Input Gear Retainer Removal 1 INPUT GEAR 2 ...

Page 2130: ... the shift fork wear pads Fig 42 The mode fork pads are serviceable and can be replaced if necessary The range fork pads are not serviceable The fork must be replaced as an assembly if the pads are worn or damaged Check both of the sleeves for wear or damage especially on the interior teeth Replace the sleeves if wear or damage is evident REAR RETAINER COMPONENTS Inspect the retainer components Re...

Page 2131: ...rain plug threads in the rear case The threads can be repaired with a thread chaser or tap if necessary Or the threads can be repaired with Helicoil stain less steel inserts if required OIL PUMP OIL PICKUP Examine the oil pump pickup parts Replace the pump if any part appears to be worn or damaged Do not disassemble the pump as individual parts are not available The pump is only available as a com...

Page 2132: ...ving the bearing out with the drift and a hammer Fig 46 7 Install new pilot bearing with Remover In staller 8684 8 Remove the front output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 47 Fig 47 Front Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 45 Remove Front Output Shaft Bearing 1 FRONT CASE 2 INSTAL...

Page 2133: ...ng Fig 51 into the rear case using Remover Installer 6953 and Handle C 4171 Fig 48 Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 Fig 49 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER Fig 50 Remove Rear Output Shaft Bearing 1 REAR CASE 2 REMOVER INSTALLER 8684 3 HANDLE C 4171 Fig 51 Install Rear...

Page 2134: ...ing 6 Align and install low range input gear assem bly in front case Fig 53 Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing 7 Install snap ring to hold input low range gear into front bearing Fig 54 8 Install a new input gear seal using Installer 8841 and Handle C 4171 Fig 52 Input Low Range Gear Components 1 SNAP RING 2 RETAINE...

Page 2135: ...tch gear Fig 58 onto the output shaft 6 Install the drive sprocket Fig 59 onto the out put shaft Fig 55 Install Mode Hub 1 OUTPUT SHAFT 2 MODE HUB Fig 56 Install Mode Hub Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 MODE HUB Fig 57 Install Sprocket Hub 1 OUTPUT SHAFT 2 SPROCKET HUB Fig 58 Install Clutch Gear 1 OUTPUT SHAFT 2 CLUTCH GEAR 3 MODE HUB Fig 59 Install Drive Sprocket 1 OUTPUT SHAFT 2...

Page 2136: ...en shift forks are installed 10 Install the shift sector support Fig 63 Tighten the sector support to 27 42 N m 20 30 ft lbs Fig 60 Install Drive Sprocket Thrust Washer 1 OUTPUT SHAFT 2 THRUST WASHER 3 DRIVE SPROCKET Fig 61 Install The Drive Sprocket Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 DRIVE SPROCKET Fig 62 Install Shift Sector 1 SHIFT SECTOR Fig 63 Install Sector Support 1 SECTOR SUP...

Page 2137: ... 16 Install mainshaft into the transfer case Fig 66 Guide mainshaft through the mode and range sleeves and into the input gear 17 Install the transfer case position sensor Fig 67 Tighten the sensor to 20 34 N m 16 25 ft lbs torque Fig 64 Install Range Fork And Hub Assembly 1 RANGE HUB 2 RANGE FORK Fig 65 Install Mode Fork and Shift Rail 1 MODE FORK 2 SHIFT RAIL 3 MODE SLEEVE Fig 66 Install Mainsha...

Page 2138: ...71 into the front output shaft bearing 2 Install the front output shaft retaining ring Fig 72 onto the output shaft 3 Install the new front output shaft seal with Installer MB991168A 4 Insert front sprocket in drive chain Fig 68 Install Range Lever Nut 1 RANGE LEVER Fig 69 O Ring Installation On Detent Plug 1 O RING 2 DETENT PLUG Fig 70 Install Detent Plug Spring and Plunger 1 FRONT CASE 2 DETENT ...

Page 2139: ...nner bear ing race and will become mis aligned if the bolts are loosened If the transfer case failure has gener ated any debris which may have become trapped in the oil pump the rear case and oil pump assembly MUST be replaced 1 Apply bead of Mopart Gasket Maker or equiv alent to mating surface of front case Keep sealer bead width to maximum of 3 16 inch Do not use excessive amount of sealer as ex...

Page 2140: ... Tighten bolts to 20 27 N m 15 24 ft lbs 5 Install rear output bearing snap ring Fig 79 to output shaft SEAL BOOT 1 Install the front output shaft seal slinger with Installer 8840 Install the slinger onto the shaft until the tool contacts the rear of the output shaft 2 Install a new seal boot clamp onto the seal boot 3 Install the seal boot and clamp onto the slinger hub and tighten the clamp with...

Page 2141: ... Tighten nuts to 30 41 N m 20 30 ft lbs 3 Remove jack stand from under transmission 4 Align and connect propeller shafts Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION 5 Connect vent hose and transfer case position sensor connector 6 Connect shift rod to transfer case lever or floor shift arm Use channel lock style pliers to press rod back into lever grommet 7 Adjus...

Page 2142: ...sal C 4171 Installer Seal 6888 Installer Bearing 6953 Installer Seal C 4210 Remover Bushing 6957 Installer Bushing 8157 Installer Seal D 163 Installer Seal 7884 Installer Bushing 5066 DR TRANSFER CASE NV241 GENII 21 439 TRANSFER CASE NV241 GENII Continued ...

Page 2143: ...sealing surface and inspect for defects 2 Using Installer D 163 install seal in extension housing Fig 81 3 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 4 Verify proper transfer case fluid level 5 Lower vehicle Plug Extension C 293 3 Remover L 4454 Cup 8148 Installer Pump Housing Seal 7888 Fig 81 Install Rear Seal in Extension Housing 1 SP...

Page 2144: ...Automatic Transmis sion fluid 7 Install and tighten fill plug to 20 34 N m 15 25 ft lbs 8 Lower vehicle FRONT OUTPUT SHAFT SEAL REMOVAL 1 Remove the front propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT REMOVAL 2 Remove the front propeller shaft seal boot retaining clamp Fig 83 3 Remove the front propeller shaft seal boot Fig 84 Fig 83 Remove Boot Clamp 1 SEAL BOO...

Page 2145: ...is an electronic device whose output can be interpreted to indicate the transfer case s current operating mode The sen sor consists of a five position resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module PCM for each trans fer case operating mode The sensor is located on the top of the transfer case just left of the transfer case centerline and r...

Page 2146: ... seal on the transfer case position sensor Replace the o ring if necessary 2 Install the transfer case position sensor into the transfer case Torque the sensor to 20 34 N m 15 25 ft lbs 3 Engage the transfer case position sensor con nector to the position sensor 4 Lower vehicle 5 Verify proper sensor operation Fig 87 Position Sensor Linear Movement 1 POSITION 1 10mm 0 5mm 2 POSITION 2 12mm 0 5mm 3...

Page 2147: ...le 5 Remove transfer case shifter knob cap 6 Remove nut holding shifter knob to shift lever 7 Remove shifter knob 8 Remove the shift boot from the shifter console 9 Remove the bolts securing the shifter mecha nism to the floor pan Fig 88 10 Separate shift lever mechanism from the vehi cle Fig 88 Transfer Case Shifter 1 SHIFTER BOOT 4 SHIFTER MECHANISM 2 SHIFTER KNOB 5 ALIGNMENT PIN 3 SHIFTER CONSO...

Page 2148: ...nd position from full forward 6 Install trunnion to shift lever if necessary 7 Install shift rod to trunnion if necessary 8 Tighten the shift rod lock bolt to 10 N m 90 in lbs 9 Remove the shifter adjustment locating pin from the adjustment channel and the locating hole 10 Lower vehicle 11 Install the transfer case shifter console 12 Install the shifter boot and the shifter knob onto the shifter l...

Page 2149: ...he lower shifter lever with the adjustment channel on the shifter bracket assembly Fig 90 7 Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position 8 Tighten shift rod lock bolt to 10 N m 90 in lbs torque 9 Remove the locating pin from the adjustment channel and locating hole 10 Check shift linkage operation Be...

Page 2150: ...ALLATION 478 SHIFT LEVER REMOVAL 479 INSTALLATION 480 ADJUSTMENTS ADJUSTMENT SHIFT LEVER 481 TRANSFER CASE NV271 DESCRIPTION The NV271 transfer case is a part time transfer case with a low range gear system It provides three operating ranges plus a NEUTRAL position The low range position provides a gear reduction ratio of 2 72 1 for increased low speed torque capability The gear cases and extensio...

Page 2151: ...rectly attached to the shift sector The sector operates the range and mode forks within the trans fer case A straight line shift pattern is used with a NEU TRAL detent Lever range positions are imprinted in the shift knob SHIFTING The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion The vehicle must have the transmission placed in NEUTRAL or the cl...

Page 2152: ... MoparT ATF 4 Automatic Transmission fluid Noisy in or jumps out of four wheel drive low range 1 Transfer case not completely engaged in 4L position 1 With the transmission in NEUTRAL or the clutch depressed in the case of a manual transmission and the vehicle moving under 3 4 km h 2 3 mph shift the transfer case to NEUTRAL and then shift into the 4L position 2 Shift linkage out of adjustment 2 Ad...

Page 2153: ...ttaching transfer case to trans mission 12 Move transfer case assembly rearward until free of transmission output shaft 13 Lower jack and move transfer case from under vehicle DISASSEMBLY Position transfer case in a shallow drain pan Remove drain plug and drain any remaining lubri cant remaining in case COMPANION FLANGE AND EXTENSION HOUSING 1 Install two bolts 180 apart into the front out put sha...

Page 2154: ... pump with an o ring Verify that the o ring was removed with the tube and is in good condition Replace the o ring if necessary 2 Remove the oil pump Fig 8 Fig 5 Remove Extension Housing Bolts 1 EXTENSION HOUSING 2 BOLTS Fig 6 Remove Extension Housing 1 REAR CASE HALF 2 EXTENSION HOUSING Fig 7 Disengage The Oil Pick up From Oil Pump 1 OIL PUMP 2 OIL PICK UP TUBE Fig 8 Remove Oil Pump 1 REAR CASE HA...

Page 2155: ...case with pry tool to break sealer bead Insert tool at each end of case Fig 12 Fig 9 Remove Case Half Bolts 1 FRONT CASE HALF 2 REAR CASE HALF 3 BOLTS Fig 10 Remove Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RING Fig 11 Remove Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RING Fig 12 Separate Front and Rear Case Halves 1 FRONT CASE HALF 2 REAR CASE HA...

Page 2156: ...emove the front output shaft drive sprocket retaining ring Fig 16 Fig 16 Remove Front Output Shaft Sprocket Retaining Ring 1 FRONT OUTPUT SHAFT 2 DRIVE SPROCKET 3 RETAINING RING Fig 13 Remove Rear Case Half 1 FRONT CASE HALF 2 REAR CASE HALF Fig 14 Remove Oil Pick Up Tube and Screen 1 FRONT CASE HALF 2 OIL SCREEN 3 PICK UP TUBE Fig 15 Remove Shift Rail Spring 1 SHIFT RAIL 2 SPRING DR TRANSFER CASE...

Page 2157: ...ft Then remove shift lever Fig 19 and spacer from the shaft 3 Remove the sector support with Socket 9033 4 Remove the transfer case position sensor Fig 20 Fig 17 Remove Rear Output Shaft Sprocket Retaining Ring 1 REAR OUTPUT SHAFT 2 DRIVE SPROCKET 3 RETAINING RING Fig 18 Remove Drive Chain and Sprockets 1 FRONT CASE HALF 2 CHAIN 3 DRIVE SPROCKETS Fig 19 Remove Manual Shift Lever 1 SHIFT SECTOR 2 S...

Page 2158: ...haft snap ring Fig 23 9 Remove front output shaft from bearing in case Fig 24 Fig 21 Loosen the Detent Plug 1 FRONT CASE HALF 2 DETENT PLUG Fig 22 Remove Detent plug Spring and Plunger 1 FRONT CASE HALF 2 DETENT PLUG 3 SPRING 4 PLUNGER Fig 23 Remove Front Output Shaft Bearing Inner Snap Ring 1 FRONT CASE HALF 2 SNAP RING Fig 24 Remove Front Output Shaft 1 FRONT CASE 2 FRONT OUTPUT SHAFT DR TRANSFE...

Page 2159: ...ar of case 12 Remove range fork and hub as an assembly Fig 27 Note fork position for installation reference 13 Remove shift sector Fig 28 Fig 25 Remove Mainshaft Assembly 1 FRONT CASE HALF 2 MAINSHAFT ASSEMBLY Fig 26 Remove Mode Fork Sleeve and Shift Rail Assembly 1 SHIFT RAIL 2 MODE FORK 3 MODE SLEEVE Fig 27 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 28 Remove Shift Sector 1 SHIFT SE...

Page 2160: ... the drive sprocket drive hub Fig 32 from the mainshaft Fig 29 Remove Clutch Gear 1 OUTPUT SHAFT 2 CLUTCH GEAR 3 MODE HUB Fig 30 Remove Mode Hub Retaining Ring 1 MAINSHAFT 2 MODE HUB 3 RETAINING RING Fig 31 Remove Mode Hub 1 MAINSHAFT 2 MODE HUB Fig 32 Remove the Drive Sprocket Drive Hub 1 MAINSHAFT 2 DRIVE SPROCKET DRIVE HUB DR TRANSFER CASE NV271 21 457 TRANSFER CASE NV271 Continued ...

Page 2161: ...ut of bearing with plastic mallet if necessary 4 Remove snap ring that retains input gear in the low range gear Fig 35 5 Remove retainer Fig 36 Fig 35 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 36 Remove Input Gear Retainer 1 INPUT GEAR 2 RETAINER Fig 33 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 34 Remove Input Planetary Assembly 1 FRONT CASE 2 INPU...

Page 2162: ...try to salvage the shaft if nicks or wear is severe INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear Fig 40 Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage Check the pinion...

Page 2163: ...es for wear or damage especially on the interior teeth Replace the sleeves if wear or damage is evident Fig 40 Input Gear And Carrier Components 1 PLANETARY CARRIER 4 CARRIER LOCK RING 2 REAR THRUST WASHER 5 CARRIER LOCK RETAINING RING 3 FRONT THRUST WASHER 6 INPUT GEAR Fig 41 Shift forks 1 RANGE FORK 2 MODE FORK AND RAIL 3 MODE SPRING Fig 42 Shift Fork And Wear Pad Locations 1 RANGE FORK 2 MODE F...

Page 2164: ...ry Or the threads can be repaired with Helicoil stain less steel inserts if required OIL PUMP OIL PICKUP Examine the oil pump pickup parts Replace the pump if any part appears to be worn or damaged Do not disassemble the pump as individual parts are not available The pump is only available as a complete assembly The pickup screen hose and tube are the only serviceable parts and are available separ...

Page 2165: ... driving the bearing out with the drift and a hammer Fig 48 10 Install new pilot bearing with Installer 9035 11 Remove the front output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 49 Fig 46 Remove Front Output Shaft Front Bearing 1 FRONT CASE HALF 2 HANDLE C 4171 3 INSTALLER 6953 Fig 47 Install Front Output Shaft Front Bearing 1 FRONT CASE HALF 2 INSTALLER 8891 ...

Page 2166: ... output shaft bearing snap ring Fig 53 from the rear case half Fig 53 Remove Rear Output Bearing Outer Snap Ring 1 REAR CASE HALF 2 REAR OUTPUT SHAFT BEARING 3 SNAP RING Fig 50 Install Front Output Shaft Rear Bearing 1 REAR CASE HALF 2 HANDLE C 4171 3 INSTALLER 8128 Fig 51 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER Fig 52 Oil Pump Seal Installa...

Page 2167: ...stall bottom thrust washer Fig 56 in low range gear planetary Be sure washer tabs are prop erly aligned in gear notches 3 Install input gear in low range gear Fig 57 Be sure input gear is fully seated Fig 54 Remove Rear Output Shaft Bearing 1 REAR CASE HALF 2 INSTALLER 7888 Fig 55 Install Rear Output Shaft Bearing 1 REAR CASE HALF 2 HANDLE C 4171 3 INSTALLER 8152 Fig 56 Install Bottom Input Gear T...

Page 2168: ...ange gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing Fig 61 Install Input Planetary Assembly 1 FRONT CASE 2 INPUT PLANETARY ASSEMBLY Fig 58 Install Input Gear Thrust Plate 1 INPUT GEAR 2 THRUST PLATE Fig 59 Install Input Gear Retainer 1 INPUT GEAR 2 RETAINER Fig 60 Install Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING DR TRANSFER CASE N...

Page 2169: ...e sprocket hub with ATF 4 and install the drive sprocket drive hub Fig 63 onto the mainshaft 3 Install the mode hub Fig 64 onto the main shaft 4 Install the mode hub retaining ring Fig 65 onto the mainshaft Fig 62 Install Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 63 Install the Drive Sprocket Drive Hub 1 MAINSHAFT 2 DRIVE SPROCKET DRIVE HUB Fig 64 Install Mode Hub 1 MAINSHAFT 2 M...

Page 2170: ...r support with Socket 9033 to 27 34 N m 20 25 ft lbs 8 Assemble and install range fork and hub Fig 68 Be sure hub is properly seated in low range gear and engaged to the input gear 9 Align and insert range fork pin in shift sector slot 10 Install mode fork and shift rail onto the mode sleeve 11 Install the mode fork sleeve and shift rail into the transfer case Fig 69 Fig 66 Install Clutch Gear 1 O...

Page 2171: ... secure shift lever Apply 1 2 drops Mopart Lock N Seal or equivalent to nut threads before installation Then tighten nut to 27 34 N m 20 25 ft lbs torque 16 Install new o ring on detent plug Fig 73 Fig 73 O Ring Installation On Detent Plug 1 O RING 2 DETENT PLUG Fig 70 Install Mainshaft Assembly 1 FRONT CASE HALF 2 MAINSHAFT ASSEMBLY Fig 71 Install Position Sensor 1 FRONT CASE 2 POSITION SENSOR Fi...

Page 2172: ... drive sprocket Fig 77 over the output shaft and lower the sprocket and chain assembly until the front sprocket is positioned over the front output shaft 7 Align the splines in the sprockets to the splines on the output shafts and install the sprockets onto the output shafts Fig 74 Install Detent plug Spring and Plunger 1 FRONT CASE HALF 2 DETENT PLUG 3 SPRING 4 PLUNGER Fig 75 Install Front Output...

Page 2173: ...put shaft bearing and align shift rail with bore in rear case Then install rear case Fig 82 Verify that the case alignment dowels correctly seat into their mating recesses 4 Install 4 5 rear case to front case bolts Fig 83 to hold rear case in position Tighten bolts snug but not to specified torque at this time Fig 78 Install Front Output Shaft Sprocket Retaining Ring 1 FRONT OUTPUT SHAFT 2 DRIVE ...

Page 2174: ...to output shaft OIL PUMP AND REAR EXTENSION 1 Install the oil pump Fig 85 onto the output shaft Fig 85 Install Oil Pump 1 REAR CASE HALF 2 REAR OUTPUT SHAFT 3 OIL PUMP Fig 82 Install Rear Case Half 1 FRONT CASE HALF 2 REAR CASE HALF Fig 83 Install Case Half Bolts 1 FRONT CASE HALF 2 REAR CASE HALF 3 BOLTS Fig 84 Install Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RING DR TR...

Page 2175: ...ll extension housing Fig 87 onto the rear case half 5 Install rear extension bolts Fig 88 Tighten the bolts to 27 34 N m 20 25 ft lbs 6 Install the extension housing boot and seal assembly with Installer 9037 and Handle C 4171 Fig 89 Fig 86 Engage The Oil Pick up To Oil Pump 1 OIL PUMP 2 OIL PICK UP TUBE Fig 87 Install Extension Housing 1 REAR CASE HALF 2 EXTENSION HOUSING Fig 88 Install Extension...

Page 2176: ...and connect propeller shafts Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION 5 Connect vent hose and transfer case position sensor connector 6 Connect shift rod to transfer case lever or floor shift arm Use channel lock style pliers to press rod back into lever grommet 7 Adjust shift linkage if necessary 8 Fill transfer case with recommended transmis sion fluid and i...

Page 2177: ... NV271 NV273 Handle Universal C 4171 Remover L 4454 Installer Bearing 6953 Installer Pump Housing Seal 7888 Installer Bearing 8128 Cup 8148 Installer 8151 Installer 8152 21 474 TRANSFER CASE NV271 DR TRANSFER CASE NV271 Continued ...

Page 2178: ...Installer 8891 Socket 9033 Installer Bearing 9035 Installer Seal 9036 Installer Seal 9037 DR TRANSFER CASE NV271 21 475 TRANSFER CASE NV271 Continued ...

Page 2179: ...ig 92 3 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 4 Verify proper transfer case fluid level 5 Lower vehicle FLUID STANDARD PROCEDURE FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case Fig 93 1 Raise vehicle 2 Position drain pan under transfer case 3 Remove drain and fill plugs and drain lubri cant completely 4 In...

Page 2180: ...he companion flange nut to 258 312 N m 190 230 ft lbs 6 Install front propeller shaft Refer to 3 DIF FERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION POSITION SENSOR DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case s current operating mode The sen sor consists of a five position resistive multiplexed...

Page 2181: ...ing seal on the transfer case position sensor Replace the o ring if necessary 2 Install the transfer case position sensor into the transfer case Torque the sensor to 20 34 N m 15 25 ft lbs 3 Engage the transfer case position sensor con nector to the position sensor 4 Lower vehicle 5 Verify proper sensor operation Fig 96 Position Sensor Linear Movement 1 POSITION 1 10mm 0 5mm 2 POSITION 2 12mm 0 5m...

Page 2182: ...hicle 5 Remove transfer case shifter knob cap 6 Remove nut holding shifter knob to shift lever 7 Remove shifter knob 8 Remove the shift boot from the shifter console 9 Remove the bolts securing the shifter mecha nism to the floor pan Fig 97 10 Separate shift lever mechanism from the vehi cle Fig 97 Transfer Case Shifter 1 SHIFTER BOOT 4 SHIFTER MECHANISM 2 SHIFTER KNOB 5 ALIGNMENT PIN 3 SHIFTER CO...

Page 2183: ...econd position from full forward 6 Install trunnion to shift lever if necessary 7 Install shift rod to trunnion if necessary 8 Tighten the shift rod lock bolt to 10 N m 90 in lbs 9 Remove the shifter adjustment locating pin from the adjustment channel and the locating hole 10 Lower vehicle 11 Install the transfer case shifter console 12 Install the shifter boot and the shifter knob onto the shifte...

Page 2184: ...n the lower shifter lever with the adjustment channel on the shifter bracket assembly Fig 99 7 Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position 8 Tighten shift rod lock bolt to 10 N m 90 in lbs torque 9 Remove the locating pin from the adjustment channel and locating hole 10 Check shift linkage operation...

Page 2185: ...mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case halves OPERATING RANGES Transfer case operating ranges are 2WD 2 wheel drive 4HI 4 wheel drive 4LO 4 wheel drive low range NEUTRAL The 2WD range is for use on any road surface at any time The 4HI and 4LO ranges are for off road use only They are not for use on hard surface roads The only exception being ...

Page 2186: ...1 Transfer case electronically controlled shift system malfunction 1 Verify proper operation per the appropriate diagnostic manual 2 If vehicle was operated for an extended period in 4HI mode on dry surface driveline torque load may cause difficulty 2 Drive the vehicle in a straight line and momentarily release the accelerator The transfer case can then be shifted to the desired mode 3 Insufficien...

Page 2187: ...ended operation in 4HI mode on dry surfaces 1 Operate vehicle in 2WD mode on dry surfaces REMOVAL 1 Shift transfer case into 2WD 2 Raise vehicle 3 Drain transfer case lubricant 4 Mark front and rear propeller shafts for align ment reference 5 Support transmission with jack stand 6 Remove the transfer case skid plate if equipped 7 Disconnect front and rear propeller shafts at transfer case 8 Discon...

Page 2188: ...ont propeller shaft seal boot Fig 5 5 Remove the front output shaft seal slinger by bending Fig 6 the slinger ears away from the transfer case Fig 4 Remove Boot Clamp Typical 1 SEAL BOOT 2 BOOT CLAMP Fig 5 Remove Seal Boot Typical 1 SEAL BOOT 2 SEAL SLINGER Fig 6 Bend Slinger Ears Typical 1 SLINGER 2 BEND UPWARD Fig 3 Remove the Shift Motor and Mode Sensor Assembly Bolts Typical 1 TRANSFER CASE 2 ...

Page 2189: ...astic mallet to break sealer bead and loosen it 3 Remove output bearing retaining ring with heavy duty snap ring pliers Fig 10 Fig 7 Remove Slinger From Shaft Typical 1 SLINGER 2 PRY TOOL Fig 8 Remove Rear Extension Bolts 1 EXTENSION HOUSING 2 TRANSFER CASE Fig 9 Remove Rear Extension 1 EXTENSION HOUSING 2 TRANSFER CASE 3 PRY SLOT Fig 10 Remove Output Shaft Retaining Ring 1 REAR OUTPUT SHAFT 2 OUT...

Page 2190: ...ng race and will become mis aligned if the bolts are loosened If the transfer case failure has gener ated any debris which may have become trapped in the oil pump the rear case and oil pump assembly MUST be replaced 5 Remove the oil pump pickup tube FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Remove shift rail cup and spring Fig 14 Fig 11 Remove Case Bolts 1 REAR CASE 2 FRONT CASE 3 BOLT Fig 12 Loosen Ca...

Page 2191: ...lug has an O ring seal Remove and discard this seal 3 Remove the front output shaft snap ring Fig 18 Fig 15 Removing Front Sprocket Retaining Ring 1 FRONT SPROCKET 2 RETAINING RING 3 FRONT OUTPUT SHAFT Fig 16 Remove Front Sprocket and Drive Chain 1 FRONT DRIVE SPROCKET 2 DRIVE CHAIN 3 MAINSHAFT Fig 17 Remove Detent Plug Spring and Plunger 1 FRONT CASE 2 DETENT PLUG 3 DETENT SPRING 4 DETENT PLUNGER...

Page 2192: ...eve goes to front 7 Remove range fork retaining ring 8 Remove range fork and hub as an assembly Fig 22 Note fork position for installation reference Fig 22 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 19 Remove Front Output Shaft 1 FRONT CASE 2 FRONT OUTPUT SHAFT Fig 20 Remove Mainshaft 1 FRONT CASE 2 MAINSHAFT Fig 21 Mode Fork And Sleeve Removal 1 MODE SLEEVE 2 MODE FORK AND RAIL DR TR...

Page 2193: ... from the output shaft Fig 23 Shift Sector Removal 1 SHIFT SECTOR Fig 24 Remove the Shift Sector O Ring 1 TRANSFER CASE FRONT HOUSING 2 SHIFT SECTOR O RING Fig 25 Remove The Drive Sprocket Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 DRIVE SPROCKET Fig 26 Remove Drive Sprocket Thrust Washer 1 OUTPUT SHAFT 2 THRUST WASHER 3 DRIVE SPROCKET 21 490 TRANSFER CASE NV243 DR TRANSFER CASE NV243 Contin...

Page 2194: ...ing ring Fig 30 from the output shaft Fig 30 Remove Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 MODE HUB Fig 27 Remove Drive Sprocket 1 OUTPUT SHAFT 2 DRIVE SPROCKET Fig 28 Remove Clutch Gear 1 OUTPUT SHAFT 2 CLUTCH GEAR 3 MODE HUB Fig 29 Remove Sprocket Hub 1 OUTPUT SHAFT 2 SPROCKET HUB DR TRANSFER CASE NV243 21 491 TRANSFER CASE NV243 Continued ...

Page 2195: ...gear as an assem bly Fig 33 Tap gear out of bearing with plastic mallet if necessary INPUT AND PLANETARY GEAR 1 Remove snap ring that retains input gear in low range gear Fig 34 Fig 34 Input Gear Snap Ring Removal 1 INPUT GEAR SNAP RING Fig 31 Remove Mode Hub 1 OUTPUT SHAFT 2 MODE HUB Fig 32 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 33 Remove Input Planetary Assembly 1 FRO...

Page 2196: ...lines on the hub and shaft and the teeth on the sprocket Minor nicks and scratches can be smoothed with an oilstone However replace any part that is damaged Check the contact surfaces in the sprocket bore and on the mainshaft Minor nicks and scratches can be smoothed with 320 400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe Fig 35 Input Gear Retainer Removal 1 IN...

Page 2197: ...re damaged Check the lock ring and both thrust washers for wear or cracks Replace them if necessary Also replace the lock retaining ring if bent distorted or broken SHIFT FORKS HUBS SLEEVES Check condition of the shift forks and mode fork shift rail Fig 40 Minor nicks on the shift rail can be smoothed with 320 400 grit emery cloth Fig 39 Input Gear and Carrier Components 1 PLANETARY CARRIER 4 CARR...

Page 2198: ...is damaged it will be necessary to replace the gear and front case as an assembly Do not attempt to remove the gear Fig 42 FRONT AND REAR CASES Inspect the cases for wear and damage Check case condition If leaks were a problem look for gouges and severe scoring of case sealing sur faces Also make sure the front case mounting studs are in good condition Check the front case mounting studs and vent ...

Page 2199: ... C 4171 and Installer 6953 5 Install front output shaft bearing retaining ring 6 Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 45 7 Install new pilot bearing with Remover In staller 8684 Fig 43 Remove Input Gear Bearing 1 INPUT GEAR BEARING 2 FRONT CASE Fig 44 Remove Front Outpu...

Page 2200: ...so it is flush with the lower edge of this chamfer Fig 48 Fig 46 Front Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 47 Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 Fig 48 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER DR TRANSFER CA...

Page 2201: ...ear notches 3 Install input gear in low range gear Be sure input gear is fully seated 4 Install remaining thrust washer in low range gear and on top of input gear Be sure washer tabs are properly aligned in gear notches 5 Install retainer on input gear and install snap ring Fig 49 Remove Rear Output Shaft Bearing 1 REAR CASE 2 REMOVER INSTALLER 8684 3 HANDLE C 4171 Fig 50 Install Rear Output Shaft...

Page 2202: ...ORKS AND MAINSHAFT 1 Lubricate mainshaft splines with recommended transmission fluid 2 Install the mode hub Fig 54 onto the output shaft 3 Install the mode hub retaining ring Fig 55 onto the output shaft Fig 52 Install Input Planetary Assembly 1 FRONT CASE 2 INPUT PLANETARY ASSEMBLY Fig 53 Install Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 54 Install Mode Hub 1 OUTPUT SHAFT 2 MODE...

Page 2203: ...e sprocket thrust washer Fig 59 onto the output shaft Fig 59 Install Drive Sprocket Thrust Washer 1 OUTPUT SHAFT 2 THRUST WASHER 3 DRIVE SPROCKET Fig 56 Install Sprocket Hub 1 OUTPUT SHAFT 2 SPROCKET HUB Fig 57 Install Clutch Gear 1 OUTPUT SHAFT 2 CLUTCH GEAR 3 MODE HUB Fig 58 Install Drive Sprocket 1 OUTPUT SHAFT 2 DRIVE SPROCKET 21 500 TRANSFER CASE NV243 DR TRANSFER CASE NV243 Continued ...

Page 2204: ...ngaged to the input gear 12 Align and insert range fork pin in shift sector slot 13 Install the range fork retaining ring 14 Install mode fork and shift rail onto the mode sleeve 15 Install the mode fork sleeve and shift rail into the transfer case Fig 63 Fig 63 Mode Fork And Sleeve Installation 1 MODE SLEEVE 2 MODE FORK AND RAIL Fig 60 Install The Drive Sprocket Retaining Ring 1 OUTPUT SHAFT 2 RE...

Page 2205: ...output shaft retaining ring Fig 68 onto the output shaft 3 Install the new front output shaft seal with Installer MB991168A 4 Insert front sprocket in drive chain Fig 64 Install Mainshaft 1 FRONT CASE 2 MAINSHAFT Fig 65 O Ring Installation On Detent Plug 1 O RING 2 DETENT PLUG Fig 66 Install Detent Plug Spring and Plunger 1 FRONT CASE 2 DETENT PLUG 3 DETENT SPRING 4 DETENT PLUNGER Fig 67 Install F...

Page 2206: ... and hub 8 Install front sprocket retaining ring Fig 70 9 Install spring and cup on shift rail Fig 71 10 Insert magnet in front case pocket Fig 72 Fig 69 Install Front Sprocket and Drive Chain 1 FRONT DRIVE SPROCKET 2 DRIVE CHAIN 3 MAINSHAFT Fig 70 Front Sprocket Retaining Ring Installation 1 FRONT SPROCKET 2 RETAINING RING Fig 71 Shift Rail Spring And Cup Installation 1 CUP 2 SPRING Fig 72 Case M...

Page 2207: ...se and oil pump assembly Fig 73 5 Install 4 5 rear case to front case bolts Fig 74 to hold rear case in position Tighten bolts snug but not to specified torque at this time CAUTION Verify that shift rail and case alignment dowels are seated before installing any bolts Case could be cracked if shaft rail or dowels are mis aligned 6 Apply Loctite 242 to remainder of rear case to front case bolt thre...

Page 2208: ...er case under vehicle 4 Align transfer case and transmission shafts and install transfer case onto the transmission 5 Install and tighten transfer case attaching nuts to 27 34 N m 20 25 ft lbs torque 6 Connect the vent hose 7 Connect the shift motor and mode sensor wir ing connectors Secure wire harness to clips on trans fer case 8 Align and connect the propeller shafts 9 Fill transfer case with c...

Page 2209: ... C 4171 Installer Seal D 163 Tool Set L 4518 Installer Seal MB991168A Installer Bushing 5066 Installer Bearing 6953 Cup 8148 Installer Bearing 8684 Installer 8840 Installer Seal 8841 21 506 TRANSFER CASE NV243 DR TRANSFER CASE NV243 Continued ...

Page 2210: ...he rear case Fig 78 1 Raise vehicle 2 Position drain pan under transfer case 3 Remove drain and fill plugs and drain lubri cant completely 4 Install drain plug Tighten plug to 20 34 N m 15 25 ft lbs 5 Remove drain pan 6 Fill transfer case to bottom edge of fill plug open ing with Mopart ATF 4 Automatic Transmission fluid 7 Install and tighten fill plug to 20 34 N m 15 25 ft lbs 8 Lower vehicle FRO...

Page 2211: ...all the front output shaft seal slinger with Installer 8840 Install the slinger onto the shaft until the tool contacts the rear of the output shaft 3 Install a new seal boot clamp onto the seal boot 4 Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C 4975 A 5 Install front propeller shaft Refer to 3 DIF FERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT ...

Page 2212: ...ignal between 3 8 Volts and 0 8 Volts is considered to be undefined Refer to SECTOR ANGLES vs TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode Refer to MODE SENSOR CHAN NEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position The various between gears positions can also ...

Page 2213: ...1850 2300 4HI E 3050 5950 2WD Default F 9 5 12 5K In between positions G 15 5K Open For resistances between the ranges B E shown for each valid position T Case NEUTRAL 4LO 4HI 2WD the TCCM may interpret the resistance as either of the neighboring valid positions as an invalid fault position For resistances between the ranges E and F shown for 2WD and in between positions the TCCM may interpret the...

Page 2214: ...hich internally moves the mode and range forks that change the transfer case operating ranges The motor is rated at 25 amps maximum at 72 F with 10 volts at the motor leads OPERATION The transfer case shift motor responds to the Transfer Case Control Module TCCM commands to move the transfer case shift sector bi directionally as required to obtain the transfer case operating mode indicated by the ...

Page 2215: ...apability for off road operation The low range provides a 2 72 1 reduction ratio The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case halves OPERATING RANGES NV244 GENII operating ranges are AWD All Wheel Drive 4HI Part time 4LO NEUTRAL The AWD mode can be used at any time and on ...

Page 2216: ... malfunction 1 Verify proper operation per the appropriate diagnostic manual 2 Insufficient or incorrect lubricant 2 Drain and refill transfer case with the correct quantity of MoparT ATF 4 Automatic Transmission Fluid 3 Internal transfer case components binding worn or damaged 3 Repair or replace components as necessary Transfer case noisy in all drive modes 1 Insufficient or incorrect lubricant ...

Page 2217: ... jack stand 6 Remove the transfer case skid plate if equipped 7 Disconnect front and rear propeller shafts at transfer case 8 Disconnect transfer case shift motor and mode sensor wire connectors 9 Disconnect transfer case vent hose 10 Support transfer case with transmission jack 11 Secure transfer case to jack with chains 12 Remove nuts attaching transfer case to trans mission Fig 2 13 Pull transf...

Page 2218: ...suitable pry tool remove the slinger from the output shaft using care not to damage the shaft 7 Using a screw and a slide hammer remove the front output shaft seal REAR EXTENSION 1 Remove rear extension bolts Fig 7 Fig 7 Remove Rear Extension Bolts 1 EXTENSION HOUSING 2 TRANSFER CASE Fig 4 Remove Boot Clamp 1 SEAL BOOT 2 CLAMP Fig 5 Remove Seal Boot 1 SEAL BOOT 2 SEAL SLINGER Fig 6 Bend Slinger Up...

Page 2219: ...rear case half The oil pump cover is aligned to the rear output shaft inner bear ing race and will become mis aligned if the bolts are loosened If the transfer case failure has gener ated any debris which may have become trapped in the oil pump the rear case and oil pump assembly MUST be replaced Fig 8 Remove Rear Extension 1 EXTENSION HOUSING 2 TRANSFER CASE 3 PRY SLOT Fig 9 Remove Output Shaft R...

Page 2220: ...move the mode fork Fig 15 and sleeve from the shift rail and mainshaft Fig 12 Remove Rear Case 1 REAR CASE 2 FRONT CASE Fig 13 Remove Shift Rail Spring 1 SHIFT RAIL 2 SPRING Fig 14 Removing Front Sprocket Retaining Ring 1 FRONT SPROCKET 2 RETAINING RING 3 FRONT OUTPUT SHAFT Fig 15 Remove Mode Fork and Sleeve 1 SHIFT RAIL 2 MODE FORK 3 MODE SLEEVE DR TRANSFER CASE NV244 GENII 21 517 TRANSFER CASE N...

Page 2221: ...as an O ring seal Remove and discard this seal 3 Remove the front output shaft snap ring Fig 19 Fig 18 Remove Detent Plug Spring and Plunger 1 FRONT CASE 2 DETENT PLUG 3 DETENT SPRING 4 DETENT PLUNGER Fig 19 Remove Front Output Shaft Snap ring 1 FRONT OUTPUT SHAFT 2 SNAP RING Fig 16 Remove Rear Output Shaft Retaining Ring 1 REAR OUTPUT SHAFT 2 RETAINING RING Fig 17 Remove Drive Sprockets and Chain...

Page 2222: ... and hub as an assembly Fig 22 Note fork position for installation reference 8 Remove shift sector Fig 23 Fig 20 Remove Mainshaft and Differential Assembly 1 FRONT CASE 2 MAINSHAFT AND DIFFERENTIAL ASSEMBLY Fig 21 Remove Shift Rail 1 SHIFT RAIL 2 RANGE FORK ASSEMBLY Fig 22 Remove Range Fork and Sleeve 1 RANGE SLEEVE 2 RANGE FORK Fig 23 Shift Sector Removal 1 SHIFT SECTOR DR TRANSFER CASE NV244 GEN...

Page 2223: ...ig 24 Remove the Shift Sector O Ring 1 TRANSFER CASE FRONT HOUSING 2 SHIFT SECTOR O RING Fig 25 Remove the Intermediate Clutch Shaft Snap ring 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT Fig 26 Remove the Intermediate Clutch Shaft Thrust Ring 1 CLUTCH SHAFT THRUST RING Fig 27 Remove the Intermediate Clutch Shaft 1 INTERMEDIATE CLUTCH SHAFT 21 520 TRANSFER CASE NV244 GENII DR TRANSFER CASE NV244 GENII ...

Page 2224: ...ode hub retainer Fig 31 from the mode hub Fig 28 Remove the Differential Snap ring 1 DIFFERENTIAL SNAP RING Fig 29 Remove the Differential 1 DIFFERENTIAL ASSEMBLY 2 MAINSHAFT Fig 30 Remove the Mode Hub and Retainer 1 DIFFERENTIAL ASSEMBLY 2 MODE HUB AND RETAINER Fig 31 Remove Retainer from Mode Hub 1 MODE HUB RETAINER 2 MODE HUB DR TRANSFER CASE NV244 GENII 21 521 TRANSFER CASE NV244 GENII Continu...

Page 2225: ...lastic mallet if necessary INPUT AND PLANETARY GEAR 1 Remove snap ring that retains input gear in low range gear Fig 34 2 Remove retainer Fig 35 Fig 32 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 33 Remove Input Planetary Assembly 1 FRONT CASE 2 INPUT PLANETARY ASSEMBLY Fig 34 Input Gear Snap Ring Removal 1 INPUT GEAR SNAP RING Fig 35 Input Gear Retainer Removal 1 INPUT GEAR...

Page 2226: ...ut replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage The carrier will have to be replaced as an assembly if the body pinion pins or pinion gears are damaged Check the lock ring and both thrust washers for wear or cracks Replace them if ne...

Page 2227: ...retched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully The gear is only serviced as part of the front case If the gear is damaged it will be necessary to replace the gear and front case as an assembly Do not attempt to remove the gear Fig 41 Fig 39 Input Gear and Carrier Components 1 PLANETARY CARRIER 4 C...

Page 2228: ...se and tube are the only serviceable parts and are available separately ASSEMBLY BEARINGS AND SEALS 1 Remove the input shaft bearing Fig 42 from the front case with suitable snap ring pliers 2 Transfer the retaining ring to the new bearing if necessary and install the bearing into the front case 3 Remove the front output shaft bearing retain ing ring from inside the front case half 4 Using Install...

Page 2229: ...r in low range gear Fig 48 Be sure washer tabs are properly aligned in gear notches 3 Install input gear in low range gear Be sure input gear is fully seated Fig 45 Front Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 Fig 46 Remove Rear Output Shaft Bearing 1 HANDLE C 4171 2 INSTALLER 5065 Fig 47 Install Rear Output Shaft Bearing 1 REAR CASE 2 ...

Page 2230: ... AND MAINSHAFT 1 Lubricate mainshaft splines with recommended transmission fluid NOTE Replace the mode hub retainer if the legs were distorted during removal 2 Install the mode hub retainer Fig 51 onto the mode hub 3 Install the mode hub Fig 52 and mode hub retainer onto the differential assembly Make sure the retainer is fully seated onto the differential Fig 49 Install Input Planetary Assembly 1...

Page 2231: ...h shaft thrust ring Fig 56 Fig 53 Install the Differential 1 DIFFERENTIAL ASSEMBLY 2 MAINSHAFT Fig 54 Installing Differential Snap Ring 1 DIFFERENTIAL SNAP RING Fig 55 Installing Intermediate Clutch Shaft 1 INTERMEDIATE CLUTCH SHAFT Fig 56 Installing Clutch Shaft Thrust Ring 1 CLUTCH SHAFT THRUST RING 21 528 TRANSFER CASE NV244 GENII DR TRANSFER CASE NV244 GENII Continued ...

Page 2232: ...s properly seated in low range gear and engaged to the input gear 12 Align and insert range fork pin in shift sector slot 13 Install the shift rail Fig 60 into the range fork assembly and the front case Fig 57 Installing Clutch Shaft Snap Ring 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT Fig 58 Install Shift Sector 1 SHIFT SECTOR Fig 59 Install Range Fork And Hub Assembly 1 RANGE HUB 2 RANGE FORK Fig 6...

Page 2233: ...e range mode position it was in when the shift motor was removed prior to installing the shift detent compo nents 5 Install detent plunger spring and plug Fig 64 Tighten the plug to 16 25 N m 12 18 ft lbs Fig 61 Install Mainshaft and Differential Assembly 1 FRONT CASE 2 MAINSHAFT AND DIFFERENTIAL ASSEMBLY Fig 62 Install Front Output Shaft Snap ring 1 FRONT OUTPUT SHAFT 2 SNAP RING Fig 63 O Ring In...

Page 2234: ... splines 9 Install the rear output shaft retaining ring Fig 67 onto the output shaft 10 Install the front sprocket retaining ring Fig 68 Fig 65 Install Front Output Shaft Seal Slinger 1 SEAL SLINGER 2 INSTALLER 8840 Fig 66 Install Drive Sprockets and Chain 1 FRONT DRIVE SPROCKET 2 DRIVE CHAIN 3 REAR DRIVE SPROCKET Fig 67 Install Rear Output Shaft Retaining Ring 1 REAR OUTPUT SHAFT 2 RETAINING RING...

Page 2235: ...t 13 Install spring onto the shift rail Fig 71 14 Insert magnet in front case pocket Fig 72 Fig 69 Mode Fork Assembly 1 MODE FORK 2 SPRING Fig 70 Install Mode Fork and Sleeve 1 SHIFT RAIL 2 MODE FORK 3 MODE SLEEVE Fig 71 Install Shift Rail Spring 1 SHIFT RAIL 2 SPRING Fig 72 Install the Transfer Case Sump Magnet 1 SUMP MAGNET 2 CASE POCKET 21 532 TRANSFER CASE NV244 GENII DR TRANSFER CASE NV244 GE...

Page 2236: ...essive amount of sealer as excess will be displaced into case interior 4 Align oil pump with mainshaft and align shift rail with bore in rear case Then install rear case and oil pump assembly Fig 73 5 Install rear output bearing snap ring Fig 74 to output shaft 6 Install 4 5 rear case to front case bolts Fig 75 to hold rear case in position Tighten bolts snug but not to specified torque at this ti...

Page 2237: ...olts Then install and tighten bolts to 16 24 N m 12 18 ft lbs torque INSTALLATION 1 Mount transfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case onto the transmission 5 Install and tighten transfer case attaching nuts to 27 34 N m 20 25 ft lbs torque 6 Connect the...

Page 2238: ...g 16 24 12 18 Bolt Case Half 25 28 18 21 Screw Oil Pump 14 19 10 14 Nuts Mounting 30 41 20 30 Bolts Shift Motor and Mode Sensor Assembly 16 24 12 18 SPECIAL TOOLS TRANSFER CASE NV244 GENII Handle Universal C 4171 Installer Seal D 163 Remover L 4454 Installer Seal MB991168A Installer Bushing 5065 DR TRANSFER CASE NV244 GENII 21 535 TRANSFER CASE NV244 GENII Continued ...

Page 2239: ...face and inspect for defects 2 Using Installer D 163 install seal in extension housing Fig 79 3 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 4 Verify proper transfer case fluid level 5 Lower vehicle Installer Bushing 5066 Installer Bearing 6953 Cup 8148 Installer 8840 Installer Seal 8841 Fig 79 Install Rear Seal in Extension Housing 1 SPE...

Page 2240: ... 4 Automatic Transmis sion fluid 7 Install and tighten fill plug to 20 34 N m 15 25 ft lbs 8 Lower vehicle FRONT OUTPUT SHAFT SEAL REMOVAL 1 Remove the front propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT REMOVAL 2 Remove the front propeller shaft seal boot retaining clamp Fig 81 3 Remove the front propeller shaft seal boot Fig 82 Fig 80 Fill Drain Plug and I D T...

Page 2241: ...ropeller shaft Refer to 3 DIF FERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION MODE SENSOR DESCRIPTION The transfer case mode sensor Fig 84 is an elec tronic device whose output can be interpreted to indi cate the shift motor shaft s rotary position The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device non contacting whose outp...

Page 2242: ... MODE SENSOR CHANNEL STATES Transfer Case Angle degrees Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D Between Gears H H L H 40 4LO H H L L Between Gears H H L H Between Gears H L L H 20 NEUTRAL H L L L Between Gears H L L H Between Gears H L H H 0 2WD AWD H L H L Between Gears H L H H Between Gears L L H H 20 4HI L L H L Between Gears L L H H Between Gears L H H H SELECTOR SW...

Page 2243: ...s fully completed shift and the current operating mode of the transfer case While a shift has been requested but not yet completed the LED for the desired trans fer case position is flashed A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested but all of the driver controllable conditions have not been met This is in an attempt to notify the ...

Page 2244: ...ectors from the shift motor and mode sensor 3 Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case 4 Separate the shift motor and mode sensor assembly from the transfer case INSTALLATION 1 Verify that the shift sector o ring is clean and properly positioned over the shift sector and against the transfer case NOTE Verify that the shift motor position and sec tor ...

Page 2245: ...s attached with bolts The mainshaft front and rear bearings are mounted in aluminum case halves OPERATING RANGES Transfer case operating ranges are 2WD 2 wheel drive 4HI 4 wheel drive 4LO 4 wheel drive low range NEUTRAL The 2WD range is for use on any road surface at any time The 4HI and 4LO ranges are for off road use only They are not for use on hard surface roads The only exception being when t...

Page 2246: ...range 1 Transfer case electronically controlled shift system malfunction 1 Verify proper operation per the appropriate diagnostic manual 2 If vehicle was operated for an extended period in 4HI mode on dry surface driveline torque load may cause difficulty 2 Drive the vehicle in a straight line and momentarily release the accelerator The transfer case can then be shifted to the desired mode 3 Insuf...

Page 2247: ...ended operation in 4HI mode on dry surfaces 1 Operate vehicle in 2WD mode on dry surfaces REMOVAL 1 Shift transfer case into 2WD 2 Raise vehicle 3 Drain transfer case lubricant 4 Mark front and rear propeller shafts for align ment reference 5 Support transmission with jack stand 6 Remove the transfer case skid plate if equipped 7 Disconnect front and rear propeller shafts at transfer case 8 Discon...

Page 2248: ...use Flange puller 8992 to remove the companion flange 5 Use a suitable chisel or pry tool to remove the rear extension housing dust boot Fig 4 6 Use a suitable chisel or pry tool to remove the rear extension housing seal 7 Remove rear extension bolts Fig 5 Fig 3 Remove Companion Flange Nut Typical 1 HOLDER 6719 2 BOLTS Fig 4 Remove Extension Housing Dust Boot 1 EXTENSION HOUSING 2 DUST BOOT Fig 5 ...

Page 2249: ...was removed with the tube and is in good condition Replace the o ring if necessary 2 Remove the oil pump Fig 8 3 Remove rear case to front case bolts Fig 9 Fig 7 Disengage The Oil Pick up From Oil Pump 1 OIL PUMP 2 OIL PICK UP TUBE Fig 6 Remove Extension Housing 1 REAR CASE HALF 2 EXTENSION HOUSING Fig 8 Remove Oil Pump 1 REAR CASE HALF 2 REAR OUTPUT SHAFT 3 OIL PUMP Fig 9 Remove Case Half Bolts 1...

Page 2250: ...of case Fig 12 7 Unseat rear case from alignment dowels 8 Remove the rear case from the front case Fig 13 Fig 10 Remove Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RING Fig 11 Remove Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RING Fig 12 Separate Front and Rear Case Halves 1 FRONT CASE HALF 2 REAR CASE HALF Fig 13 Remove Rear Case Half 1 FRONT CASE ...

Page 2251: ...d rear output shaft sprocket splines 5 Remove chain and sprockets as an assembly Fig 14 Remove Oil Pick Up Tube and Screen 1 FRONT CASE HALF 2 OIL SCREEN 3 PICK UP TUBE Fig 15 Remove Front Output Shaft Sprocket Retaining Ring 1 FRONT OUTPUT SHAFT 2 DRIVE SPROCKET 3 RETAINING RING Fig 16 Remove Rear Output Shaft Sprocket Retaining Ring 1 REAR OUTPUT SHAFT 2 DRIVE SPROCKET 3 RETAINING RING Fig 17 Re...

Page 2252: ...lunger Fig 21 Note that the plug has an O ring seal Remove and discard this seal Fig 18 Remove Shift Motor Assembly Bolts 1 TRANSFER CASE 2 SHIFT MOTOR ASSEMBLY 3 BOLTS Fig 19 Remove Shift Motor Assembly From Transfer Case 1 TRANSFER CASE 2 SHIFT MOTOR ASSEMBLY Fig 20 Loosen the Detent Plug 1 FRONT CASE HALF 2 DETENT PLUG Fig 21 Remove Detent plug Spring and Plunger 1 FRONT CASE HALF 2 DETENT PLUG...

Page 2253: ...assembly Fig 25 Note which way the sleeve fits in the fork long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case Fig 22 Remove Front Output Shaft Bearing Inner Snap Ring 1 FRONT CASE HALF 2 SNAP RING Fig 23 Remove Front Output Shaft 1 FRONT CASE 2 FRONT OUTPUT SHAFT Fig 24 Remove Mainshaft Assembly 1 FRONT CASE HALF 2 MAINSHAFT ASSEMBLY Fig 25 Mode Fork And Sle...

Page 2254: ...e out put shaft 2 Remove the mode hub retaining ring Fig 29 from the mainshaft Fig 29 Remove Mode Hub Retaining Ring 1 MAINSHAFT 2 MODE HUB 3 RETAINING RING Fig 26 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 27 Remove Shift Sector 1 SHIFT SECTOR Fig 28 Remove Clutch Gear 1 OUTPUT SHAFT 2 CLUTCH GEAR 3 MODE HUB DR TRANSFER CASE NV273 21 551 TRANSFER CASE NV273 Continued ...

Page 2255: ...nt case in horizontal position Then remove input gear and low range gear as an assem bly Fig 33 Tap gear out of bearing with plastic mallet if necessary Fig 30 Remove Mode Hub 1 MAINSHAFT 2 MODE HUB Fig 31 Remove the Drive Sprocket Drive Hub 1 MAINSHAFT 2 DRIVE SPROCKET DRIVE HUB Fig 32 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 33 Remove Input Planetary Assembly 1 FRONT CA...

Page 2256: ...nput gear Fig 37 Fig 37 Remove Input Gear From Planetary 1 INPUT GEAR 2 LOW RANGE PLANETARY Fig 34 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 35 Remove Input Gear Retainer 1 INPUT GEAR 2 RETAINER Fig 36 Remove Input Gear Thrust Plate 1 INPUT GEAR 2 THRUST PLATE DR TRANSFER CASE NV273 21 553 TRANSFER CASE NV273 Continued ...

Page 2257: ...ar is severe INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear Fig 39 Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage Check the pinion gear thrust wash ers on the pinon pins...

Page 2258: ...reads are dam aged bearing surfaces are scored or if any sprocket teeth are cracked or broken Examine the drive chain and shaft bearings Replace the chain and both sprockets if the chain is stretched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully The gear is only serviced as part of the front case If the ...

Page 2259: ...D SEALS 1 Remove the input shaft bearing snap ring from the front case half with suitable snap ring pliers 2 Remove the input shaft bearing from the front case half with Installer 6953 and Handle C 4171 Fig 43 3 Install the input shaft bearing into the front case half with Installer 8151 inverted on Handle C 4171 Fig 44 4 Install the input shaft bearing snap ring into the front case half with suit...

Page 2260: ...ft and a hammer Fig 47 10 Install new pilot bearing with Installer 9035 11 Remove the front output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 48 Fig 47 Remove Input Gear Cup Bearing 1 DRIFT 2 INPUT GEAR Fig 48 Front Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 46 Install Front Output Shaft Front Bear...

Page 2261: ... output shaft bearing snap ring Fig 52 from the rear case half Fig 52 Remove Rear Output Bearing Outer Snap Ring 1 REAR CASE HALF 2 REAR OUTPUT SHAFT BEARING 3 SNAP RING Fig 49 Install Front Output Shaft Rear Bearing 1 REAR CASE HALF 2 HANDLE C 4171 3 INSTALLER 8128 Fig 50 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER Fig 51 Oil Pump Seal Installa...

Page 2262: ...stall bottom thrust washer Fig 55 in low range gear planetary Be sure washer tabs are prop erly aligned in gear notches 3 Install input gear in low range gear Fig 56 Be sure input gear is fully seated Fig 53 Remove Rear Output Shaft Bearing 1 REAR CASE HALF 2 INSTALLER 7888 Fig 54 Install Rear Output Shaft Bearing 1 REAR CASE HALF 2 HANDLE C 4171 3 INSTALLER 8152 Fig 55 Install Bottom Input Gear T...

Page 2263: ...ange gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing Fig 60 Install Input Planetary Assembly 1 FRONT CASE 2 INPUT PLANETARY ASSEMBLY Fig 57 Install Input Gear Thrust Plate 1 INPUT GEAR 2 THRUST PLATE Fig 58 Install Input Gear Retainer 1 INPUT GEAR 2 RETAINER Fig 59 Install Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING 21 560 TRANSFER CA...

Page 2264: ...e sprocket hub with ATF 4 and install the drive sprocket drive hub Fig 62 onto the mainshaft 3 Install the mode hub Fig 63 onto the main shaft 4 Install the mode hub retaining ring Fig 64 onto the mainshaft Fig 61 Install Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 62 Install the Drive Sprocket Drive Hub 1 MAINSHAFT 2 DRIVE SPROCKET DRIVE HUB Fig 63 Install Mode Hub 1 MAINSHAFT 2 M...

Page 2265: ...the sector support with Socket 9033 to 27 34 N m 20 25 ft lbs 8 Assemble and install range fork and hub Fig 67 Be sure hub is properly seated in low range gear and engaged to the input gear 9 Align and insert range fork pin in shift sector slot 10 Install mode fork and shift rail onto the mode sleeve 11 Install the mode fork sleeve and shift rail into the transfer case Fig 68 Fig 65 Install Clutch...

Page 2266: ...nsor assembly to the transfer case Tighten the bolts to 16 25 N m 12 18 ft lbs Fig 69 O Ring Installation On Detent Plug 1 O RING 2 DETENT PLUG Fig 70 Install Detent plug Spring and Plunger 1 FRONT CASE HALF 2 DETENT PLUG 3 SPRING 4 PLUNGER Fig 71 Install Shift Motor Assembly Onto Transfer Case 1 TRANSFER CASE 2 SHIFT MOTOR ASSEMBLY Fig 72 Install Shift Motor Assembly Bolts 1 TRANSFER CASE 2 SHIFT...

Page 2267: ...rive sprocket 6 Position rear drive sprocket Fig 76 over the output shaft and lower the sprocket and chain assembly until the front sprocket is positioned over the front output shaft 7 Align the splines in the sprockets to the splines on the output shafts and install the sprockets onto the output shafts Fig 73 Install Mainshaft Assembly 1 FRONT CASE HALF 2 MAINSHAFT ASSEMBLY Fig 74 Install Front O...

Page 2268: ...e interior 3 Align mainshaft with the rear output shaft bearing and align shift rail with bore in rear case Then install rear case Fig 80 Verify that the case alignment dowels correctly seat into their mating recesses Fig 77 Install Front Output Shaft Sprocket Retaining Ring 1 FRONT OUTPUT SHAFT 2 DRIVE SPROCKET 3 RETAINING RING Fig 78 Install Rear Output Shaft Sprocket Retaining Ring 1 REAR OUTPU...

Page 2269: ... shaft OIL PUMP AND REAR EXTENSION 1 Install the oil pump Fig 83 onto the output shaft 2 Engage the oil pump pick up tube Fig 84 into the oil pump Verify that the pick up tube o ring is on the tube and is correctly installed to the oil pump Fig 81 Install Case Half Bolts 1 FRONT CASE HALF 2 REAR CASE HALF 3 BOLTS Fig 82 Install Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RI...

Page 2270: ...se half 5 Install rear extension bolts Fig 86 Tighten the bolts to 27 34 N m 20 25 ft lbs 6 Install the extension housing dust boot and seal assembly with Installer 9037 and Handle C 4171 Fig 87 Fig 85 Install Extension Housing 1 REAR CASE HALF 2 EXTENSION HOUSING Fig 86 Install Extension Housing Bolts 1 EXTENSION HOUSING 2 BOLTS Fig 87 Install Extension Housing Seal 1 EXTENSION HOUSING 2 HANDLE C...

Page 2271: ...ose 7 Connect the shift motor and mode sensor wir ing connectors Secure wire harness to clips on trans fer case 8 Align and connect the propeller shafts 9 Fill transfer case with correct fluid Refer to 21 TRANSMISSION TRANSFER CASE FLUID STANDARD PROCEDURE 10 Install skid plate if equipped 11 Remove transmission jack and support stand 12 Lower vehicle and verify transfer case shift operation SPECI...

Page 2272: ... NV271 NV273 Handle Universal C 4171 Remover L 4454 Installer Bearing 6953 Installer Pump Housing Seal 7888 Installer Bearing 8128 Cup 8148 Installer 8151 Installer 8152 DR TRANSFER CASE NV273 21 569 TRANSFER CASE NV273 Continued ...

Page 2273: ...Installer 8891 Socket 9033 Installer Bearing 9035 Installer Seal 9036 Installer Seal 9037 21 570 TRANSFER CASE NV273 DR TRANSFER CASE NV273 Continued ...

Page 2274: ...ig 90 3 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 4 Verify proper transfer case fluid level 5 Lower vehicle FLUID STANDARD PROCEDURE FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case Fig 91 1 Raise vehicle 2 Position drain pan under transfer case 3 Remove drain and fill plugs and drain lubri cant completely 4 In...

Page 2275: ... to use Flange puller 8992 to remove the companion flange 6 Using a screw and a slide hammer remove the front output shaft seal INSTALLATION 1 Install the new front output shaft seal with Installer MB991168A 2 Install the front companion flange onto the front output shaft 3 Install two bolts 180 apart into the front out put shaft companion flange 4 Place holder over the bolts and against the compa...

Page 2276: ...ignal between 3 8 Volts and 0 8 Volts is considered to be undefined Refer to SECTOR ANGLES vs TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode Refer to MODE SENSOR CHAN NEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position The various between gears positions can also ...

Page 2277: ... Open For resistances between the ranges B E shown for each valid position T Case NEUTRAL 4LO 4HI 2WD the TCCM may interpret the resistance as either of the neighboring valid positions as an invalid fault position For resistances between the ranges E and F shown for 2WD and in between positions the TCCM may interpret the resistance as the 2WD position an invalid fault position a valid in between p...

Page 2278: ...erating ranges The motor is rated at 25 amps maximum at 72 F with 10 volts at the motor leads OPERATION The transfer case shift motor responds to the Transfer Case Control Module TCCM commands to move the transfer case shift sector bi directionally as required to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch REMOVAL NOTE New shift motor assemblie...

Page 2279: ......

Page 2280: ...SPECTION 11 STANDARD PROCEDURE STANDARD PROCEDURE WHEEL REPLACEMENT 12 STANDARD PROCEDURE DUAL REAR WHEEL INSTALLATION 12 SPECIFICATIONS TORQUE CHART 13 STUDS REMOVAL 14 INSTALLATION 14 WHEEL COVER REMOVAL 14 INSTALLATION INSTALLATION REAR 14 INSTALLATION FRONT 14 SPARE TIRE DESCRIPTION DESCRIPTION SPARE TEMPORARY TIRE 15 DESCRIPTION FULL SIZE SPARE WHEEL WITH MATCHING TIRE 15 TIRES WHEELS DIAGNOS...

Page 2281: ...re is runout in both tire and wheel 1 Remove tire from wheel and mount wheel on service dynamic balance machine 2 Check wheel radial runout Fig 2 and lateral runout Fig 3 STEEL WHEELS Radial runout 0 031 in Lat eral runout 0 031 in maximum ALUMINUM WHEELS Radial runout 0 020 in Lateral runout 0 025 in maximum 3 If point of greatest wheel lateral runout is near original chalk mark remount tire 180 ...

Page 2282: ...the low spot on the wheel rim Each are marked with a bright colored temporary label on the out board surface for alignment The wheel is also marked permanently on the inside of the rim in the tire well This permanent mark may be a paint dot or line a permanent label or a stamped impression such as an X An optional location mark is a small spherical indentation on the vertical face of the out board...

Page 2283: ...one mounting proce dures Typically use front cone mounting method for steel wheels For aluminum wheel use back cone mounting method without cone spring NOTE Static should be used only when a two plane balancer is not available NOTE Cast aluminum and forged aluminum wheels require coated balance weights and special align ment equipment Wheel balancing can be accomplished with either on or off vehic...

Page 2284: ...ANCE WEIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 10 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 2 ADD BALANCE WEIGHTS HERE 3 CORRECTIVE WEIGHT LOCATION 4 HEAVY SPOT WHEEL SHIMMY AND VIBRATION DR TIRES WHEELS 22 5 TIRES WHEELS Continued ...

Page 2285: ...e Refer to the chart to decipher the tire identification code Fig 11 Performance tires have a speed rating letter after the aspect ratio number The speed rating is not always printed on the tire sidewall These ratings are Q up to 100 mph R up to 106 mph S up to 112 mph T up to 118 mph U up to 124 mph H up to 130 mph V up to 149 mph Z more than 149 mph consult the tire manu facturer for the specifi...

Page 2286: ...oss of the tire s ability to cushion shocks Fig 13 Improper inflation can cause Uneven wear patterns Reduced tread life Reduced fuel economy Unsatisfactory ride Vehicle drift For proper tire pressure specification refer to the vehicles Owners Manual WARNING OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND TREAD WEAR THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY RESULTING IN LOSS OF VEHICLE ...

Page 2287: ...lders of tire Over inflation will cause wear at the center of tire Excessive camber causes the tire to run at an angle to the road One side of tread is then worn more than the other Fig 15 Excessive toe in or toe out causes wear on the tread edges and a feathered effect across the tread Fig 15 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Cor rection Chart to...

Page 2288: ...Fig 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART DR TIRES WHEELS 22 9 TIRES Continued ...

Page 2289: ...sary Install wheel on vehicle and tighten to proper torque specification Refer to 22 TIRES WHEELS WHEELS SPECIFICATIONS SPECIFICATIONS TIRE REVOLUTIONS PER MILE TIRE SIZE SUPPLIER REVOLUTIONS PER MILE P245 70R17 WRANGLER SRA GOODYEART 685 LT245 70R17 LTX A S MICHELINT 675 LT265 70R17 LTX A S MICHELINT 657 LT245 70R17 RUGGED TRAIL T A BF GOODRICHT 684 LT265 70R17 RUGGED TRAIL T A BF GOODRICHT 658 P...

Page 2290: ...G WHEEL INSPECTION Inspect wheels for Excessive run out Dents or cracks Damaged wheel lug nut holes Air Leaks from any area or surface of the rim NOTE Do not attempt to repair a wheel by hammer ing heating or welding If a wheel is damaged an original equipment replacement wheel should be used When obtaining replacement wheels they should be equivalent in load carrying capacity The diameter width o...

Page 2291: ...o the proper torque specification Fig 22 Fig 23 Never use oil or grease on studs or nuts Wheels must be replaced if they have Excessive runout Bent or dented Leak air through welds Have damaged bolt holes Wheel repairs employing hammering heating or welding are not allowed Original equipment wheels are available through your dealer Replacement wheels from any other source should be equivalent in L...

Page 2292: ...mbered sequential pattern until they are snug tight Then tighten lug nut to specified torque following same number sequence Refer to 22 TIRES WHEELS WHEELS SPECIFICATIONS Tighten lug nuts in same numbered sequence a second time to the specified torque This will ensure that the wheels are thoroughly mated Check lug nut specified torque after 100 miles 160 kilometers Also after 500 miles 800 kilome ...

Page 2293: ...he blade on the end of the tool to pry the cap off in a back and forth motion 2 On 3500 models with dual rear wheels DRW you must first remove the hub caps The hub cap remover installer combination tool must be inserted in the pry off notch of the rear hub caps 3 Position the hub cap remover installer combina tion tool and pull out on the tool firmly The cap should come off 4 The wheel skins can n...

Page 2294: ...PARE TEMPORARY TIRE The temporary spare tire is designed for emer gency use only The original tire should be repaired or replaced at the first opportunity then reinstalled Do not exceed speeds of 50 M P H when using the temporary spare tire Refer to Owner s Manual for complete details DESCRIPTION FULL SIZE SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire It can b...

Page 2295: ......

Page 2296: ...use when welding Disconnect the negative cable clamp from the battery when servicing electrical components that are live when the ignition is OFF Damage to electrical system can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result D...

Page 2297: ...ting stopping turning or when on an incline MIRROR INSPECTION METHOD When a leak point area is visually obstructed use a suitable mirror to gain visual access A mirror can also be used to deflect light to a limited access area to assist in locating a leak point BRIGHT LIGHT LEAK TEST METHOD Some water leaks in the luggage compartment can be detected without water testing Position the vehi cle in a...

Page 2298: ...RE HEAT STAKING 1 Remove trim panel 2 Bend or move the trim panel components at the heat staked joints Observe the heat staked loca tions and or component seams for looseness 3 Heat stake the components a If the heat staked or component seam loca tion is loose hold the two components tightly together and using a soldering gun with a flat tip melt the material securing the components together Do no...

Page 2299: ...hemicals or compounds on undamaged painted surfaces around repair areas Damage to finish can result RIGID SEMI RIGID AND FLEXIBLE PLASTIC PARTS TYPES CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION ASA ACRYLONITRILE STYRENE ACRYLITE LURAN S CONSOLES GRILLES ABS ACRYLONITRILE BUTADIENE STYRENE TERLURAN 9A9 PILLARS CONSOLES GRILLES ABS PC ABS PC ALLOY PULSE PROLOY BAYBLEND DOORS INSTRUMENT PA...

Page 2300: ...ENING PANEL LIFTGATES FLARESIDE FENDERS FENDER EXTENSIONS EEBC ETHER ESTER BLOCKED CO POLYMER EEBC BUMPERS EEBC PBTP EEBC POLYBUTYLENE TEREPTHALATE EEBC PBTP BEXLOY BUMPER ROCKER PANELS EMPP ETHYLENE MODIFIED POLYPROPYLENE EMPP BUMPER COVERS EPDM ETHYLENE PROPROPYLENE DIENE MONOMER EPDM NORDEL VISTALON BUMPERS EPM ETHYLENE PROPROPYLENE CO POLYMER EPM FENDERS MPU FOAM POLYURETHANE MPU SPOILERS PE P...

Page 2301: ...spreader wooden tongue depressor or squeegee For fine texturing a small amount of water can be applied to the filler surface while smoothing The cured filler can be sanded as neces sary and as a final step cleanup can be done with soapy water Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on with the repair PANEL REINFORCEMENT Structural repair procedures ...

Page 2302: ...et a true damage assessment Close inspection may require partial removal of interior trim or inner panels Identify the type of repair Puncture or Crack Damage that has penetrated completely through the panel Damage is confined to one general area a panel section is not required However a backer panel open fiberglass tape or matted material must be bonded from behind Fig 7 Fig 6 PANEL SURFACE PREPA...

Page 2303: ...red Fig 8 2 Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area 3 Apply a liberal coat of adhesive over the rein forcement mesh Fig 8 If necessary apply a second or third coat of adhesive and mesh after first coat has cured The thickness of the patch should be the same as the repair area 4 After patch has cured peel waxed paper or plastic from ...

Page 2304: ...nstall screws to hold the patch to support squares Fig 12 Tighten screws until patch surface is flush with panel surface 16 Allow adhesive to cure and remove all screws 17 Using a 125 mm 5 in 24 grit disc grinder grind a 50 mm 2 in to 75 mm 3 in wide and 2 mm 0 080 in deep path across the gaps around the patch Fig 13 With compressed air blow dust from around patch 18 Apply adhesive backed nylon me...

Page 2305: ... the patched area grind surface down and apply a coat of high quality rigid plastic body filler Prime block sand and paint as required Fig 12 INSTALL SCREWS 1 PATCH 2 GAP Fig 13 GRIND SURFACE 1 PATCH 2 GAP 3 DISC GRINDER Fig 14 COVER GAPS WITH MESH 1 GROUND DOWN AREA 2 PATCH 3 MESH Fig 15 COVER MESH WITH ADHESIVE 1 ADHESIVE 2 MESH 3 PATCH 4 SPREADER 23 10 BODY DR BODY Continued ...

Page 2306: ...t also isolates components Water resistant Between metal and metal metal and plastic vinyl and plastic Examples Pull cups bezels clips ducts top cover to glass cowl panel 40 to 180 Fahrenheit 40 to 82 Celsius High Density Urethane Foam Tear resistant highly resilient and durable Between metal and metal metal and plastic Water resistant Examples I P heavy metal rattles isolating brackets 40 to 180 ...

Page 2307: ...ass lift plate nuts 10 89 Front door hinge to a pillar nuts 28 21 Front door hinge to door nuts bolts 28 21 Front door inside handle bolt 9 80 Front door latch adjustment screw 3 30 Front door latch assembly bolts 10 89 Front door latch striker bolts 28 21 Front door latch striker bolts 28 21 Front door regulator bolts 10 89 Front door regulator stabilizer nuts 10 89 Front door remote handle actua...

Page 2308: ...s 10 89 Rear door latch striker bolts 28 21 Rear door regulator bolts 10 89 Rear door regulator stabilizer nuts 10 89 Rear door remote handle actuator nuts 10 89 Rear fender bottom screws 7 60 Rear fender nuts 7 60 Rear fender support bracket bolts 11 8 Rear seat assembly bolts 40 30 Rear seat back hinge bolts 25 18 Rear seat cushion hinge bolts 32 24 Rear shoulder belt anchor bolts 40 30 Rear vie...

Page 2309: ...SPECIAL TOOLS BODY Trim Stick C 4755 Torx Bit Set C 4794 B REMOVER MOLDINGS C 4829 A 23 14 BODY DR BODY Continued ...

Page 2310: ... is in clearance hole portion of cable end 4 Separate cable end from stud 5 Remove screw attaching cable to tailgate Fig 2 6 Separate check cable from tailgate INSTALLATION 1 Position check cable on tailgate 2 Install bolt attaching small end of cable to tail gate 3 Tighten tailgate check cable bolt to 23 N m 17 ft lbs 4 Position large end of cable onto stud head and slide downward to secure lock ...

Page 2311: ...ent mark the actuator rod for installation 3 Disconnect the actuator rod at the control assembly Fig 3 4 Remove the latch bolt and the check cable bolt Fig 5 5 Remove the latch and actuator rod assembly INSTALLATION 1 Install the latch and actuator rod assembly 2 Install the latch and the check cable bolts and tighten to 23 N m 17 ft lbs 3 Connect the actuator rod to the control assem bly line up ...

Page 2312: ...R INSTALLATION TAILGATE REMOVAL 1 Open the tailgate 2 Disconnect the tailgate check cables Fig 6 Refer to 23 BODY TAILGATE CHECK CABLE REMOVAL 3 Close tailgate until the notch in the right hand collar aligns with the pivot pin 4 Slip tailgate hinge collar from pivot pins 5 Slide tailgate to the right and separate left hand collar from the pivot pin 6 Separate tailgate from vehicle INSTALLATION 1 P...

Page 2313: ...TALLATION 27 SIDE VIEW MIRROR FLAG REMOVAL 27 INSTALLATION 27 DOOR REMOVAL 1 Disconnect the door wire harness electrical con nector at the A pillar Fig 1 2 Using a grease pencil or equivalent mark the outline of the door hinges on the door to aid in instal lation 3 Support the door with a suitable lifting device NOTE The epoxy bonded washers should not be seperated from the hinge If the washers ar...

Page 2314: ...oor to hinge fasteners it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool NOTE When the up down adjustments are done correctly the top of the door is positioned over flush to the roof Refer to 23 BODY BODY STRUC TURE GAP AND FLUSH SPECIFICATIONS 1 Support the door with a suitable lifting device 2 Loosen the latch striker bolts Refer to 23 BODY DOOR FRONT...

Page 2315: ... window opening 2 Engage the glass into the glass run weather strip 3 Raise the glass within the door opening and connect the window regulator to the lift plate 4 Install the nuts and tighten to 10 N m 89 in lbs 5 Install the inner belt molding Refer to 23 BODY WEATHERSTRIP SEALS FRONT DOOR INNER BELT WEATHERSTRIP INSTALLATION 6 Position the front run channel and install the screws Refer to 23 BOD...

Page 2316: ...3 Separate the glass run weatherstrip from the channel and remove the front channel REAR RUN CHANNEL 1 On standard cab models remove the screws from the side of the door Fig 5 2 On quad cab models remove the lower screw from the side of the door loosen the upper screw and disengage from the door Fig 6 3 Separate the glass run weatherstrip from the rear channel and remove the channel Fig 4 FRONT RU...

Page 2317: ...HINGE REMOVAL 1 Remove the door Refer to 23 BODY DOOR FRONT DOOR REMOVAL 2 Using a grease pencil or equivalent mark the hinge location and remove the bolts INSTALLATION 1 Install the hinges and bolts 2 Tighten bolts to 28 N m 21 ft lbs 3 Install the door Refer to 23 BODY DOOR FRONT DOOR INSTALLATION INSIDE HANDLE ACTUATOR REMOVAL 1 Remove the screw and remove the inside han dle Fig 7 2 Remove the ...

Page 2318: ...T LATCH INSTALLATION ADJUSTMENTS ADJUSTMENT 1 Locate access hole and remove the mylar tape covering it Fig 10 2 Insert a 5 32 inch hex wrench through hole and into adjustment screw Loosen screw 3 Operate outside handle several times to release any restriction because of mis alignment 4 Tighten adjustment screw to 3 N m 30 in lbs 5 Test handle for proper operation LATCH STRIKER REMOVAL 1 Using a gr...

Page 2319: ... HANDLE ACTUA TOR REMOVAL 3 Remove the screws at the mirror flag and near the inside handle Fig 12 CAUTION Trim panel is attached to the door using hooks molded into the panel Do not pull the trim panel straight off or damage to the panel and or power switch assembly may occur 4 Lift the trim panel up off the belt seal and attachment hooks and separate the panel from the door slightly 5 Disconnect...

Page 2320: ...e holes in the waterdam 2 Secure the waterdam to the inner door panel 3 Install the speaker Refer to 8 ELECTRICAL AUDIO SPEAKER INSTALLATION 4 Install the inside handle actuator Refer to 23 BODY DOOR FRONT INSIDE HANDLE ACTUA TOR INSTALLATION WINDOW REGULATOR POWER REMOVAL 1 Remove the waterdam Refer to 23 BODY DOOR FRONT WATERDAM REMOVAL 2 Remove the window switch from the door trim panel and rec...

Page 2321: ...ATOR MANUAL REMOVAL 1 Remove the waterdam Refer to 23 BODY DOOR FRONT WATERDAM REMOVAL 2 Reinstall the window handle and raise the win dow to the position shown and remove the nuts Fig 14 3 Disengage the door glass from the regulator lift plate and position into the full up position 4 Secure the glass in the up position using a wood wedge or equivalent 5 Lower the regulator 6 Remove the stabilizer...

Page 2322: ...ss nuts and tighten to 10 N m 89 in lbs 9 Remove the window handle and install the waterdam SIDE VIEW MIRROR FLAG REMOVAL 1 Remove the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL CAUTION Do not use a drill to remove the heat stakes 2 Remove the heat stakes using a razor knife or equivalent 3 Release the tabs and remove the mirror flag INSTALLATION NOTE Clean the excess heat stak...

Page 2323: ...epoxy bonded washers should not be seperated from the hinge If the washers are removed the door may have to be re adjusted 4 Remove the nuts and bolts attaching the door hinges to the door INSTALLATION 1 Support the door with a suitable lifting device and install the door onto the hinges 2 Install the bolts nuts and washers if there were removed previously and tighten to 28 N m 21 ft lbs 3 Connect...

Page 2324: ...hinge to hinge pillar fasteners Refer to 23 BODY DOORS REAR HINGE REMOVAL or loosen the hinge to door fasteners Refer to 23 BODY DOORS REAR DOOR REMOVAL 4 Adjust the door to the correct position Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS 5 Tighten to hinge pillar fasteners or the door to hinges fasteners and fasteners to 28 N m 21 ft lbs Refer to 23 BODY DOORS REAR HINGE INSTALLA...

Page 2325: ...equivalent 5 Install the glass run channels Refer to 23 BODY DOORS REAR GLASS RUN CHANNEL INSTALLATION EXTERIOR HANDLE REMOVAL 1 Remove the front glass run channel Refer to 23 BODY DOORS REAR GLASS RUN CHANNEL REMOVAL 2 Disconnect the latch actuator rod Fig 2 3 Remove the nuts and remove the handle INSTALLATION 1 Install the latch and install the nuts 2 Connect the latch actuator rod 3 Install the...

Page 2326: ...RIM REMOVAL 3 Remove the nut and bolt attaching the hinge to the door 4 Remove the two bolts attaching the hinge to the b pillar 5 From the inside of the vehicle remove the remaining bolt attaching the hinge to the b pillar and remove the hinge INSTALLATION UPPER HINGE 1 Install the hinge to door washers if there were removed previously nut and bolt and tighten to 28 N m 21 ft lbs 2 Install the th...

Page 2327: ...Remove the bolts Fig 7 5 Disconnect the electrical connector and remove the latch INSTALLATION 1 Connect the electrical connector and install the latch assembly 2 Install the bolts and tighten to 10 N m 89 in lbs 3 Connect the actuator rods 4 Adjust the latch as needed Refer to 23 BODY DOORS REAR LATCH ADJUSTMENTS 5 Install the waterdam Refer to 23 BODY DOORS REAR WATERDAM INSTALLATION Fig 5 INSID...

Page 2328: ... CATIONS 4 Tighten the bolts to 28 N m 21 ft lbs TRIM PANEL REMOVAL 1 Remove the window crank if equipped Fig 10 2 Remove the interior handle Refer to 23 BODY DOORS REAR INSIDE HANDLE ACTUA TOR REMOVAL 3 Remove the screw near the inside handle Fig 9 CAUTION Trim panel is attached to the door using hooks molded into the panel Do not pull the trim panel straight off or damage to the panel and or pow...

Page 2329: ...stabilizer nut 5 Disengage the door glass from the regulator lift plate and position into the full up position 6 Secure the glass in the up position using a wood wedge or equivalent 7 Lower the regulator 8 Disconnect the electrical connector Fig 12 9 Remove the lower regulator bolt and loosen the upper two Fig 12 10 Slide the regulator up and out of the keyhole slots in the door panel 11 Remove th...

Page 2330: ...1 Install the regulator through the hole in the inner door panel 2 Position the regulator bolts into the keyhole slots and slide into place 3 Install the back regulator bolts and tighten all four to 10 N m 89 in lbs 4 Position the stabilizer install the nuts and tighten to 10 N m 89 in lbs 5 Using the window handle raise the regulator to the position shown in Fig 11 6 Remove the glass support and ...

Page 2331: ... the top edge of the molding and to one end to use as a guide for installation if neces sary 2 If temperature is below 21 C 70 F warm molding with a heat lamp or gun Do not exceed 52 C 120 F when heating molding 3 Using a trim stick C 4755 or equivalent remove and discard the molding from the outside of the body panel INSTALLATION 1 Thoroughly clean all residue from the body side molding attachmen...

Page 2332: ...olts Fig 2 or Fig 3 4 Remove the cargo box INSTALLATION 1 Install the cargo box and install the bolts 2 Tighten the bolts to 108 N m 80 ft lbs 3 Connect the fuel fill and vent hoses Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL TANK INSTALLATION 4 Connect the tail lamp wire harness Fig 1 BODY ISOLATORS TYPICAL 1 CAB SILL 2 ISOLATORS 3 REBOUND CUSHION 4 WASHER REAR ISOLATOR ONLY 5 BOLTS 6 REINFORCEMEN...

Page 2333: ...a length of masking tape on the body parallel to the top edge and one end of the name plate to use as a guide for installation if necessary 2 If temperature is below 21 C 70 F warm emblem with a heat lamp or gun Do not exceed 52 C 120 F when heating name plate 3 Using a trim stick C 4755 or equivalent remove and discard the name plate INSTALLATION 1 Thoroughly clean all residue from the name plate...

Page 2334: ... to 9 N m 80 in lbs 4 Install the inside and lower bolts and tighten to 17 N m 13 ft lbs 5 Check the fender positioning and adjust as required by adding shims Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFI CATIONS 6 Install the wheelhouse splash shield Refer to 23 BODY EXTERIOR FRONT WHEELHOUSE SPLASH SHIELD INSTALLATION 7 Install the headlamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTE...

Page 2335: ...stall the six lower screws GRILLE FRAME REMOVAL 1 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL 2 Remove the screws and remove the grille frame Fig 9 INSTALLATION 1 Install the grille frame and install the six screws 2 Install the grille Refer to 23 BODY EXTERI OR GRILLE INSTALLATION Fig 8 GRILLE 1 NUTS 6 2 HOOD 3 GRILLE 4 GRILLE FRAME 5 SCREWS 6 Fig 9 GRILLE FRAME 1 HOOD 2 GRILLE FR...

Page 2336: ...SE SPLASH SHIELD REMOVAL 1 Remove the screws and remove the shield Fig 11 INSTALLATION 1 Install the splash shield and install the screws SIDE VIEW MIRROR REMOVAL 1 Remove the door trim panel as necessary to gain access to the mirror Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Disconnect the electrical connector and remove the nuts Fig 12 3 Squeeze the electrical connector tabs and remove the...

Page 2337: ...ll the radiator and condenser bolts and tighten to 8 N m 75 in lbs 4 Install the hood latch Refer to 23 BODY HOOD LATCH INSTALLATION SIDE VIEW MIRROR GLASS REMOVAL WARNING ALWAYS WEAR EYE AND HAND PRO TECTION WHEN SERVICING THE MIRROR ASSEM BLY FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY FROM BRO KEN GLASS Standard Mirror 1 Position the mirror glass so that it s facing in towar...

Page 2338: ... Position the mirror glass mounting holes over the four feet of the mirror motor and slide down Fig 22 3 Engage the lower glass retaining tab to the motor Fig 18 4 Position the rear housing cover and seat the retaining tabs fully Fig 17 Tow Package Mirror 1 Make sure the retaining clip is seated in the closed position on the mirror glass Fig 16 STANDARD MIRROR POSITION 1 RETAINING TABS 2 2 MIRROR ...

Page 2339: ...ve the two bolts at the front bottom edge 8 Remove the four inner nuts front edge Fig 25 9 Loosen bolts and loosen the two fender support brackets Fig 26 CAUTION Mask off the surrounding box area to avoid damage to the painted surfaces 10 Lift the fender up off the support brackets and remove the fender INSTALLATION CAUTION Mask off the surrounding box area to avoid damage to the painted surfaces ...

Page 2340: ...ctrical connec tors 7 Install the wheelhouse splash shield Refer to 23 BODY EXTERIOR REAR WHEELHOUSE SPLASH SHIELD INSTALLATION 8 Install the two nuts from within the tail lamp opening and tighten to 7 N m 60 in lbs 9 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION Fig 23 TAIL LAMP OPENING 1 TAIL LAMP OPENING 2 FENDER NUTS 2 Fig 24 LOWER REAR F...

Page 2341: ...fender remove the two hinge bolts Fig 2 8 Slide the hinge forward and remove from the fender rail INSTALLATION 1 Install the hinge and slide back into position on the fender rail 2 From inside the fender install the two hinge bolts and tighten to 20 N m 15 ft lbs 3 Install the hood nuts and line up the marks made previously 4 Tighten the nuts to 23 N m 17 ft lbs 5 Install the support cylinder Refe...

Page 2342: ...P AND FLUSH SPECIFICATIONS LATCH RELEASE CABLE HANDLE ASSEMBLY REMOVAL 1 Remove the hood latch Refer to 23 BODY HOOD LATCH REMOVAL 2 Remove the batter tray Refer to 8 ELECTRI CAL BATTERY SYSTEM TRAY REMOVAL 3 Disconnect the three cable push pin fasteners 4 From inside the cab loosen the two handle screws and disconnect the handle from the instru ment panel bracket 5 Separate the grommet at the cow...

Page 2343: ... supports from the middle while removing 3 Pulling at the ends only remove the support cylinder INSTALLATION 1 Make sure the retaining clips are seated into the ball socket fully CAUTION Do not install the support cylinders by pressing at the center of the cylinder Press the ends only 2 Install the support cylinder over the ball studs with the thin end connected to the body side of the hinge and t...

Page 2344: ...O DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the headlamp switch bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL SWITCH BEZEL REMOVAL 2 Remove the center bezel Refer to 23 BODY INSTRUMENT PANEL INSTRU...

Page 2345: ...ECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Open ash receiver and place hand inside Fig 2 2 Apply force with a...

Page 2346: ...VICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the center bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL REMOVAL 2 Remove the airbag control module trim cover Fig 4 3 Open the cupholder and fold down the inner panel 4 Remove the two inner scr...

Page 2347: ...ION 1 Engage the glove box hinges and partially close 2 From the inside of the box press down on the rearward edge of the bin and raise the glove box fully past the stops 3 Check for proper glove box operation GLOVE BOX LATCH REMOVAL 1 Remove the glove box Refer to 23 BODY IN STRUMENT PANEL GLOVE BOX REMOVAL 2 Remove the 11 screws and separate the box and inner panel from the outer door 3 Remove t...

Page 2348: ...Remove the instrument panel drivers side bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL DRIVERS SIDE BEZEL REMOVAL 9 Remove the left side mounting bolts Fig 8 10 Disconnect the wire harness electrical connec tors above the brake pedal Fig 9 11 Loosen the screws and remove the hood release handle from the bracket 12 Disconnect the park brake release handle actuator rod 13 Remove the air b...

Page 2349: ...one HVAC screw Fig 13 21 Using a trim stick C 4755 or equivalent from the notch on the bottom remove the right end cap Fig 14 22 Remove the right a pillar trim Refer to 23 BODY INTERIOR A PILLAR TRIM GRAB HANDLE REMOVAL Fig 10 CENTER MOUNTING BOLTS 1 INSTRUMENT PANEL 2 BOLTS Fig 11 RIGHT WIRE HARNESS CONNECTIONS 1 COWL SIDE PANEL 2 ELECTRICAL CONNECTORS Fig 12 ANTENNA CONNECTION 1 ANTENNA CABLE 2 ...

Page 2350: ...ERSONAL INJURY 1 Position the instrument panel assembly in vehicle 2 Route the park brake release rod through the instrument panel Fig 16 3 Install the instrument panel onto the left side guide pin and the right side guide hook 4 Install the left side mounting bolts and tighten to 12 N m 9 ft lbs 5 Install the instrument panel drivers side bezel Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ...

Page 2351: ... to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER INSTALLATION INSTRUMENT PANEL HEADLAMP SWITCH BEZEL REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AI...

Page 2352: ...or if the center bezel is not being com pletely removed from the instrument panel 5 Using a trim stick C 4755 or equivalent gently pry the center bezel free from the instrument panel 6 Working behind the center bezel disconnect all electrical connectors and remove the bezel INSTALLATION WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERI...

Page 2353: ...TES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Position the bezel onto the lower hooks and lift up 2 Connect the adjustable pedal switch electrical connector if equipped 3 Seat the ...

Page 2354: ...r to 23 BODY INTERIOR COWL TRIM REMOVAL 3 Remove the glove box Refer to 23 BODY IN STRUMENT PANEL GLOVE BOX REMOVAL 4 Remove the cup holder if equipped Refer to 23 BODY INSTRUMENT PANEL CUP HOLDER REMOVAL 5 Remove the storage bin if equipped Refer to 23 BODY INSTRUMENT PANEL STORAGE BIN REMOVAL 6 Remove the ash receiver Refer to 23 BODY INSTRUMENT PANEL ASH RECEIVER REMOVAL 7 Remove the steering c...

Page 2355: ...lips and remove the cover INSTALLATION WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SER...

Page 2356: ...e four screws and remove the bin Fig 23 INSTALLATION WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DI...

Page 2357: ...RT BRACKET 70 SUN VISOR REMOVAL 70 INSTALLATION 70 SUN VISOR SUPPORT REMOVAL 70 INSTALLATION 71 BODY VENT REMOVAL 71 INSTALLATION 71 REAR DOOR SILL TRIM COVER REMOVAL 71 INSTALLATION 71 LOAD FLOOR REMOVAL 71 INSTALLATION 72 LOAD FLOOR SUPPORT CYLINDER REMOVAL 72 INSTALLATION 72 INTERIOR CAUTION CAUTION Do not attempt to remove interior trim panels moldings without first removing the neces sary adj...

Page 2358: ...lar trim Refer to 23 BODY INTERIOR B PILLAR UPPER TRIM REMOVAL 2 Remove the cowl trim Refer to 23 BODY IN TERIOR COWL TRIM REMOVAL STANDARD CAB 1 Remove the shoulder belt anchor bolt 2 Using a trim stick C 4755 or equivalent remove the lower b pillar trim Fig 4 QUAD CAB 1 Remove the rear door sill trim Refer to 23 BODY INTERIOR REAR DOOR SILL TRIM COVER REMOVAL 2 Using a trim stick C 4755 or equiv...

Page 2359: ...AR UPPER TRIM REMOVAL 1 Remove the seat belt turning loop Refer to 8 ELECTRICAL RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER REMOVAL 2 Open the trim plugs and remove the grab han dle bolts if equipped Fig 6 3 Using a trim stick C 4755 or equivalent remove the upper b pillar trim Fig 7 or Fig 8 INSTALLATION 1 Position the upper b pillar trim and seat the attachment clips fully 2 Install the grab hand...

Page 2360: ...nstall the rear cup holder if equipped 4 Install the lower b pillar trim Refer to 23 BODY INTERIOR B PILLAR LOWER TRIM INSTALLATION 5 On quad cab models install the lower seatbelt anchor bolt next to the b pillar and tighten to 40 N m 30 ft lbs 6 Install the floor console if equipped Refer to 23 BODY INTERIOR FLOOR CONSOLE INSTAL LATION 7 Install the rear seats if equipped Refer to 23 BODY SEATS S...

Page 2361: ...m and seat the attachment clips fully C PILLAR LOWER TRIM REMOVAL 1 Remove the upper c pillar trim Refer to 23 BODY INTERIOR C PILLAR TRIM REMOVAL 2 Remove the seat belt anchor bolt Fig 11 3 Using a trim stick C 4755 or equivalent remove the lower c pillar trim 4 Pull seat belt out of the trim panel through the slot provided Fig 9 COAT HOOK 1 COAT HOOK 2 RELEASE CLIP 3 HEADLINER Fig 10 COWL SILL T...

Page 2362: ...boot Refer to 23 BODY INTERIOR 4WD FLOOR SHIFT BOOT REMOVAL 2 Using a trim stick C 4755 or equivalent pry up the transmission shifter boot from the console 3 Remove the transmission shifter extension 4 Remove the console inserts Fig 12 5 Remove and discard the three bolts Fig 13 6 Lift up on the back and remove the console INSTALLATION 1 Position the front of the console up under the instrument pa...

Page 2363: ...h mounted stop light electrical connector 4 Install the sun visor supports Refer to 23 BODY INTERIOR SUN VISOR SUPPORT INSTAL LATION 5 Install the coat hooks Refer to 23 BODY IN TERIOR COAT HOOK INSTALLATION 6 Install the sun visors Refer to 23 BODY IN TERIOR SUN VISOR INSTALLATION 7 Install the overhead console Refer to 8 ELECTRICAL OVERHEAD CONSOLE INSTALLA TION 8 Install the dome lamp Refer to ...

Page 2364: ...ION 4 On quad cab models install the left lower c pil lar trim panel Refer to 23 BODY INTERIOR C PILLAR TRIM INSTALLATION 5 Position the center belt trim bezel if equipped and seat the attachment clips fully 6 Install the utility hooks bin latch and screws if equipped 7 Install the child seat tethers if equipped Refer to 8 ELECTRICAL RESTRAINTS CHILD TETHER INSTALLATION REAR VIEW MIRROR REMOVAL 1 ...

Page 2365: ... on the windshield glass Allow the accel erator to dry for one minute Do not touch the glass contact surface after the accelerator has been applied 6 Install the bracket according to the following instructions a Apply one drop of adhesive at the center of the bracket contact surface on the windshield glass b Apply an even coat of adhesive to the contact surface on the bracket c Align the bracket w...

Page 2366: ...all the cab back panel trim Refer to 23 BODY INTERIOR REAR CAB BACK PANEL TRIM INSTALLATION REAR DOOR SILL TRIM COVER REMOVAL 1 Using a trim stick C 4755 or equivalent pry up the sill trim and remove Fig 21 INSTALLATION 1 Position the sill trim and seat the attachment clips fully LOAD FLOOR REMOVAL 1 Fold the rear seat cushion up 2 Remove the rear nuts in each corner Fig 22 3 Fold the load floor u...

Page 2367: ...pen the load floor 2 Remove the snap clips and retaining pins Fig 24 3 Remove the support cylinder INSTALLATION 1 Install the support cylinder with the thin end down 2 Install the retaining pins and clips Fig 23 REAR LOAD FLOOR TYPICAL 1 REAR STORAGE BIN 2 LOAD FLOOR 3 BOLTS 2 4 SUPPORT CYLINDER Fig 24 LOAD FLOOR SUPPORT CYLINDER 1 RETAINING PINS CLIPS 2 2 LOAD FLOOR 3 SUPPORT CYLINDER 23 72 INTER...

Page 2368: ...W7 Timberline Green AGW INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER CODE Taupe L5 Dark Slate Gray DV PAINT CODE DESCRIPTION Exterior vehicle body colors are identified on the Vehicle Certification Label Refer to VEHICLE DATA VEHICLE INFORMATION VEHICLE CERTI FICATION LABEL DESCRIPTION or the Body Code Plate Refer to VEHICLE DATA VEHICLE INFORMATION BODY CODE PLATE DESCRIP TION The first digit o...

Page 2369: ...int Do not overlap touch up color onto the original color coat around the scratch or chip Butt the new color to the original color if possible Do not stroke applicator brush on body surface Allow touch up paint to dry hard 5 On vehicles without clearcoat the touch up color can be lightly finesse sanded 1500 grit and polished with rubbing compound 6 On vehicles with clearcoat apply clear top coat t...

Page 2370: ... BEZEL REMOVAL 82 INSTALLATION 82 SEAT BACK CUSHION COVER FRONT REMOVAL 82 INSTALLATION 82 SEAT CUSHION COVER FRONT REMOVAL 83 INSTALLATION 83 SEAT TRACK REMOVAL 83 INSTALLATION 83 SEAT REAR REMOVAL 83 INSTALLATION 83 SEAT BACK REAR REMOVAL 83 INSTALLATION 83 SEAT BACK CUSHION COVER REAR REMOVAL 84 INSTALLATION 84 SEAT CUSHION COVER REAR REMOVAL 84 INSTALLATION 84 SEAT CUSHION FRAME REAR REMOVAL 8...

Page 2371: ...new front bolts and tighten to 28 N m 21 ft lbs CENTER ARMREST SEAT BACK REMOVAL NOTE Do not reuse the seat fasteners always replace with new ones 1 Remove the center seat Refer to 23 BODY SEATS SEAT CENTER REMOVAL 2 Disconnect the storage bin cushion cover j straps and position aside 3 Remove and discard the hinge bolts and sepa rate the seat back from the storage bin cushion Fig 4 Fig 1 FRONT SE...

Page 2372: ...or the inertia hinge cover disconnect the zip strip Fig 5 2 Position aside the storage bin cushion cover 3 Remove the pivot bolt 4 Open the hinge cover at the bottom and remove the hinge cover Fig 6 INSTALLATION NOTE Free pivot hinge cover is installed with the free pivot hinge Refer to 23 BODY SEATS CEN TER SEAT BACK HINGE INSTALLATION Fig 4 CENTER SEAT BACK HINGES 1 STORAGE BIN CUSHION COVERING ...

Page 2373: ...1 Disconnect the storage bin cushion cover j strap and position aside 2 Remove and discard the pivot bolt Fig 7 3 Remove the hinge spacer Fig 8 4 Open the hinge cover flap and remove the wire harness if equipped Fig 9 5 Remove the cover from the hinge Fig 7 PIVOT HINGE COVER 1 PIVOT BOLT 2 HINGE COVER 3 STORAGE BIN COVER 4 12V POWER SUPPLY HARNESS 5 HINGE BOLTS 2 6 HINGE Fig 8 PIVOT HINGE SPACER 1...

Page 2374: ...1 Open the center armrest seat back 2 Remove the four screws attaching the hinge to the storage bin cushion and remove the lid INSTALLATION 1 Position the center seat back lid onto the stor age bin cushion and install the screws CENTER SEAT CUSHION REMOVAL 1 Remove the center seat Refer to 23 BODY SEATS CENTER SEAT REMOVAL 2 Remove the center armrest seat back Refer to 23 BODY SEATS CENTER ARMREST...

Page 2375: ... Install the center seat cushion Refer to 23 BODY SEATS CENTER SEAT CUSHION INSTAL LATION UNDER SEAT STORAGE BIN COVERING REMOVAL 1 Remove the under seat storage bin Refer to 23 BODY SEATS UNDER SEAT STORAGE BIN REMOVAL 2 Disconnect the j straps and remove the cover INSTALLATION 1 Install the storage bin cover and connect the j straps 2 Install the under seat storage bin Refer to 23 BODY SEATS UND...

Page 2376: ...ped Fig 13 4 Fold the seat backs forward and roll the seat assembly back in the vehicle 5 Separate the seat assembly by removing and discarding the three nuts on either the drivers or passengers seat Fig 14 6 Remove each section of the seat assembly from the vehicle INSTALLATION NOTE Do not reuse the seat fasteners always replace with new ones 1 Position each seat section into the vehicle and tip ...

Page 2377: ...nto the shaft of the drive mechanism into the bezel surround SEAT BACK CUSHION COVER FRONT REMOVAL 1 Remove the front seat Refer to 23 BODY SEATS SEAT FRONT REMOVAL 2 Remove the lumbar handle and bezel if equipped Refer to 23 BODY SEATS LUMBAR SUPPORT HANDLE BEZEL REMOVAL 3 Remove the headrest sleeves Refer to 23 BODY SEATS HEADREST SLEEVE REMOVAL 4 Unzip the zip strip at the lower end of the seat...

Page 2378: ...o the seat and remove the track INSTALLATION 1 Position the seat track onto the seat and install the four nuts 2 Tighten the four nuts to 25 N m 18 ft lbs 3 Connect the heated seat electrical connectors if equipped 4 Install the seat Refer to 23 BODY SEATS SEAT FRONT INSTALLATION SEAT REAR REMOVAL 1 Remove the load floor Refer to 23 BODY IN TERIOR LOAD FLOOR REMOVAL 2 Fold the rear seat cushions u...

Page 2379: ...at back Refer to 23 BODY SEATS SEAT BACK REAR INSTALLATION SEAT CUSHION COVER REAR REMOVAL 1 Remove the rear seat Refer to 23 BODY SEATS SEAT REAR REMOVAL 2 Separate the zip strip at the rear of the seat cushion and remove the cushion and cover INSTALLATION 1 Install the seat cushion and cover over the cushion frame assembly and connect the zip strip 2 Install the seat Refer to 23 BODY SEATS SEAT ...

Page 2380: ...SHION COVER REAR INSTALLATION SEAT BACK REAR FOOTMANS LOOP BRACKETS REMOVAL 1 Remove the rear seat Refer to 23 BODY SEATS SEAT REAR REMOVAL 2 Remove bolts and remove the loop Fig 21 INSTALLATION 1 Install the loop and install the bolts 2 Tighten the bolts to 12 N m 9 ft lbs 3 Install the seat Refer to 23 BODY SEATS SEAT REAR INSTALLATION Fig 20 SEAT CUSHION FRAME ATTACHMENT 1 REAR SEAT BACK 2 REAR...

Page 2381: ...INTERIOR C PILLAR UPPER TRIM REMOVAL 5 Bend backlite retaining tabs Fig 1 inward against glass 6 Disconnect the rear window defogger electrical connector if equipped 7 Using a suitable pneumatic knife from inside the vehicle cut urethane holding backlite frame to opening fence 8 Separate glass from vehicle INSTALLATION 1 Clean urethane adhesive from around backlite opening fence 2 If necessary app...

Page 2382: ... the vent glass upward to remove from the lower window frame 3 Lower the glass out of the upper window frame and remove INSTALLATION 1 Slide the vent glass upper edge into window frame and insert the lower edge into the lower mold ing 2 Position the upper run channel into the win dow frame and slide it into place 3 Verify vent glass operation Fig 2 Urethane Adhesive Application 1 WINDOW FRAME 2 GL...

Page 2383: ...inside of the vehicle cut the upper urethane bonding from around windshield upper edge using a suitable sharp cold knife C 4849 A pneumatic cutting device can be used but is not recommended Refer to 23 BODY INTERIOR HEADLINER REMOVAL 6 From the outside of the vehicle cut urethane bonding from the remaining sides of the windshield using a suitable sharp cold knife C 4849 A pneu matic cutting device...

Page 2384: ...cers 12 Slowly lower windshield glass to the fence opening guiding the lower corners into proper posi tion Beginning at the bottom and continuing to the top push glass onto fence along the A Pillars Push windshield inward to the fence at the bottom corners Fig 9 13 Push windshield upward setting the wind shield to roof gap to 1 5 mm 0 06 in to 3 mm 0 12 in and ratchet up the adjustable support bra...

Page 2385: ... 2 SPACER LOCATION 75 MM 2 95 IN 3 LOWER FOAM SPACERS 3 4 SIDE FOAM SPACERS 4 Fig 8 APPLICATOR TIP 1 APPLICATOR TIP Fig 9 LOWER WINDSHIELD INTO POSITION 1 COMPRESSION SPACER 2 WINDSHIELD 3 ADJUSTABLE SUPPORT SPACERS 23 90 STATIONARY GLASS DR WINDSHIELD Continued ...

Page 2386: ... 1 Remove the drip rail weatherstrip retainer Refer to 23 BODY WEATHERSTRIP SEALS DRIP RAIL WEATHERSTRIP REMOVAL 2 Remove the five screws and remove the weath erstip retainer Fig 1 INSTALLATION 1 Install the weatherstip retainer and install the screws 2 Install the drip rail weatherstrip retainer Refer to 23 BODY WEATHERSTRIP SEALS DRIP RAIL WEATHERSTRIP INSTALLATION DRIP RAIL WEATHERSTRIP REMOVAL...

Page 2387: ... and work around the perimeter of the door opening until fully seated Work in one direction smoothing the seal to avoid puckers or wrinkles 2 Install the lower c pillar trim Refer to 23 BODY INTERIOR C PILLAR TRIM INSTALLA TION 3 Install the lower b pillar trim Refer to 23 BODY INTERIOR B PILLAR LOWER TRIM INSTALLATION 4 When installing a new weatherstrip on the rear door opening remove the tear s...

Page 2388: ...ough the window opening Fig 4 INSTALLATION NOTE A mixture of soap and water may be used to aid installation of the weatherstrip into the corners 1 Position the glass run weatherstrip into the door through the window opening 2 Position the weatherstrip into the upper cor ners and seat firmly 3 From back to front seat the weatherstrip between the corners and then down the sides firmly REAR DOOR OUTE...

Page 2389: ...e back to the front Fig 5 INSTALLATION 1 Position the belt molding and seat onto the mounting flange fully 2 Install the door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLA TION Fig 4 REAR DOOR GLASS SEALS 1 OUTER BELT MOLDING 2 REAR DOOR 3 SCREW 4 LOWER DOOR SEAL 5 GLASS RUN WEATHERSTRIP Fig 5 REAR DOOR INNER SEALS 1 REAR SECONDARY SEAL 2 INNER BELT MOLDING 3 FRONT SECONDARY SEAL 4 SC...

Page 2390: ...PECIFICATIONS BODY OPENING DIMENSIONS 99 SEALER LOCATIONS SPECIFICATIONS 102 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS 112 WELD LOCATIONS SPECIFICATIONS 120 GAP AND FLUSH SPECIFICATIONS GAP FLUSH DIMENSIONS INDEX DESCRIPTION FIGURE STANDARD CAB 1 QUAD CAB 2 PICKUP BOX 3 DR BODY STRUCTURE 23 95 ...

Page 2391: ... door to windshield O F 20 5 1 5 Base of windshield O F 9 0 1 5 Top of windshield 6 Roof to front door U F 6 0 1 5 Parallel within 1 5 7 Quarter to front door 5 0 1 5 Parallel within 1 0 0 0 1 5 8 Front door to quarter character line alignment Up Down 0 0 1 5 9 Front door to fender character line alignment Up Down 0 0 1 5 10 Front door to fender 5 0 1 5 Parallel within 1 0 0 0 1 5 11 Bumper to fen...

Page 2392: ... within 1 5 2 Quarter to rear door 5 0 1 5 Parallel within 2 0 0 0 1 5 3 Rear door to quarter character line alignment Up Down 0 0 1 5 4 Rear door to front door character line alignment Up Down 0 0 1 5 5 Rear door to front door 5 0 1 5 Parallel within 2 0 0 0 1 5 Fig 2 GAP FLUSH QUAD CAB DR BODY STRUCTURE 23 97 GAP AND FLUSH Continued ...

Page 2393: ...0 0 1 5 4 Cab to box side 31 0 5 0 Parallel within 3 0 4 0 2 5 Standard Cab O F 5 0 2 5 Quad Cab 5 Cab to box character line alignment Up Down 0 0 3 0 6 Tailgate to outer box 5 0 2 0 Parallel within 1 0 U F 1 5 1 5 7 Bumper to outer box 24 75 5 0 F A 23 75 5 0 C C Parallel within 5 0 8 Tailgate to outer box character line adjustment Up Down 0 0 1 5 9 Bumper to tailgate 30 25 3 0 Parallel within 4 ...

Page 2394: ...NS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 4 DOOR OPENING STANDARD CAB 5 DOOR OPENINGS QUAD CAB 6 REAR WINDOW OPENING 7 ENGINE COMPARTMENT FRONT STRUCTURE 8 Fig 4 WINDSHIELD OPENING DR BODY STRUCTURE 23 99 ...

Page 2395: ...Fig 5 DOOR OPENING STANDARD CAB Fig 6 DOOR OPENINGS QUAD CAB 23 100 BODY STRUCTURE DR OPENING DIMENSIONS Continued ...

Page 2396: ...Fig 7 REAR WINDOW OPENING Fig 8 ENGINE COMPARTMENT FRONT STRUCTURE DR BODY STRUCTURE 23 101 OPENING DIMENSIONS Continued ...

Page 2397: ... DASH PANEL LOWER COWL SIDE AND FLOOR PAN SUPPORT 11 ROOF PANEL OUTER BODY SIDE APERTURE AND BACKLITE 12 CAB BACK BODY SIDE APERTURE REAR AND BACKLITE LOWER CORNER 13 LOWER DASH PANEL AND FLOOR PAN 14 FLOOR PAN AND BODY SIDE APERTURE 15 FRONT FLOOR PAN AND REAR PAN 16 FLOOR PAN TO CAB BACK 17 PICKUP BOX 18 Fig 9 LOWER WINDSHIELD PILLAR 23 102 BODY STRUCTURE DR ...

Page 2398: ...Fig 10 DASH PANEL DR BODY STRUCTURE 23 103 SEALER LOCATIONS Continued ...

Page 2399: ...Fig 11 LOWER DASH PANEL 23 104 BODY STRUCTURE DR SEALER LOCATIONS Continued ...

Page 2400: ...Fig 12 ROOF PANEL DR BODY STRUCTURE 23 105 SEALER LOCATIONS Continued ...

Page 2401: ...Fig 13 CAB BACK PANEL 23 106 BODY STRUCTURE DR SEALER LOCATIONS Continued ...

Page 2402: ...Fig 14 LOWER DASH PANEL DR BODY STRUCTURE 23 107 SEALER LOCATIONS Continued ...

Page 2403: ...Fig 15 FLOOR PAN 23 108 BODY STRUCTURE DR SEALER LOCATIONS Continued ...

Page 2404: ...Fig 16 FRONT FLOOR PAN DR BODY STRUCTURE 23 109 SEALER LOCATIONS Continued ...

Page 2405: ...Fig 17 FLOOR PAN 23 110 BODY STRUCTURE DR SEALER LOCATIONS Continued ...

Page 2406: ...Fig 18 PICKUP BOX DR BODY STRUCTURE 23 111 SEALER LOCATIONS Continued ...

Page 2407: ...OX SIDE PANEL 23 INNER WHEELHOUSE CROSSMEMBERS AND CROSSMEMBER END SUPPORT BRACKET TO INNER BOX SIDE PANEL 24 INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL 25 INNER DOOR PANEL TO OUTER DOOR PANEL FRONT DOOR QUAD CAB 26 INNER DOOR PANEL TO OUTER DOOR PANEL FRONT DOOR STANDARD CAB 27 INNER DOOR PANEL TO OUTER DOOR PANEL REAR DOOR QUAD CAB 28 SILL RAIL STD CAB 29 SILL RAIL QUAD CAB 30 Fig 19 FLOOR PAN...

Page 2408: ...Fig 20 FRONT FENDER Fig 21 FLOOR PAN DR BODY STRUCTURE 23 113 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2409: ...Fig 22 INNER WHEELHOUSE Fig 23 INNER BOX SIDE PANEL 23 114 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2410: ...Fig 24 INNER WHEELHOUSE Fig 25 INNER BOX SIDE PANEL DR BODY STRUCTURE 23 115 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2411: ...Fig 26 INNER DOOR PANEL Fig 27 INNER DOOR PANEL 23 116 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2412: ...Fig 28 REAR DOOR INNER PANEL DR BODY STRUCTURE 23 117 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2413: ...Fig 29 SILL RAIL STD CAB 23 118 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2414: ...Fig 30 SILL RAIL QUAD CAB DR BODY STRUCTURE 23 119 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 2415: ... 40 REINFORCEMENT AND HEADLAMP MOUNTING PANEL TO OUTER FENDER PANEL 41 SEAT MOUNTING FRONT BRACKETS TO SEAT MOUNTING FRONT CROSSMEMBER TO FRONT FLOOR PAN 42 AIR BAG MODULE BRACKET SHIFTER MOUNTING PLATE AND REAR FLOOR PANE TO FRONT FLOOR PAN 43 RIGHT TO LEFT REAR FLOOR CROSSMEMBER AND RIGHT TO LEFT SEAT MOUNTING CROSSMEMBER 44 REAR FLOOR CROSSMEMBER SEAT MOUNTING CROSSMEMBER AND UNDERBODY SUPPORT ...

Page 2416: ...UTER BODY SIDE APERTURE TO A PILLAR REINFORCEMENT 66 OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE 67 B PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 68 UPPER B PILLAR TAPPING PLATE AND LOWER B PILLAR TAPPING PLATE TO OUTER BODY SIDE APERTURE 69 UPPER A PILLAR TAPPING PLATE AND LOWER A PILLAR TAPPING PLATE TO INNER BODY SIDE APERTURE 70 SEAT BELT MOUNTING PLAT...

Page 2417: ...KETS TO REAR CROSS BOX SILL FRONT WHEELHOUSE LONG AND BRACKET SUPPORT CROSSMEMBERS 93 STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER BOX SIDE PANEL 94 OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE PANEL MOUNTING 95 OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL 96 WELD NUT STRIKER CAGE NUT OUTER BOX SIDE PANEL AND NUT PLATE TO BOX SIDE TAILGATE REINFORCEMENT 97 FRONT...

Page 2418: ...E PANEL TO BOX FRONT PANEL 117 BOX FRONT PANEL TO BOX FLOOR PANEL 118 BOX FLOOR PANEL TO INNER BOX SIDE PANEL 119 LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER BOX SIDE PANEL 120 INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 121 TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER BOX SIDE PANEL 122 REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX S...

Page 2419: ...Fig 31 FENDER BRACE 23 124 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2420: ...Fig 32 STEERING COLUMN SUPPORT DR BODY STRUCTURE 23 125 WELD LOCATIONS Continued ...

Page 2421: ...Fig 33 WIPER ATTACHING WELD NUTS Fig 34 DASH PANEL 23 126 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2422: ...Fig 35 DASH PANEL Fig 36 LOWER PLENUM PANEL DR BODY STRUCTURE 23 127 WELD LOCATIONS Continued ...

Page 2423: ...Fig 37 FRONT FENDER Fig 38 DASH PANEL 23 128 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2424: ...Fig 39 FRONT FENDER Fig 40 DASH PANEL DR BODY STRUCTURE 23 129 WELD LOCATIONS Continued ...

Page 2425: ...Fig 41 HEADLAMP MOUNTING PANEL 23 130 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2426: ...Fig 42 SEAT MOUNTING FRONT BRACKETS STANDARD CAB DR BODY STRUCTURE 23 131 WELD LOCATIONS Continued ...

Page 2427: ...Fig 43 AIR BAG MODULE BRACKET STANDARD CAB 23 132 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2428: ...Fig 44 001 RIGHT TO LEFT REAR FLOOR CROSSMEMBER STANDARD CAB DR BODY STRUCTURE 23 133 WELD LOCATIONS Continued ...

Page 2429: ...Fig 45 REAR FLOOR CROSSMEMBER STANDARD CAB 23 134 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2430: ...Fig 46 SEAT MOUNTING FRONT CROSSMEMBER STANDARD CAB DR BODY STRUCTURE 23 135 WELD LOCATIONS Continued ...

Page 2431: ...Fig 47 FRONT SEAT MOUNTING CROSSMEMBERS STANDARD CAB Fig 48 REAR FLOOR CROSSMEMBERS STANDARD CAB 23 136 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2432: ...Fig 49 FLOOR SILL STANDARD CAB DR BODY STRUCTURE 23 137 WELD LOCATIONS Continued ...

Page 2433: ...Fig 50 AIR BAG MODULE BRACKET QUAD CAB 23 138 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2434: ...Fig 51 REAR SEAT MIDDLE MOUNTING PLATE QUAD CAB DR BODY STRUCTURE 23 139 WELD LOCATIONS Continued ...

Page 2435: ...Fig 52 REAR FLOOR CROSSMEMBER QUAD CAB 23 140 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2436: ...Fig 53 002 LEFT REAR CROSSMEMBER QUAD CAB Fig 54 STORAGE BIN QUAD CAB DR BODY STRUCTURE 23 141 WELD LOCATIONS Continued ...

Page 2437: ...Fig 55 RIGHT REAR FRONT SEAT MOUNTING CROSSMEMBER QUAD CAB 23 142 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2438: ...Fig 56 FRONT SEAT MOUNTING FRONT CROSSMEMBER QUAD CAB DR BODY STRUCTURE 23 143 WELD LOCATIONS Continued ...

Page 2439: ...Fig 57 FRONT SEAT MOUNTING FRONT CROSSMEMBER 23 144 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2440: ...Fig 58 A PILLAR REINFORCEMENT STANDARD CAB DR BODY STRUCTURE 23 145 WELD LOCATIONS Continued ...

Page 2441: ...Fig 59 A PILLAR REINFORCEMENT STANDARD CAB Fig 60 INNER BODY SIDE APERTURE STANDARD CAB 23 146 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2442: ...Fig 61 SHOULDER BELT REINFORCEMENT STANDARD CAB Fig 62 FRONT PILLAR TAPPING PLATES STANDARD CAB DR BODY STRUCTURE 23 147 WELD LOCATIONS Continued ...

Page 2443: ...Fig 63 INNER BODY SIDE APERTURE STANDARD CAB Fig 64 C PILLAR BAFFLE QUAD CAB 23 148 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2444: ...Fig 65 A PILLAR REINFORCEMENT QUAD CAB Fig 66 003 FRONT EXTENSION PLATE QUAD CAB DR BODY STRUCTURE 23 149 WELD LOCATIONS Continued ...

Page 2445: ...Fig 67 OUTER BODY SIDE APERTURE QUAD CAB Fig 68 B PILLAR REINFORCEMENT QUAD CAB 23 150 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2446: ...Fig 69 UPPER TAPPING PLATE QUAD CAB Fig 70 UPPER A PILLAR TAPPING PLATE QUAD CAB DR BODY STRUCTURE 23 151 WELD LOCATIONS Continued ...

Page 2447: ...Fig 71 SEAT BELT MOUNTING PLATES QUAD CAB Fig 72 OUTER BODY SIDE APERTURE QUAD CAB 23 152 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2448: ...Fig 73 C PILLAR REINFORCEMENT QUAD CAB Fig 74 SEAT BELT RETRACTOR PLATE STANDARD CAB DR BODY STRUCTURE 23 153 WELD LOCATIONS Continued ...

Page 2449: ...Fig 75 FLOOR SILL STANDARD CAB 23 154 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2450: ...Fig 76 BACK REINFORCEMENT STANDARD CAB DR BODY STRUCTURE 23 155 WELD LOCATIONS Continued ...

Page 2451: ...Fig 77 004 CAB BACK REINFORCEMENT STANDARD CAB 23 156 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2452: ...Fig 78 COWL SIDE PANEL STANDARD CAB Fig 79 OUTER ROOF PANEL STANDARD CAB DR BODY STRUCTURE 23 157 WELD LOCATIONS Continued ...

Page 2453: ...Fig 80 FRONT ROOF HEADER STANDARD CAB Fig 81 REAR ROOF HEADER STANDARD CAB 23 158 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2454: ...Fig 82 OUTER BODY SIDE APERTURE QUAD CAB DR BODY STRUCTURE 23 159 WELD LOCATIONS Continued ...

Page 2455: ...Fig 83 OUTER BODY SIDE APERTURE QUAD CAB 23 160 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2456: ...Fig 84 REAR FLOOR CROSSMEMBER QUAD CAB DR BODY STRUCTURE 23 161 WELD LOCATIONS Continued ...

Page 2457: ...Fig 85 CAB BACK REINFORCEMENT QUAD CAB 23 162 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2458: ...Fig 86 CENTER SHOULDER BELT REINFORCEMENT QUAD CAB DR BODY STRUCTURE 23 163 WELD LOCATIONS Continued ...

Page 2459: ...Fig 87 A PILLAR REINFORCEMENT QUAD CAB 23 164 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2460: ...Fig 88 B PILLAR REINFORCEMENT QUAD CAB DR BODY STRUCTURE 23 165 WELD LOCATIONS Continued ...

Page 2461: ...Fig 89 FRONT ROOF HEADER QUAD CAB 23 166 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2462: ...Fig 90 INNER BODY SIDE APERTURE QUAD CAB DR BODY STRUCTURE 23 167 WELD LOCATIONS Continued ...

Page 2463: ...Fig 91 FRONT CROSSMEMBER SHORT CARGO BOX ONLY 23 168 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2464: ...Fig 92 LONG CROSSMEMBER SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 169 WELD LOCATIONS Continued ...

Page 2465: ...Fig 93 TAPPING PLATES SHORT CARGO BOX ONLY 23 170 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2466: ...Fig 94 STAKE POCKET REINFORCEMENTS SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 171 WELD LOCATIONS Continued ...

Page 2467: ...Fig 95 OUTER BOX SIDE REINFORCEMENT BRACES SHORT CARGO BOX ONLY Fig 96 OUTER WHEELHOUSE SHORT CARGO BOX ONLY 23 172 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2468: ...Fig 97 005 WELD NUT SHORT CARGO BOX ONLY SHORT CARGO BOX ONLY Fig 98 FRONT BOX PANEL SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 173 WELD LOCATIONS Continued ...

Page 2469: ...Fig 99 FRONT CROSSMEMBER SHORT CARGO BOX ONLY Fig 100 BOX FLOOR PANEL SHORT CARGO BOX ONLY 23 174 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2470: ...Fig 101 FRONT CROSSMEMBER SHORT CARGO BOX ONLY Fig 102 STAKE POCKET REINFORCEMENT SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 175 WELD LOCATIONS Continued ...

Page 2471: ...Fig 103 INNER TAILGATE PILLAR PANEL SHORT CARGO BOX ONLY Fig 104 BOX FLOOR SILL CROSSMEMBER SHORT CARGO BOX ONLY 23 176 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2472: ...Fig 105 INNER TAILGATE PILLAR SHORT CARGO BOX ONLY Fig 106 006 BOX SIDE PANEL SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 177 WELD LOCATIONS Continued ...

Page 2473: ...Fig 107 FRONT BOX PANEL SHORT CARGO BOX ONLY Fig 108 INNER BOX SIDE PANEL SHORT CARGO BOX ONLY 23 178 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2474: ...Fig 109 OUTER WHEELHOUSE PANEL SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 179 WELD LOCATIONS Continued ...

Page 2475: ...Fig 110 007 FRONT CROSSMEMBER LONG CARGO BOX ONLY 23 180 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2476: ...Fig 111 008 WHEELHOUSE CROSSMEMBER LONG CARGO BOX ONLY DR BODY STRUCTURE 23 181 WELD LOCATIONS Continued ...

Page 2477: ...Fig 112 FRONT AND CENTER STAKE POCKET REINFORCEMENTS LONG CARGO BOX ONLY Fig 113 OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT LONG CARGO BOX ONLY 23 182 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2478: ...Fig 114 OUTER WHEELHOUSE LONG CARGO BOX ONLY Fig 115 TAILGATE BOX SIDE PIVOT REINFORCEMENT LONG CARGO BOX ONLY DR BODY STRUCTURE 23 183 WELD LOCATIONS Continued ...

Page 2479: ...Fig 116 FRONT BOX SIDE PANEL LONG CARGO BOX ONLY Fig 117 FRONT BOX SIDE PANEL LONG CARGO BOX ONLY 23 184 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2480: ...Fig 118 BOX FRONT PANEL LONG CARGO BOX ONLY Fig 119 BOX FLOOR PANEL LONG CARGO BOX ONLY DR BODY STRUCTURE 23 185 WELD LOCATIONS Continued ...

Page 2481: ...Fig 120 LONG CROSSMEMBERS LONG CARGO BOX ONLY Fig 121 INNER WHEELHOUSE PANEL LONG CARGO BOX ONLY 23 186 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2482: ...Fig 122 TAILGATE PILLAR OUTER PANEL LONG CARGO BOX ONLY Fig 123 REAR SILL CROSS BOX LONG CARGO BOX ONLY DR BODY STRUCTURE 23 187 WELD LOCATIONS Continued ...

Page 2483: ...Fig 124 OUTER BOX SIDE PANEL LONG CARGO BOX ONLY Fig 125 STAKE POCKET REINFORCEMENTS LONG CARGO BOX ONLY 23 188 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2484: ...Fig 126 TAILGATE PIVOT REINFORCEMENT LONG CARGO BOX ONLY Fig 127 INNER WHEELHOUSE LONG CARGO BOX ONLY DR BODY STRUCTURE 23 189 WELD LOCATIONS Continued ...

Page 2485: ...Fig 128 009 OUTER TAILGATE PILLAR LONG CARGO BOX ONLY Fig 129 INNER DOOR PANEL QUAD CAB 23 190 BODY STRUCTURE DR WELD LOCATIONS Continued ...

Page 2486: ...Fig 130 INNER DOOR PANEL STANDARD CAB Fig 131 INNER DOOR PANEL QUAD CAB DR BODY STRUCTURE 23 191 WELD LOCATIONS Continued ...

Page 2487: ......

Page 2488: ...nder the instrument panel The HVAC housing includes Blower motor Blower motor resistor block Heater core Evaporator coil Blend door and actuator Defrost door and actuator Mode door and actuator Recirculation door and actuator Based upon the system and mode selected condi tioned air can exit the HVAC housing through one or a combination of the three main housing outlets defrost panel or floor The d...

Page 2489: ...ation Mode with the mode control knob This will operate a electric actu ated recirculation air door that closes off the outside fresh air intake and recirculates the air that is already inside the vehicle The air conditioning compressor can be engaged in any mode by pressing the snowflake A C on off but ton It can also be engaged by placing the mode con trol in the mix to defrost positions This wi...

Page 2490: ... effect that humidity has on the performance of the air condition ing system When humidity is high the evaporator has to perform a double duty It must lower the air temperature and it must lower the temperature of the moisture in the air that condenses on the evapo rator fins Condensing the moisture in the air trans fers heat energy into the evaporator fins and tubing This reduces the amount of he...

Page 2491: ...rge the refrigerant system if required Equal pressures but the compressor clutch does not engage 1 No refrigerant in the refrigerant system 1 See Refrigerant System Leaks in this group Test the refrigerant system for leaks Repair evacuate and charge the refrigerant system if required 2 Faulty fuse 2 Check the fuses in the Power Distribution Center and the junction block Repair the shorted circuit ...

Page 2492: ...ide pressure is normal or slightly high and the high side pressure is too high 1 Condenser air flow restricted 1 Check the A C condenser for damaged fins foreign objects obstructing air flow through the condenser fins and missing or improperly installed air seals Refer to Cooling for more information on air seals Clean repair or replace components as required 2 Inoperative cooling fan 2 Refer to C...

Page 2493: ... maximum heat the mode control to the floor posi tion and the blower in the highest speed position Using a test thermometer check the temperature of the air being discharged from the floor outlets Com pare the test thermometer reading to the Tempera ture Reference chart TEMPERATURE REFERENCE CHART Ambient Air Temperature 15 5 C 60 F 21 1 C 70 F 26 6 C 80 F 32 2 C 90 F Minimum Air Temperature at Fl...

Page 2494: ...e 2 2 amps 12V 0 5V 21 C 70 F 3 7L 4 7L 5 7L engines Compressor Clutch Air Gap 0 41 0 79 mm 0 016 0 031 in 5 9L engine 0 35 0 65 mm 0 013 0 025 in 3 7L 4 7L 5 7L engines TORQUE SPECIFICATIONS Description N m Ft Lbs In Lbs A C Compressor Shaft Nut 15 20 11 15 A C Compressor Bolt Inner Front 3 7L 4 7L 40 30 A C Compressor Bolt Inner Rear 3 7L 4 7L 55 41 A C Compressor Rear Bolt 3 7L 4 7L 55 41 A C C...

Page 2495: ...line to Condenser Nut 20 180 Floor Distribution Duct Screws 2 2 20 Heater Core Tube Bracket Screws 2 2 20 HVAC Door Actuators Screws 2 17 HVAC Door Spring Retainer Screws 2 2 20 HVAC Housing Screws 2 2 20 HVAC Housing to Dash Panel Nuts 6 2 55 HVAC Housing to Floor Bracket Bolt 6 2 55 Liquid Line to Condenser Nut 20 180 Mode Door Adapter Screws 2 2 20 Panel Duct Screws 2 2 20 Recirculation Housing...

Page 2496: ...ATION 22 REMOVAL 22 INSTALLATION 22 MODE DOOR ACTUATOR DESCRIPTION 23 OPERATION 23 REMOVAL 23 INSTALLATION 23 RECIRCULATION DOOR ACTUATOR DESCRIPTION 24 OPERATION 24 REMOVAL 24 INSTALLATION 25 A C COMPRESSOR CLUTCH COIL DESCRIPTION The compressor clutch assembly consists of a sta tionary electromagnetic coil a pulley bearing and pulley assembly and a clutch plate Fig 1 The elec tromagnetic coil an...

Page 2497: ...ransducer Evaporator temperature sensor Powertrain control module PCM 4 The compressor clutch coil is acceptable if the current draw measured at the clutch coil is within specifications with the electrical system voltage at 11 5 to 12 5 volts Refer to 24 HEATING AIR CONDITIONING SPECIFICATIONS This should only be checked with the work area temperature at 21 C 70 F If system voltage is more than 12...

Page 2498: ...ig 5 Turn the puller center bolt clockwise until the rotor is free CAUTION DO NOT APPLY FORCE TO THE END OF THE COMPRESSOR SHAFT 12 Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing Fig 6 13 Remove the snap ring from the compressor hub and remove the clutch field coil Fig 7 Slide the clutch field coil off of the compressor hub INSPECTION Examine t...

Page 2499: ...bly is seated 5 Install the external front housing snap ring with snap ring pliers The bevel side of the snap ring must be facing outward Press the snap ring to make sure it is properly seated in the groove CAUTION If the snap ring is not fully seated in the groove it will vibrate out resulting in a clutch fail ure and severe damage to the front housing of the compressor 6 Install the original clu...

Page 2500: ... is molded into the base adjacent to each terminal The ISO terminal designations are as follows 30 Common Feed This terminal is con nected to the movable contact point of the relay 85 Coil Ground This terminal is connected to the ground feed side of the relay control coil 86 Coil Battery This terminal is connected to the battery feed side of the relay control coil 87 Normally Open This terminal is...

Page 2501: ... 4 Remove the A C compressor clutch relay from the IPM INSTALLATION 1 See the fuse and relay layout label affixed to the underside of the IPM cover for A C compressor clutch relay location 2 Position the A C compressor clutch relay in the proper receptacle in the IPM 3 Align the A C compressor clutch relay termi nals with the terminal cavities in the IPM receptacle 4 Push down firmly on the A C co...

Page 2502: ... the battery negative cable A C PRESSURE TRANSDUCER DESCRIPTION The A C pressure transducer is a switch that is installed on a fitting located on the refrigerant dis charge line between the compressor and the con denser in the front corner of the engine compartment An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader type fitting on the discharge lin...

Page 2503: ...rate an A C pressure transducer voltage reading between 0 451 and 4 519 volts is required Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module PCM or Engine Control Module ECM depending on engine application The PCM ECM is programmed to respond to a low or high refrigerant system pres sure by suppressing operation of the compress...

Page 2504: ...ed two wire lead and connector from the HVAC wire harness The blend door actuator can move the blend air door in two directions When the A C heater control pulls the voltage on one side of the motor con nection high and the other connection low the blend air door will move in one direction When the A C heater control reverses the polarity of the voltage to the motor the blend air door moves in the...

Page 2505: ...the battery negative cable BLOWER MOTOR RESISTOR BLOCK DESCRIPTION The blower motor resistor is mounted to the bot tom side of the HVAC housing near the blower motor It can be accessed for service from underneath the instrument panel OPERATION The resistor has multiple resistor wires each of which will reduce the current flow to the blower motor to change the blower motor speed by changing the res...

Page 2506: ... If not OK replace the faulty blower motor resistor block REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSI...

Page 2507: ... A C heater control from the instrument panel Refer to 24 HEATING AIR CONDITION ING CONTROLS A C HEATER CONTROL REMOVAL Check for continuity between the ground circuit cavity of the A C heater control wire harness connector and a good ground There should be continuity If OK go to Step 3 If not OK repair the open circuit to ground as required 3 With the A C heater control wire harness con nector di...

Page 2508: ...M BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDE...

Page 2509: ...input by cycling the air condition ing compressor clutch as necessary to optimize air conditioning system performance and to protect the system from evaporator freezing The external loca tion of the sensor allows the sensor to be removed or installed without disturbing the refrigerant in the system The evaporator temperature sensor is diag nosed using a DRBIIIt scan tool Refer to Body Diag nostic ...

Page 2510: ... same motor connections also provide a feed back signal to the A C heater control This feedback signal allows the A C heater control to monitor the operation and relative position of the mode door actuator and the mode door The A C heater control learns the mode door stop positions during the cali bration procedure and will store a diagnostic trouble code DTC for any problems it detects in the mod...

Page 2511: ...r the recirculation air door moves in the opposite direction When the module makes the voltage to both connec tions high or both connections low the recirculation air door stops and will not move These same motor connections also provide a feedback signal to the heater A C control module This feedback signal allows the module to monitor the operation and rela tive position of the recirculation doo...

Page 2512: ...shaft with those in the recirculation air door 2 Install and tighten the screws that secure the recirculation door actuator to the air inlet housing Tighten the screws to 2 N m 17 in lbs 3 Connect the HVAC wire harness connector to the recirculation door actuator 4 Install the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 5 Reconnect the battery negative...

Page 2513: ...ETS DESCRIPTION There are four panel outlets in the instrument panel one located near each outboard end of the instrument panel facing the rear of the vehicle and two located near the top of the instrument panel cen ter bezel The air outlets can be removed individually for service replacement REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERIN...

Page 2514: ...BUTION HVAC HOUSING DISASSEMBLY 3 Remove the levers from the driver and or pas senger side blend door if equipped Fig 2 4 Gently slide the drivers and or passenger side blend door toward the out side of the housing Tilt and lift the door s out of the housing 5 Inspect the blend door s seals and the HVAC housing for damage or binding and repair or replace components as required INSTALLATION 1 Posit...

Page 2515: ...ired and if faulty or damaged must be replaced DIAGNOSIS AND TESTING BLOWER MOTOR BLOWER MOTOR INOPERATIVE WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISC...

Page 2516: ...Fig 3 Blower Motor Electrical Diagnosis DR DISTRIBUTION 24 29 BLOWER MOTOR Continued ...

Page 2517: ...Fig 4 Blower Motor Noise Vibration Diagnosis 24 30 DISTRIBUTION DR BLOWER MOTOR Continued ...

Page 2518: ...EL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE ...

Page 2519: ...panel support 5 Remove the defroster duct adapter from the defroster duct 6 Remove the six screws that secure the defroster duct to the instrument panel 7 Remove the defroster duct from the instrument panel INSTALLATION 1 Install the defroster duct into the instrument panel 2 Install the six screws that secure the defroster duct to the instrument panel Tighten the screws to 2 2 N m 20 in lbs 3 Ins...

Page 2520: ... THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the HVAC housing from the vehicle Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING REMOVAL 2 Remove the screws that secure the floor distri bution duct to the bottom of the HVAC housing 3 Remove the floor distribution duct from the HVAC housing Fig 7 Defroster Duct 1 SPEAKER...

Page 2521: ...ator inlet tube Refer to 24 HEAT ING AIR CONDITIONING PLUMBING REFRIG ERANT LINE COUPLER REMOVAL Discard the O ring seal and install plugs in or tape over the opened liquid refrigerant line fitting and evaporator inlet tube 5 Remove the accumulator Refer to 24 HEAT ING AIR CONDITIONING PLUMBING ACCU MULATOR REMOVAL Discard the O ring seals and install plugs in or tape over the opened refrig erant ...

Page 2522: ... screws that secure the upper and lower HVAC housing halves to each other and those that secure the recirculation housing to the upper HVAC housing 10 Carefully separate the recirculation housing and the upper HVAC housing from the lower hous ing ASSEMBLY 1 Position the upper HVAC housing to the lower housing During assembly be certain of the following a That each of the door pivot shaft ends are ...

Page 2523: ... and the evaporator outlet tube and install the accumulator Refer to 24 HEATING AIR CONDITIONING PLUMBING AC CUMULATOR INSTALLATION 9 Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings Connect the liquid line coupler to the evaporator inlet tube Refer to 24 HEATING AIR CONDITIONING PLUMB ING STANDARD PROCEDURE A C LINE COU PLERS 10 Evacuate the refrigerant system...

Page 2524: ...ING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOY...

Page 2525: ... half of the HVAC housing Refer to 24 HEATING AIR CONDITIONING CONTROLS MODE DOOR ACTUATOR REMOVAL 3 Remove the two screws that secure the mode door adapter to the top the HVAC housing Fig 13 4 Disconnect the two plastic retainer clips that secure the mode door adapter to the front the HVAC housing and remove the mode door adapter 5 Remove the screws that secure the two mode door spring retainers ...

Page 2526: ... WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the HVAC housing from the vehicle and place it on the workbench Refer to 24 HEAT ING AIR CONDITIONING DISTRIBUTION HVAC HOUSING REMOVAL 2 Remove the recirculation door actuator from the recirculation housing Refer to 24 HEATING AIR CONDITIO...

Page 2527: ...he front the HVAC housing 5 Install the two screws that secure the recircu lation housing to the top the HVAC housing Tighten the screws to 2 2 N m 20 in lbs 6 Install the recirculation door actuator Refer to 24 HEATING AIR CONDITIONING CONTROLS RECIRCULATION DOOR ACTUATOR INSTALLA TION 7 Install the HVAC housing Refer to 24 HEAT ING AIR CONDITIONING DISTRIBUTION HVAC HOUSING INSTALLATION Fig 14 R...

Page 2528: ... REMOVAL 3 7 4 7 AND 5 7L ENGINES 52 REMOVAL 5 9L DIESEL ENGINE 53 INSTALLATION INSTALLATION 3 7 4 7 AND 5 7L ENGINES 53 INSTALLATION 5 9L DIESEL ENGINE 54 A C CONDENSER FAN REMOVAL 3 7 4 7 and 5 7L ENGINES 55 INSTALLATION 3 7 4 7 and 5 7L ENGINES 55 A C DISCHARGE LINE DESCRIPTION 56 REMOVAL REMOVAL 5 9L DIESEL ENGINE 56 REMOVAL 3 7L 4 7L AND 5 7L HEMI ENGINE 57 INSTALLATION INSTALLATION 5 9L DIES...

Page 2529: ... of all bends at least ten times the diameter of the hose In addition the flexible hose refrigerant lines should be routed so they are at least 80 millimeters 3 inches from an exhaust manifold OPERATION REFRIGERANT LINES High pressures are produced in the refrigerant sys tem when the air conditioning compressor is operat ing Extreme care must be exercised to make sure that each of the refrigerant ...

Page 2530: ...arging will cause excessive compressor head pressure and can cause noise and system failure Recover the refrigerant before opening any fitting or connection Open the fittings with caution even after the system has been discharged Never open or loosen a connection before recovering the refrig erant If equipped do not remove the secondary retention clip from any spring lock coupler connection while ...

Page 2531: ...ed by the symptoms SYSTEM EMPTY 1 Evacuate the refrigerant system to the lowest degree of vacuum possible approx 28 in Hg Deter mine if the system holds a vacuum for 15 minutes If vacuum is held a leak is probably not present If sys tem will not maintain vacuum level proceed with this procedure 2 Prepare a 0 284 Kg 10 oz refrigerant charge to be injected into the system 3 Connect and dispense 0 28...

Page 2532: ...ped or sealed until they are ready to be used Before connecting a compo nent clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system All tools including the refrigerant dispensing mani fold the manifold gauge set and test hoses should be kept clean and dry Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly re...

Page 2533: ...sed 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 damage will result LOW PRESSURE GAUGE HOSE The low pressure hose Blue with Black stripe attaches to the low side service port This service port is located on the suc tion line between the accumulator outlet port and the A C compres...

Page 2534: ...gerant recovery equipment 3 Open the suction and discharge valves and start the vacuum pump The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system When the suction gauge reads 88 kPa 26 in Hg vacuum or greater for 30 minutes close all valves and turn off vacuum pump If the system fails to reach specified vacuum the refrigerant system likely has a lea...

Page 2535: ...hicle can be found on the underhood HVAC specfication tag A C COMPRESSOR DESCRIPTION DESCRIPTION A C COMPRESSOR The A C system on models equipped with the 5 9L engine use a Sanden SD 7 reciprocating swash plate type compressor This compressor has a fixed dis placement of 165 cubic centimeter 10 068 cubic inches and has both the suction and discharge ports located on the cylinder head The A C syste...

Page 2536: ...SOR CLUTCH INSTALLATION 3 To duplicate a high ambient temperature condi tion high head pressure restrict the air flow through the condenser Install a manifold gauge set or a DRBIIIt scan tool to be certain that the dis charge pressure does not exceed 2760 kPa 400 psi 4 Check the refrigerant system plumbing for incorrect routing rubbing or interference which can cause unusual noises Also check the ...

Page 2537: ...plugs in or tape over all of the opened refrigerant line fittings and the compressor ports 9 If equipped with the 5 7L Hemi engine remove the nuts and bolts that secure the generator and A C compressor support bracket and remove the bracket from the engine 10 Remove the bolts that secure the A C com pressor to the mounting bracket Fig 4 Fig 5 or Fig 6 11 Remove the A C compressor from the engine c...

Page 2538: ...essor support bracket and retaining nuts and bolts Tighten the nuts and bolts securely 5 For the 5 9L diesel engine install and tighten the bolts in the following sequence Fig 9 Install the four bolts into the mounting bracket and hand tightened Tightened the four bolts to 24 N m 17 ft lbs 6 Remove the tape or plugs from the opened refrigerant line fittings and compressor ports 7 Lubricate new rub...

Page 2539: ...4 7 AND 5 7L ENGINES WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING and Refer to 24 HEATING AIR CON DITIONING PLUMBING CAUTION 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDITION ING PLUMBING ...

Page 2540: ...nstall plugs in or tape over the liquid line fitting and condenser inlet port 13 Remove the four bolts that secure the con denser to the charge air cooler 14 Remove the condenser from the engine com partment INSTALLATION INSTALLATION 3 7 4 7 AND 5 7L ENGINES NOTE If the condenser is replaced add 30 millili ters 1 fluid ounce of refrigerant oil to the refriger ant system Use only refrigerant oil of...

Page 2541: ...ONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 18 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE INSTALLATION 5 9L DIESEL ENGINE NOTE If the condenser is replaced add 30 millili ters 1 fluid ounce of refrigerant oil to the refriger ant system Use only refrigerant oil of the type recommended for the compresso...

Page 2542: ...he liquid line fit ting to the condenser outlet 9 Disconnect the liquid line from the condenser 10 Remove the seal from the liquid line fitting and discard 11 Install plugs in or tape over the liquid line fitting and condenser inlet port 12 Disconnect the wire harness connector from the condenser cooling fan motor Fig 14 13 Remove the two bolts that secure the con denser to the front upper crossme...

Page 2543: ...s an assembly with the suction line The A C discharge line has no serviceable parts except the rubber O ring seals CAUTION Use only O ring seals specified for the vehicle Failure to use correct O ring seal will cause the refrigerant system connection to leak The O ring seals used on the connections are made from a special type of rubber not affected by R 134a refrigerant The O ring seals must be r...

Page 2544: ...INGS AND CAU TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING and Refer to 24 HEATING AIR CON DITIONING PLUMBING CAUTION 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 3 Di...

Page 2545: ...e A C compressor in the vehicle 5 Connect the suction line to the accumulator outlet tube Refer to 24 HEATING AIR CONDI TIONING PLUMBING REFRIGERANT LINE COU PLER INSTALLATION 6 Install the secondary retaining clip onto the spring lock coupler that secures the suction line to the accumulator outlet tube 7 Remove the tape or plugs from the suction and discharge line fittings and the compressor port...

Page 2546: ...lugs from the discharge line fitting and condenser inlet port 8 Lubricate a new rubber O ring seal with clean refrigerant oil and install it on the discharge line fit ting Use only the specified O ring as it is made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the A C compressor in the vehicle 9 Connect the discharge line to the condenser inlet p...

Page 2547: ...restricted and that the evaporator deflector shield is installed 2 Install the evaporator temperature sensor probe into the A C evaporator 3 Assemble the HVAC housing Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING ASSEMBLY 4 Install the HVAC housing Refer to 24 HEAT ING AIR CONDITIONING DISTRIBUTION HVAC HOUSING INSTALLATION A C ORIFICE TUBE DESCRIPTION The fixed A C orifice tube F...

Page 2548: ... two ends of the liquid line the A C orifice tube is obstructed or missing and the liquid line must be replaced ACCUMULATOR DESCRIPTION The accumulator Fig 21 is mounted in the engine compartment between the evaporator outlet and the compressor suction port An integral mounting bracket is used to secure the accumulator to the dash panel The accumulator cannot be repaired and if faulty or damaged i...

Page 2549: ... the bolts at this time 2 Remove the tape or plugs from the accumulator inlet tube fitting and the evaporator outlet tube 3 Lubricate a new rubber O ring seal with clean refrigerant oil and install it on the accumulator inlet tube fitting Use only the specified O ring as it is made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the A C compressor i...

Page 2550: ...EN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY NOTE Disassembly of the HVAC housing is not required to remove heater core 1 Remove the HVAC housing Refer to 24 HEA...

Page 2551: ...al 6 Remove the heater inlet hose from the engine compartment 7 Separate the heater hoses from each other as required depending on engine application INSTALLATION 1 If separated reconnect the heater hoses to each other as required depending on engine application 2 Position the heater inlet hose into the engine compartment 3 Using spring tension clamp pliers compress and slide each clamp away from ...

Page 2552: ... onto each end of the hose being installed 6 Install the heater hose retaining brackets as required depending on engine application 7 Refill the engine cooling system Refer to 7 COOLING STANDARD PROCEDURE LIQUID LINE DESCRIPTION The liquid line is the refrigerant line that carries refrigerant from the A C condenser to the evaporator The liquid line for this model consist of two separate lines that...

Page 2553: ...ng and the evaporator inlet tube 3 Lubricate a new rubber O ring seal with clean refrigerant oil and install it on the rear liquid line fitting Use only the specified O ring as it is made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the A C compressor in the vehicle 4 Connect the liquid line fitting to the evaporator inlet tube Refer to 24 HEATIN...

Page 2554: ...col PAG synthetic refrigerant oils used in an R 134a refrigerant system are not compatible with the mineral based refriger ant oils used in an R 12 refrigerant system R 134a refrigerant system service ports service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R 134a system is not accidentally contaminated with the wrong refrigerant ...

Page 2555: ...th a small wire hook DO NOT use a screwdriver and install a new garter spring 2 Clean any dirt or foreign material from both halves of the coupler fitting CAUTION Use only the specified O rings as they are made of a special material for the R 134a sys tem The use of any other O rings may allow the connection to leak intermittently during vehicle operation 3 Install new O rings on the male half of ...

Page 2556: ... it is ready for use Refrigerant lubricant will quickly absorb any moisture it comes in contact with It will not be necessary to check the oil level in the A C compressor or to add oil unless there has been an oil loss An oil loss may occur due to component replacement or a rupture or leak from a refrigerant line connector fitting component or component seal If a leak occurs add 30 milliliters 1 f...

Page 2557: ...ve the valve core from the service ports as required 5 Install a plug in or tape over the opened ser vice port s INSTALLATION 1 Lubricate the A C service port valve core with clean refrigerant oil prior to installation Use only refrigerant oil of the type recommended for the A C compressor in the vehicle 2 Remove the tape or plug from the A C service port CAUTION A valve core that is not fully sea...

Page 2558: ... 30 13 Using the proper A C line disconnect tool dis connect the suction line from the accumulator outlet tube Refer to 24 HEATING AIR CONDITION ING PLUMBING REFRIGERANT LINE COUPLER REMOVAL 14 Remove the O ring seal from the accumulator outlet tube fitting and discard 15 Install plugs in or tape over the opened suc tion line and the accumulator outlet tube fitting 16 Remove the suction discharge ...

Page 2559: ...INE 1 If removed install the A C pressure transducer onto the discharge line using a new O ring seal Tighten the transducer securely 2 Position the suction discharge line assembly into the engine compartment 3 Remove the tape or plugs from the suction line and the accumulator outlet tube fitting 4 Lubricate a new rubber O ring seal with clean refrigerant oil and install it on the accumulator out l...

Page 2560: ... into the engine com partment 2 Remove the tape or plugs from the suction line fitting and the compressor inlet port 3 Lubricate a new rubber O ring seal with clean refrigerant oil and install it on the suction line fit ting Use only the specified O ring as it is made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the A C compressor in the vehicle ...

Page 2561: ......

Page 2562: ...mittent conditions if a device functions properly during testing assume the device its associated wiring and driver circuit work cor rectly Connect the DRB scan tool to the data link connector and access the Actuators screen DESCRIPTION DIAGNOSTIC TROUBLE CODES A Diagnostic Trouble Code DTC indicates the PCM has recognized an abnormal condition in the system Remember that DTC s are the results of ...

Page 2563: ...he sen sor starts malfunctioning it could take longer to detect the changes in the oxygen content of the exhaust gas The output voltage of the O2S ranges from 0 to 1 volt A good sensor can easily generate any output voltage in this range as it is exposed to different con centrations of oxygen To detect a shift in the A F mixture lean or rich the output voltage has to change beyond a threshold valu...

Page 2564: ...y using the stricter evap purge flow monitor At an appropriate warm idle the LDP will be energized to seal the canister vent The purge flow will be clocked up from some small value in an attempt to see a shift in the 02 control system If fuel vapor indicated by a shift in the 02 control is present the test is passed If not it is assumed that the purge system is not functioning in some respect The ...

Page 2565: ...itor or Mis Fire Monitor contin uous monitor the vehicle must be operated in the Similar Condition Window for a specified amount of time to be considered a Good Trip If a Non Contiuous OBDII Monitor fails twice in a row and turns ON the MIL re running that monitor which previously failed on the next start up and passing the monitor is considered to be a Good Trip These will include the following O...

Page 2566: ...diagnostic monitor to set a DTC For instance pulling a spark plug wire to perform a spark test may set the misfire code When a repair is completed and verified connect the DRB scan tool to the 16 way data link connector to erase all DTC s and extinguish the MIL OPERATION TASK MANAGER The Task Manager determines which tests happen when and which functions occur when Many of the diagnostic steps req...

Page 2567: ...DTC faults have different priorities according to regulations As a result the priorities determine MIL illumination and DTC era sure DTCs are entered according to individual prior ity DTCs with a higher priority overwrite lower priority DTCs Priorities Priority 0 Non emissions related trouble codes Priority 1 One trip failure of a two trip fault for non fuel system and non misfire Priority 2 One t...

Page 2568: ...imilar Condition Window 1000 engine revolutions with no misfire Warm Up Cycles Once the MIL has been extinguished by the Good Trip Counter the PCM automatically switches to a Warm Up Cycle Counter that can be viewed on the DRB III Warm Up Cycles are used to erase DTCs and Freeze Frames Forty Warm Up cycles must occur in order for the PCM to self erase a DTC and Freeze Frame A Warm Up Cycle is defi...

Page 2569: ... Factor The PCM utilizes both Short Term Compensation and Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correction 200 Rev Counter Counts 0 100 720 degree cycles SCW Cat 200 Rev Counter Counts when in similar conditions SCW FTP 1000 Rev Counter Counts 0 4 when in similar conditions Misfire Good Trip Counter Counts up to three to turn OFF the MIL Misfire Data Data colle...

Page 2570: ... devices However these could cause the PCM to store a MAP sensor diagnostic trouble code and cause a high idle condition PCM SYSTEM GROUND The PCM cannot determine a poor system ground However one or more diagnostic trouble codes may be generated as a result of this condition The mod ule should be mounted to the body at all times also during diagnostic PCM CONNECTOR ENGAGEMENT The PCM may not be a...

Page 2571: ...orates in the fuel tank the vapors pass through vent hoses or tubes into the two charcoal filled evaporative canisters The canisters tempo rarily hold the vapors The Powertrain Control Mod ule PCM allows intake manifold vacuum to draw vapors into the combustion chambers during certain operating conditions All gasoline powered engines use a duty cycle purge system The PCM controls vapor flow by ope...

Page 2572: ...Fig 1 FUEL DELIVERY COMPONENTS 1 FUEL TANK 8 LDP FRESH AIR FILTER 2 CHECK VALVE 9 LEAK DETECTION PUMP 3 LIQUID EXPANSION CHAMBER 10 EVAP CANISTERS 2 4 FUEL FILTER FUEL PRESSURE REGULATOR 11 FUEL TANK STRAPS 2 5 QUICK CONNECT FITTING AND FUEL LINE TO ENGINE 12 CHECK VALVE 6 EVAP LINE CONNECTION 13 FUEL PUMP MODULE LOCK RING 7 LEAK DETECTION PUMP FRESH AIR LINE 14 FUEL PUMP MODULE DR EVAPORATIVE EMI...

Page 2573: ...ister purge solenoid is located in the engine compartment It is attached to the side of the Power Distribution Center PDC OPERATION The Powertrain Control Module PCM operates the solenoid During the cold start warm up period and the hot start time delay the PCM does not energize the sole noid When de energized no vapors are purged The PCM de energizes the solenoid during open loop oper ation The e...

Page 2574: ...o prevent the escape of fuel vapors from the fuel sys tem Fig 4 Leaks in the system even small ones can allow fuel vapors to escape into the atmosphere Government regulations require onboard testing to make sure that the evaporative EVAP system is functioning properly The leak detection system tests for EVAP system leaks and blockage It also performs self diagnostics During self diagnostics the Po...

Page 2575: ...hrough the air filter and inlet check valve and pump it out through an outlet check valve into the EVAP system The diaphragm is pulled up by engine vacuum and pushed down by spring pressure as the LDP solenoid turns on and off The LDP also has a magnetic reed switch to signal diaphragm position to the PCM When the diaphragm is down the switch is closed which sends a 12 V system voltage signal to t...

Page 2576: ...r The spring is now able to push the diaphragm down The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system The LDP reed switch turns from open to closed allowing the PCM to monitor LDP pumping diaphragm up down activity Fig 8 During the pumping mode the diaphragm will not move down far enough to open the vent val...

Page 2577: ... This is located near the front of the fuel tank The LDP and LDP filter are replaced serviced as one unit 1 Raise and support vehicle 2 Carefully remove hose at LDP filter 3 Remove LDP filter mounting bolt and remove from vehicle 4 Carefully remove vapor vacuum lines at LDP 5 Disconnect electrical connector at LDP 6 Remove LDP mounting bolt and remove LDP from vehicle INSTALLATION The LDP and LDP ...

Page 2578: ...fill tube it opens the normally closed check valve and enters the fuel tank Vapor or air is expelled from the tank through the control valve and on to the vapor canis ter Vapor is absorbed in the EVAP canister until vapor flow in the lines stops This stoppage occurs following fuel shut off or by having the fuel level in the tank rise high enough to close the control valve This control valve contai...

Page 2579: ...ation system and a positive crank case ventilation PCV valve This system consists of a PCV valve mounted on the cylinder head valve cover with a hose extending from the valve to the intake manifold Fig 14 Another hose connects the opposite cylinder head valve cover to the air cleaner housing to provide a source of clean air for the system A separate crank case breather filter is not used Fig 11 CR...

Page 2580: ...pors from flowing through the valve During periods of high manifold vacuum such as idle or cruising speeds vacuum is sufficient to com pletely compress spring It will then pull the plunger to the top of the valve Fig 17 In this position there is minimal vapor flow through the valve During periods of moderate manifold vacuum the plunger is only pulled part way back from inlet This results in maximu...

Page 2581: ... tube by placing valve locating tabs Fig 19 into cam lock Press PCV valve in and rotate valve upward A slight click will be felt when tabs have engaged cam lock Valve should be pointed towards rear of vehicle 10 Connect PCV line hose and connecting rubber hose to PCV valve 11 Disconnect rubber hose from fresh air fitting at air cleaner resonator box Start engine and bring to idle speed Hold a piec...

Page 2582: ...led to the intake manifold with 2 o rings Fig 13 1 Remove PCV valve by rotating counter clock wise 90 degrees until locating tabs have been freed After tabs have cleared pull valve straight up from intake manifold 2 After valve is removed check condition of 2 valve o rings INSTALLATION 3 7L V6 4 7L V 8 The PCV valve is located on the oil filler tube Two locating tabs are located on the side of the...

Page 2583: ...ters to be purged at predetermined times and at certain engine operating conditions REMOVAL Two maintenance free EVAP canisters are used Both canisters are mounted into a two piece support bracket located near the front of the fuel tank Fig 23 1 Raise and support vehicle 2 Remove fuel tubes lines at each EVAP canister Note location of tubes lines before removal for easier installation 3 Remove low...

Page 2584: ...s Law9 This is to say that the pres sure in a sealed vessel will change if the temperature of the gas in the vessel changes The vessel will only see this effect if it is indeed sealed Even small leaks will allow the pressure in the vessel to come to equi librium with the ambient pressure In addition to the detection of very small leaks this system has the capability of detecting medium as well as ...

Page 2585: ...5 amps of current to pull the valve open but after 100 ms will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system The device will 9blow off9 at about 0 59 H2O 0 12 KPA pressure to permit the venting of vapors during refueling An added benefit ...

Page 2586: ...nd install hose to filter The vapor vacuum lines and hoses must be firmly connected Check the vapor vacuum lines at the NVLD pump filter and EVAP canister purge solenoid for damage or leaks If a leak is present a Diag nostic Trouble Code DTC may be set 4 Connect 3 way electrical connector to pump Fig 26 REMOVE INSTALL NVLD PUMP 1 NVLD PUMP 2 RELEASE TAB DR EVAPORATIVE EMISSIONS 25 25 NATURAL VAC L...

Page 2587: ......

Page 2588: ...BLE PEDAL MOTOR REMOVAL 5 7 ADJUSTABLE PEDAL SWITCH INSTALLATION 5 6 ADJUSTABLE PEDAL SWITCH REMOVAL 5 6 ADJUSTER DIAGNOSIS AND TESTING HYDRAULIC LASH 9 125 9 32 ADJUSTER INSTALLATION SEAT BELT TURNING LOOP 8O 55 ADJUSTER REMOVAL SEAT BELT TURNING LOOP 8O 55 ADJUSTER ASSEMBLY DESCRIPTION ROCKER ARM 9 125 ADJUSTER ASSEMBLY INSTALLATION ROCKER ARM 9 126 ADJUSTER ASSEMBLY REMOVAL ROCKER ARM 9 126 ADJ...

Page 2589: ...OMATIC DAY NIGHT MIRROR DESCRIPTION 8N 11 AUTOMATIC DAY NIGHT MIRROR DIAGNOSIS AND TESTING 8N 11 AUTOMATIC DAY NIGHT MIRROR OPERATION 8N 11 AUTOMATIC DAY NIGHT MIRROR REMOVAL 8N 12 AUTOMATIC LOCKING RETRACTOR DESCRIPTION 8O 14 AUTOMATIC LOCKING RETRACTOR OPERATION 8O 14 AUTOMATIC TRANSMISSION 45RFE 545RFE DESCRIPTION 21 312 AUTOMATIC TRANSMISSION 45RFE 545RFE OPERATION 21 313 AUTOMATIC TRANSMISSIO...

Page 2590: ...BELT CHAIN COVER S INSTALLATION TIMING 9 171 9 81 BELT CHAIN COVER S REMOVAL TIMING 9 170 9 81 BELT DIAGNOSIS AND TESTING ACCESSORY DRIVE 7 24 7 27 BELT INSTALLATION FRONT CENTER SEAT 8O 31 BELT REMOVAL FRONT CENTER SEAT 8O 30 BELT RETRACTOR INSTALLATION FRONT CENTER SEAT 8O 29 BELT RETRACTOR INSTALLATION REAR CENTER SEAT 8O 45 BELT RETRACTOR INSTALLATION REAR OUTBOARD SEAT 8O 47 BELT RETRACTOR RE...

Page 2591: ...8L 22 8L 23 8L 24 8L 7 8L 9 BOX TIE DOWN INSTALLATION CARGO 23 38 BOX TIE DOWN REMOVAL CARGO 23 38 BOX LAMP SWITCH INSTALLATION GLOVE 8L 28 BOX LAMP SWITCH REMOVAL GLOVE 8L 27 BOX LATCH INSTALLATION GLOVE 23 52 BOX LATCH REMOVAL GLOVE 23 52 B PILLAR GRAB HANDLE INSTALLATION 23 68 B PILLAR GRAB HANDLE REMOVAL 23 68 B PILLAR LOWER TRIM INSTALLATION 23 64 B PILLAR LOWER TRIM REMOVAL 23 63 B PILLAR UP...

Page 2592: ...E PISTON RETAINER INSPECTION OVERRUNNING CLUTCH 21 237 CAM OVERDRIVE PISTON RETAINER OPERATION OVERRUNNING CLUTCH 21 236 CAMSHAFT INSTALLATION 9 206 9 271 CAMSHAFT REMOVAL 9 205 9 268 CAMSHAFT BEARINGS INSTALLATION 9 271 CAMSHAFT BEARINGS REMOVAL 9 268 CAMSHAFT CORE HOLE PLUG INSTALLATION 9 206 CAMSHAFT CORE HOLE PLUG REMOVAL 9 205 CAMSHAFT POSITION SENSOR DESCRIPTION 14 71 CAMSHAFT POSITION SENSO...

Page 2593: ...LT 9 171 9 81 CHAIN COVER S REMOVAL TIMING BELT 9 170 9 81 CHAIN WEAR STANDARD PROCEDURE MEASURING TIMING 9 167 CHAIN WEAR STANDARD PROCEDURE MEASURING TIMING 9 77 CHAIN TENSIONER DESCRIPTION TIMING 9 229 CHAIN TENSIONER OPERATION TIMING 9 229 CHANNEL INSTALLATION GLASS RUN 23 22 23 31 CHANNEL REMOVAL GLASS RUN 23 21 23 30 CHARGE STANDARD PROCEDURE REFRIGERANT SYSTEM 24 47 CHARGE AIR COOLER AND PL...

Page 2594: ... 9 186 9 8 9 93 COMMUNICATION DESCRIPTION 8E 1 COMMUNICATION OPERATION 8E 2 COMPASS CALIBRATION STANDARD PROCEDURE 8M 3 COMPASS DEMAGNETIZING STANDARD PROCEDURE 8M 4 COMPASS MINI TRIP COMPUTER DIAGNOSIS AND TESTING 8M 6 COMPASS VARIATION ADJUSTMENT STANDARD PROCEDURE 8M 5 COMPASS MINI TRIP COMPUTER DESCRIPTION 8M 6 COMPASS MINI TRIP COMPUTER INSTALLATION 8M 6 COMPASS MINI TRIP COMPUTER OPERATION 8...

Page 2595: ...OOLANT THERMOSTAT 8 0L REMOVAL ENGINE 7 49 COOLANT THERMOSTAT 5 7L DESCRIPTION ENGINE 7 41 COOLANT THERMOSTAT 5 7L INSTALLATION ENGINE 7 43 COOLANT THERMOSTAT 5 7L OPERATION ENGINE 7 41 COOLANT THERMOSTAT 5 7L REMOVAL ENGINE 7 42 COOLER 5 9L DIESEL DESCRIPTION TRANS 7 68 COOLER 5 9L DIESEL OPERATION TRANS 7 69 COOLER DESCRIPTION TRANS 7 67 COOLER INSTALLATION AIR TO OIL 7 70 COOLER INSTALLATION FL...

Page 2596: ... 23 79 CUSHION COVER INSTALLATION CENTER SEAT 23 79 CUSHION COVER REMOVAL CENTER SEAT 23 79 CUSHION FRAME REAR INSTALLATION SEAT 23 85 CUSHION FRAME REAR REMOVAL SEAT 23 85 CUSTOMER PREFERENCES STANDARD PROCEDURE RKE TRANSMITTER 8N 8 CV JOINT INNER INSTALLATION 3 25 CV JOINT INNER REMOVAL 3 25 CV JOINT OUTER INSTALLATION 3 23 CV JOINT OUTER REMOVAL 3 22 CYLINDER DESCRIPTION MASTER 5 24 CYLINDER DI...

Page 2597: ...G COOLING SYSTEM 5 9L 7 18 DIESEL ENGINE STANDARD PROCEDURE REFILLING COOLING SYSTEM 5 9L 7 19 DIESEL ENGINE TORQUE FUEL SYSTEM 14 48 DIESEL ENGINE SPECIAL TOOLS 5 9L 9 246 DIESEL ENGINES DESCRIPTION ENGINE OIL 0 2 DIESEL FUEL SYSTEM DESCRIPTION 14 45 DIESEL FUEL SYSTEM SPECIAL TOOLS 14 49 DIESEL ONLY ASSEMBLY 5 9L 7 70 DIESEL ONLY DISASSEMBLY 5 9L 7 70 DIFFERENTIAL ASSEMBLY 3 129 3 156 3 47 3 73 ...

Page 2598: ...CTS INSTALLATION INSTRUMENT PANEL DEMISTER 24 37 DUCTS REMOVAL INSTRUMENT PANEL 24 37 DUCTS REMOVAL INSTRUMENT PANEL DEMISTER 24 36 DUST BOOT INSTALLATION EXTENSION HOUSING SEAL 21 476 21 571 DUST BOOT REMOVAL EXTENSION HOUSING SEAL 21 476 21 571 ECM DESCRIPTION 8E 3 ECM OPERATION 8E 3 EFFECTS OF INCORRECT FLUID LEVEL DIAGNOSIS AND TESTING 21 201 21 366 ELECTRICAL CONTROLS DIAGNOSIS AND TESTING OV...

Page 2599: ...EVACUATE STANDARD PROCEDURE REFRIGERANT SYSTEM 24 47 EVAP SYSTEM DESCRIPTION 25 10 EVAP SYSTEM TORQUE 25 11 EVAPORATOR DESCRIPTION A C 24 59 EVAPORATOR INSTALLATION A C 24 60 EVAPORATOR OPERATION A C 24 59 EVAPORATOR REMOVAL A C 24 60 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 24 22 EVAPORATOR TEMPERATURE SENSOR INSTALLATION 24 22 EVAPORATOR TEMPERATURE SENSOR OPERATION 24 22 EVAPORATOR TEMPERATURE...

Page 2600: ... 23 40 FRAME REAR INSTALLATION SEAT CUSHION 23 85 FRAME REAR REMOVAL SEAT CUSHION 23 85 FRAME REMOVAL GRILLE 23 40 FRAME DIMENSIONS SPECIFICATIONS 13 16 FRAME H SECTION REPLACEMENT STANDARD PROCEDURE REAR 13 13 FRAME RAIL TIP REPLACEMENT STANDARD PROCEDURE LIGHT DUTY FRONT 13 4 FREE MODULE INSTALLATION HANDS 8T 2 FREE MODULE REMOVAL HANDS 8T 2 FRONT INSTALLATION 5 16 5 21 5 22 5 34 FRONT INSTALLAT...

Page 2601: ...OVAL 14 13 FUEL REQUIREMENTS DIESEL ENGINE DESCRIPTION 0 1 FUEL SENSOR DESCRIPTION WATER IN 14 66 FUEL SENSOR OPERATION WATER IN 14 66 FUEL SENSOR REMOVAL WATER IN 14 66 FUEL SYSTEM DESCRIPTION DIESEL 14 45 FUEL SYSTEM DIESEL ENGINE TORQUE 14 48 FUEL SYSTEM EXCEPT DIESEL TORQUE 14 3 FUEL SYSTEM PARTS STANDARD PROCEDURES CLEANING 14 47 FUEL SYSTEM PRESSURE RELEASE STANDARD PROCEDURE 14 2 FUEL SYSTE...

Page 2602: ...STALLATION RADIO NOISE SUPPRESSION 8A 10 GROUND STRAP OPERATION RADIO NOISE SUPPRESSION 8A 9 GROUND STRAP REMOVAL RADIO NOISE SUPPRESSION 8A 9 GROUNDS DESCRIPTION POWER 8E 10 GUIDE SEALS DESCRIPTION VALVE 9 32 9 38 GUIDES DESCRIPTION VALVE 9 107 9 202 GUIDES AND SPRINGS STANDARD PROCEDURE VALVES 9 256 HALF SHAFT CAUTION 3 20 HALF SHAFT DIAGNOSIS AND TESTING 3 20 HALF SHAFT INSTALLATION 3 21 HALF S...

Page 2603: ...ESCRIPTION 21 371 HOLDING CLUTCHES OPERATION 21 372 HOLE PLUG INSTALLATION CAMSHAFT CORE 9 206 HOLE PLUG REMOVAL CAMSHAFT CORE 9 205 HOLE REPAIR DESCRIPTION THREADED Intro 8 HONING STANDARD PROCEDURE CYLINDER BORE 9 128 9 38 HOOD INSTALLATION 23 47 HOOD REMOVAL 23 46 HOOK INSTALLATION COAT 23 66 HOOK REMOVAL COAT 23 66 HOOK ASSEMBLY INSTALLATION FRONT TOW 13 23 HOOK ASSEMBLY REMOVAL FRONT TOW 13 2...

Page 2604: ...KEY IMMOBILIZER SYSTEM 8Q 5 INDICATOR LAMP OPERATION SENTRY KEY IMMOBILIZER SYSTEM 8Q 5 INDICATOR LAMP MIL DESCRIPTION MALFUNCTION 8J 31 INDICATOR LAMP MIL OPERATION MALFUNCTION 8J 31 INDICATOR TEST STANDARD PROCEDURE BUILT IN 8F 10 INDICATORS DIAGNOSIS AND TESTING TREAD WEAR 22 8 INERTIA HINGE COVER INSTALLATION CENTER SEAT BACK 23 77 INERTIA HINGE COVER REMOVAL CENTER SEAT BACK 23 77 INFLATION P...

Page 2605: ...11 KEY IN IGNITION SWITCH DESCRIPTION 19 11 KEYLESS ENTRY MODULE DESCRIPTION REMOTE 8N 7 KEYLESS ENTRY MODULE DIAGNOSIS AND TESTING REMOTE 8N 7 KEYLESS ENTRY MODULE INSTALLATION REMOTE 8N 8 KEYLESS ENTRY MODULE OPERATION REMOTE 8N 7 KEYLESS ENTRY MODULE REMOVAL REMOTE 8N 7 KEYLESS ENTRY TRANSMITTER DIAGNOSIS AND TESTING REMOTE 8N 8 KEYLESS ENTRY TRANSMITTER SPECIFICATIONS REMOTE 8N 9 KNOB RELEASE ...

Page 2606: ...ATION FUEL PRESSURE 14 61 LIMITING VALVE OPERATION FUEL PRESSURE 14 61 LIMITING VALVE REMOVAL FUEL PRESSURE 14 61 LINE DESCRIPTION A C DISCHARGE 24 56 LINE DESCRIPTION LIQUID 24 65 LINE DESCRIPTION REFRIGERANT 24 42 LINE DESCRIPTION SUCTION 24 70 LINE INSTALLATION LIQUID 24 66 LINE REMOVAL LIQUID 24 65 LINE AND TERMINAL REPAIR STANDARD PROCEDURE GRID 8G 4 LINE COUPLER DESCRIPTION REFRIGERANT 24 67...

Page 2607: ...NSOR REMOVAL 14 33 MARKER LAMP INSTALLATION FENDER 8L 18 MARKER LAMP INSTALLATION TAILGATE 8L 18 MARKER LAMP REMOVAL FENDER 8L 17 MARKER LAMP REMOVAL TAILGATE 8L 18 MASTER CYLINDER DESCRIPTION 5 24 MASTER CYLINDER OPERATION 5 25 MASTER CYLINDER BLEEDING STANDARD PROCEDURE 5 26 MASTER CYLINDER POWER BOOSTER DIAGNOSIS AND TESTING 5 25 MATCH MOUNTING STANDARD PROCEDURE 22 3 MATCHING TIRE DESCRIPTION ...

Page 2608: ...8F 35 MOTOR RELAY INSTALLATION STARTER 8F 37 MOTOR RELAY OPERATION STARTER 8F 36 MOTOR RELAY REMOVAL STARTER 8F 37 MOTOR RESISTOR BLOCK DESCRIPTION BLOWER 24 18 MOTOR RESISTOR BLOCK DIAGNOSIS AND TESTING BLOWER 24 19 MOTOR RESISTOR BLOCK INSTALLATION BLOWER 24 19 MOTOR RESISTOR BLOCK OPERATION BLOWER 24 18 MOTOR RESISTOR BLOCK REMOVAL BLOWER 24 19 MOTOR SWITCH DESCRIPTION BLOWER 24 20 MOTOR SWITCH...

Page 2609: ...STALLATION 9 155 9 224 9 293 9 66 OIL PAN REMOVAL 9 155 9 224 9 293 9 66 OIL PRESSURE DIAGNOSIS AND TESTING CHECKING ENGINE 9 152 9 220 9 65 OIL PRESSURE DIAGNOSIS AND TESTING ENGINE 9 289 OIL PRESSURE GAUGE DESCRIPTION 8J 33 OIL PRESSURE GAUGE OPERATION 8J 33 OIL PRESSURE RELIEF VALVE CLEANING 9 294 OIL PRESSURE RELIEF VALVE INSPECTION 9 294 OIL PRESSURE RELIEF VALVE INSTALLATION 9 294 OIL PRESSU...

Page 2610: ...R SURROUND REMOVAL INSTRUMENT 23 59 PANEL REPAIR STANDARD PROCEDURE PLASTIC BODY 23 3 PANEL TOP COVER INSTALLATION INSTRUMENT 23 59 PANEL TOP COVER REMOVAL INSTRUMENT 23 58 PANEL TRIM INSTALLATION REAR CAB BACK 23 69 PANEL TRIM REMOVAL REAR CAB BACK 23 68 PARK BRAKE CABLE INSTALLATION REAR 5 38 PARK BRAKE CABLE REMOVAL REAR 5 37 PARK LAMP RELAY DESCRIPTION 8L 20 PARK LAMP RELAY DIAGNOSIS AND TESTI...

Page 2611: ...DAL 14 22 14 68 POSITION SENSOR OPERATION CAMSHAFT 14 71 POSITION SENSOR OPERATION CAMSHAFT 8I 7 POSITION SENSOR OPERATION CRANKSHAFT 14 23 14 72 POSITION SENSOR OPERATION THROTTLE 14 41 POSITION SENSOR REMOVAL 21 443 21 478 POSITION SENSOR REMOVAL ACCELERATOR PEDAL 14 22 14 68 POSITION SENSOR REMOVAL CAMSHAFT 14 72 POSITION SENSOR REMOVAL CAMSHAFT 8I 9 POSITION SENSOR REMOVAL CRANKSHAFT 14 24 14 ...

Page 2612: ...NJECTION 14 53 PUMP DESCRIPTION FUEL TRANSFER 14 64 PUMP DESCRIPTION LEAK DETECTION 25 13 PUMP DESCRIPTION OIL 21 213 21 386 PUMP DESCRIPTION WATER 7 59 PUMP DIAGNOSIS AND TESTING WATER 7 62 7 63 PUMP DISASSEMBLY OIL 9 157 9 68 PUMP DISASSEMBLY OIL 21 214 21 388 PUMP INITIAL OPERATION STANDARD PROCEDURE POWER STEERING 19 40 PUMP INSPECTION OIL 9 157 9 224 9 295 9 68 PUMP INSPECTION OIL 21 214 21 3...

Page 2613: ...ARD SEAT BELT RETRACTOR REMOVAL 8O 46 REAR PARK BRAKE CABLE INSTALLATION 5 38 REAR PARK BRAKE CABLE REMOVAL 5 37 REAR PROPELLER SHAFT INSTALLATION 3 8 REAR PROPELLER SHAFT REMOVAL 3 8 REAR SEAL AREA LEAKS DIAGNOSIS AND TESTING 9 137 9 209 9 65 REAR SERVO ASSEMBLY 21 251 REAR SERVO CLEANING 21 251 REAR SERVO DESCRIPTION 21 251 REAR SERVO DISASSEMBLY 21 251 REAR SERVO OPERATION 21 251 REAR TUBE HOSE...

Page 2614: ...NEL 23 3 REPAIR DAMAGED OR WORN THREADS STANDARD PROCEDURE 9 190 9 240 9 9 9 94 REPAIRING LEAKS STANDARD PROCEDURE 22 10 REQUIREMENTS DESCRIPTION ENGINE COOLING SYSTEM 24 1 REQUIREMENTS DIESEL ENGINE DESCRIPTION FUEL 0 1 RESERVOIR DESCRIPTION VACUUM 8P 9 RESERVOIR DESCRIPTION WASHER 8R 14 RESERVOIR DIAGNOSIS AND TESTING VACUUM 8P 9 RESERVOIR INSTALLATION 19 47 RESERVOIR INSTALLATION FLUID 5 24 RES...

Page 2615: ... AREA LEAKS DIAGNOSIS AND TESTING REAR 9 137 9 209 9 65 SEAL RETAINER INSTALLATION CRANKSHAFT REAR OIL 9 210 9 277 SEAL RETAINER REMOVAL CRANKSHAFT REAR OIL 9 209 9 277 SEALER LOCATIONS SPECIFICATIONS 23 102 SEALERS STANDARD PROCEDURE FORM IN PLACE GASKETS 9 239 9 9 9 94 SEALS DESCRIPTION VALVE GUIDE 9 32 9 38 SEALS DESCRIPTION VALVE STEM 9 127 9 203 SEALS INSTALLATION AXLE SHAFT 3 43 3 70 3 94 SE...

Page 2616: ...SCRIPTION OUTPUT SPEED 21 391 SENSOR DESCRIPTION OXYGEN 14 35 SENSOR DESCRIPTION POSITION 21 442 21 477 SENSOR DESCRIPTION SIDE IMPACT 8O 59 SENSOR DESCRIPTION SPEED 21 253 SENSOR DESCRIPTION THROTTLE POSITION 14 41 SENSOR DESCRIPTION TRANSMISSION RANGE 21 263 21 405 SENSOR DESCRIPTION TRANSMISSION TEMPERATURE 21 267 21 408 SENSOR DESCRIPTION WATER IN FUEL 14 66 SENSOR DIAGNOSIS AND TESTING AMBIEN...

Page 2617: ...STALLATION PROPELLER 3 7 SHAFT LD FRONT REMOVAL PROPELLER 3 6 SHAFT REAR BEARING INSTALLATION OUTPUT 21 217 SHAFT REAR BEARING REMOVAL OUTPUT 21 216 SHAFT SEAL INSTALLATION FRONT OUTPUT 21 442 21 477 21 508 21 538 21 572 SHAFT SEAL INSTALLATION STEERING GEAR INPUT 19 29 SHAFT SEAL REMOVAL FRONT OUTPUT 21 441 21 477 21 507 21 537 21 572 SHAFT SEAL REMOVAL STEERING GEAR INPUT 19 27 SHAFT SEALS INSTA...

Page 2618: ...IZER BAR OPERATION 2 25 STABILIZER BAR REMOVAL 2 25 2 39 STAKING STANDARD PROCEDURE HEAT 23 3 STANDARD CAB INSTALLATION 8O 35 8O 61 STANDARD CAB REMOVAL 8O 32 8O 59 STARTER MOTOR DIAGNOSIS AND TESTING 8F 32 STARTER MOTOR INSTALLATION 8F 34 STARTER MOTOR REMOVAL 8F 33 STARTER MOTOR RELAY DESCRIPTION 8F 35 STARTER MOTOR RELAY INSTALLATION 8F 37 STARTER MOTOR RELAY OPERATION 8F 36 STARTER MOTOR RELAY...

Page 2619: ... SWITCH INSTALLATION POWER LOCK 8N 4 SWITCH INSTALLATION TOW HAUL OVERDRIVE 21 262 21 393 SWITCH INSTALLATION WASHER FLUID LEVEL 8R 11 SWITCH INSTALLATION WINDOW 8N 21 SWITCH OPERATION 8P 7 SWITCH OPERATION BACKUP LAMP 8L 8 SWITCH OPERATION BLOWER MOTOR 24 20 SWITCH OPERATION BRAKE LAMP 8L 9 SWITCH OPERATION CLUTCH PEDAL POSITION 6 13 SWITCH OPERATION DOOR AJAR 8L 27 SWITCH OPERATION DRIVER SEAT 8...

Page 2620: ...AGNOSIS AND TESTING 7 42 7 44 7 47 7 48 THERMOSTAT 5 7L DESCRIPTION ENGINE COOLANT 7 41 THERMOSTAT 5 7L INSTALLATION ENGINE COOLANT 7 43 THERMOSTAT 5 7L OPERATION ENGINE COOLANT 7 41 THERMOSTAT 5 7L REMOVAL ENGINE COOLANT 7 42 THREAD REPAIR STANDARD PROCEDURE ALUMINUM 21 158 21 318 THREADED HOLE REPAIR DESCRIPTION Intro 8 THREADS STANDARD PROCEDURE REPAIR DAMAGED OR WORN 9 190 9 240 9 9 9 94 THROT...

Page 2621: ...82 TRANSFER CASE NV243 DIAGNOSIS AND TESTING 21 483 TRANSFER CASE NV243 DISASSEMBLY 21 484 TRANSFER CASE NV243 INSPECTION 21 493 TRANSFER CASE NV243 INSTALLATION 21 505 TRANSFER CASE NV243 OPERATION 21 483 TRANSFER CASE NV243 REMOVAL 21 484 TRANSFER CASE NV244 DIAGNOSIS AND TESTING 21 513 TRANSFER CASE NV244 GENII ASSEMBLY 21 525 TRANSFER CASE NV244 GENII CLEANING 21 523 TRANSFER CASE NV244 GENII ...

Page 2622: ...NG A C ORIFICE 24 61 TUBE HOSE ASSEMBLY INSTALLATION REAR 5 13 TUBE HOSE ASSEMBLY REMOVAL REAR 5 12 TUBE OPERATION A C ORIFICE 24 60 TUBING AND FITTINGS STANDARD PROCEDURE HANDLING 24 45 TURBO DIESEL MAINTENANCE SCHEDULES 24 VALVE CUMMINS 0 12 TURBOCHARGER CLEANING 11 15 TURBOCHARGER DESCRIPTION 11 12 TURBOCHARGER INSPECTION 11 15 TURBOCHARGER INSTALLATION 11 15 TURBOCHARGER OPERATION 11 13 TURBOC...

Page 2623: ...RATION DIAGNOSIS AND TESTING TIRE NOISE OR 22 7 VIBRATION DAMPER INSPECTION 9 285 VIBRATION DAMPER INSTALLATION 9 144 9 215 9 286 9 56 VIBRATION DAMPER REMOVAL 9 144 9 215 9 285 9 55 VIEW MIRROR INSTALLATION SIDE 23 42 VIEW MIRROR REMOVAL REAR 23 69 VIEW MIRROR REMOVAL SIDE 23 41 VIEW MIRROR FLAG INSTALLATION SIDE 23 27 VIEW MIRROR FLAG REMOVAL SIDE 23 27 VIEW MIRROR GLASS INSTALLATION SIDE 23 43 ...

Page 2624: ...TION REAR 23 41 WHEELHOUSE SPLASH SHIELD REMOVAL FRONT 23 41 WHEELHOUSE SPLASH SHIELD REMOVAL REAR 23 41 WHEELS DESCRIPTION 22 11 WHEELS INSTALLATION REAR DUAL 5 35 WHEELS OPERATION 22 11 WHEELS REMOVAL REAR DUAL 5 34 WIND NOISE DIAGNOSIS AND TESTING 23 2 WINDOW DEFOGGER RELAY DESCRIPTION REAR 8G 2 WINDOW DEFOGGER RELAY INSTALLATION REAR 8G 4 WINDOW DEFOGGER RELAY OPERATION REAR 8G 3 WINDOW DEFOGG...

Page 2625: ......

Page 2626: ...____________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Dealership Technician Dealer Code Retail Customer Manual Title Year Number and Page _________________________________________________ _______________________________________...

Page 2627: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757 ...

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