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Dodge 2001 Ram 1500, Owner'S Manual

The Dodge 2001 Ram 1500 Owner's Manual is available for free download. This comprehensive manual provides detailed information on maintaining and operating your vehicle. Get your copy today at manualshive.com and ensure you have all the necessary information to keep your Dodge Ram 1500 running smoothly.

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8W-10 POWER DISTRIBUTION

Component

Page

A/C Compressor Clutch Relay . . . . . . . . . . 8W-10-27
A/C Compressor Clutch . . . . . . . . . . . . . . . 8W-10-27
Aftermarket Center High Mounted

Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13

Aftermarket Trailer Tow Connector . . . . . . 8W-10-21
Automatic Shut Down Relay . . . . . . . . . 8W-10-14, 20
Auxiliary Battery . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Blower Motor Relay . . . . . . . . . . . . . . . . . . 8W-10-23
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-10-13
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
Center High Mounted Stop Lamp No. 1 . . . 8W-10-13
Center High Mounted Stop Lamp No. 2 . . . 8W-10-13
Central Timer Module C1 . . . . . . . . . . . . . 8W-10-22
Central Timer Module C2 . . . . . . . . . . . . . 8W-10-26
Circuit Breaker 2 . . . . . . . . . . . . . . . . . . . . 8W-10-10
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Combination Flasher . . . . . . . . . . . . . . . . . 8W-10-13
Controller Antilock Brake . . . . . . . . . . . . . 8W-10-23
Daytime Running Lamp Module . . . . . . . . 8W-10-25
Electric Brake Provision . . . . . . . . . . . . 8W-10-13, 21
Engine Control Module . . . . . . . . . . . . . . . 8W-10-12
Engine Starter Motor Relay . . . . . . . . . . . . 8W-10-23
Engine Starter Motor . . . . . . . . . . . . . . . . . 8W-10-23
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . 8W-10-25
Fuel Heater Relay . . . . . . . . . . . . . . . . . . . 8W-10-20
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 8W-10-12
Fuel Injector No. 1 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 2 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 3 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 4 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 5 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 6 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 7 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 8 . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuel Injector No. 9 . . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel Injector No. 10 . . . . . . . . . . . . . . . . . . 8W-10-16
Fuel Pump Module . . . . . . . . . . . . . . . . . . . 8W-10-11
Fuel Pump Relay . . . . . . . . . . . . . . . . . 8W-10-11, 12
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 1 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 8
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . 8W-10-8, 10, 22
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . 8W-10-8, 11, 12
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 8
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 8
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . 8W-10-14, 20, 8
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 8
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-21, 8
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-23, 8
Fuse 10 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-22, 8
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-23, 8
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-23, 8
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10

Component

Page

Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse B (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-24, 9
Fuse C (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-24, 9
Fuse E (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-24, 9
Fuse F (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-24, 9
Fuse G (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 9
Fuse GEN (PDC) . . . . . . . . . . . . . . . . . . 8W-10-27, 8
Fuse H (PDC) . . . . . . . . . . . . . . . . . . . . 8W-10-26, 9
Fuse I (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 9
Fuse J (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-27, 9
Fuse K (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 9
Fuse L (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-27, 9
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
Headlamp Beam Select Switch . . . . . . . . . . 8W-10-25
Headlamp Switch . . . . . . . . . . . . . . . . . . . . 8W-10-24
High Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Horn Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 9
Ignition Coil 4-Pack . . . . . . . . . . . . . . . . . . 8W-10-16
Ignition Coil 6-Pack . . . . . . . . . . . . . . . . . . 8W-10-16
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
Ignition Switch . . . . . . . . . . . . . . . . . . . 8W-10-10, 22
Joint Connector No. 1 . . . . . . . . . . . . . . 8W-10-25, 26
Joint Connector No. 2 . . . . . 8W-10-11, 12, 14, 20, 21
Joint Connector No. 5 . . . . . . . . . . . . . . . . 8W-10-22
Joint Connector No. 6 . . . . . . . . . . . 8W-10-13, 22, 26
Joint Connector No. 8 . . . . . . . . . . . . . . . . 8W-10-22
Junction Block . . . . . . . . . . . . . . . . . . . 8W-10-10, 13
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-10-25
Left Headlamp . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Left Outboard Headlamp . . . . . . . . . . . 8W-10-24, 25
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Oxygen Sensor 1/1 Left Bank Up . . 8W-10-17, 18, 19
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-10-17
Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-10-17
Oxygen Sensor 1/2 Left Bank Down . . . . . . 8W-10-19
Oxygen Sensor 1/2 Pre-Catalyst . . . . . . . . . 8W-10-18
Oxygen Sensor 1/3 Post-Catalyst . . . . . . . . 8W-10-18
Oxygen Sensor 2/1 Right Bank Up . 8W-10-17, 18, 19
Oxygen Sensor 2/2 Right Bank Down . . . . . 8W-10-19
Oxygen Sensor Downstream Relay . . . . 8W-10-18, 19
Power Distribution Center . 8W-10-2, 8, 9, 10, 11, 12,

13, 14, 20, 21, 22, 23,

24, 25, 26, 27

Power Outlet . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
Powertrain Control Module . 8W-10-11, 12, 15, 16, 20
Quad High Beam Relay . . . . . . . . . . . . . . . 8W-10-24
Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-10-25
Right Headlamp . . . . . . . . . . . . . . . . . . . . . 8W-10-24
Right Outboard Headlamp . . . . . . . . . . 8W-10-24, 25
Security Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10-25
Trailer Tow Connector . . . . . . . . . . . . . . . . 8W-10-21
Trailer Tow Relay . . . . . . . . . . . . . . . . . . . . 8W-10-21
Transmission Control Relay . . . . . . . . . . . . 8W-10-26
Transmission Solenoid Assembly . . . . . . . . 8W-10-26
Turn Signal/Hazard Switch . . . . . . . . . . . . 8W-10-13

BR/BE

8W-10 POWER DISTRIBUTION

8W - 10 - 1

Summary of Contents for 2001 Ram 1500

Page 1: ...ol 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bumpers 1...

Page 2: ...nted on a vehicle code plate will be followed by the imprinted word END When two vehicle code plates are required the last available spaces on the first plate will be imprinted with the letters CTD fo...

Page 3: ...GIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20 21 AND 22 Engine Code EHC 3 9 L 6 cyl MPI Gasoline ELF 5...

Page 4: ...ch bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 10 9 The metric strength class identification...

Page 5: ...Fastener Identification 4 INTRODUCTION BR BE FASTENER IDENTIFICATION Continued...

Page 6: ...Fastener Strength BR BE INTRODUCTION 5 FASTENER IDENTIFICATION Continued...

Page 7: ...g International Control and Display Symbols Chart are used to identify various instrument controls The symbols correspond to the controls and displays that are located on the instrument panel METRIC S...

Page 8: ...x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec mph x 0 4470 Meters Sec M S M S x 2 237 mph Kilometers Hr Km h x 0 27778 Meters Sec M S M S x 3 600...

Page 9: ...Metric Conversion Chart 8 INTRODUCTION BR BE METRIC SYSTEM Continued...

Page 10: ...IPTION Individual Torque Charts appear at the end of many Groups Refer to the Standard Torque Specifi cations Chart for torque references not listed in the individual torque charts Torque Specificatio...

Page 11: ...late located to the right side of the generator Fig 3 OPERATION There are unique VECI labels for vehicles built for sale in the country of Canada and for both Light Duty Cycle LDC and Heavy Duty Cycle...

Page 12: ...01 14 000 5 Vehicle Line C Ram Cab Chassis Ram Pick Up 4x2 F Ram Cab Chassis Ram Pick Up 4x4 6 Series 1 1500 2 2500 3 3500 7 Body Style 2 Club Cab 3 Quad Cab 6 Conventional Cab Cab Chassis 8 Engine 6...

Page 13: ...e 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 EQUIPMENT IDENTIFICATIO...

Page 14: ...el properties necessary to deliver enhanced emissions performance and durability for your vehicle We rec ommend the use of gasolines that meet the WWFC specifications if they are available REFORMULATE...

Page 15: ...ht smoke your engine may be out of tune or malfunctioning and may require immediate service Contact your dealer for service assistance When pulling a heavy load or driving a fully loaded vehicle when...

Page 16: ...es the best engineered products for servicing Daimler Chrysler Corporation vehicles FLUID TYPES DESCRIPTION ENGINE OIL WARNING NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED OR R...

Page 17: ...R OR GOVERN MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil The identifying notat...

Page 18: ...in the vehicle such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehicle is driven the ATF will begin to look darker in color and may e...

Page 19: ...ON SPECIFICATION Dry fill capacity Depending on type and size of internal cooler length and inside diameter of cooler lines or use of an auxiliary cooler these figures may vary Refer to 21 Transmissio...

Page 20: ...ng of the emission control system These and all other maintenance services included in this manual should be done to provide the best vehicle performance and reliability More frequent mainte nance may...

Page 21: ...n permanently sealed ball joints Check manual transmission fluid level Inspect exhaust system 75 000 Miles 120 000 km or at 60 months Inspect auto tension drive belt and replace if required Change eng...

Page 22: ...r more of the following conditions Frequent short trips of less than 5 miles Frequent driving in dusty conditions Trailer towing Frequent long periods of engine idling More than 50 percent of the driv...

Page 23: ...nsmission fluid level Inspect exhaust system 33 000 Miles 53 000 km Change engine oil Replace engine oil filter Inspect engine coolant level hoses and clamps Inspect brake hoses Lubricate the steering...

Page 24: ...nt axle fluid 4x4 Inspect exhaust system 63 000 Miles 101 000 km Change engine oil Replace engine oil filter Inspect engine coolant level hoses and clamps Inspect brake hoses Lubricate the steering li...

Page 25: ...Inspect engine coolant level hoses and clamps Inspect brake hoses Lubricate the steering linkages Check manual transmission fluid level Inspect exhaust system 96 000 Miles 154 000 km Change engine oi...

Page 26: ...NLY There are two maintenance schedules that show proper service based on the conditions that the vehi cle is subjected to Use the schedule that best describes these conditions Schedule A lists all th...

Page 27: ...60 months Replace engine oil and filter Replace engine air cleaner element Replace ignition cables Replace spark plugs Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 mont...

Page 28: ...r 24 000 Miles 38 000 km Replace engine oil and filter Drain and refill automatic transmission fluid Replace filter and adjust bands Inspect front wheel bearings Clean and repack if required 4x2 Chang...

Page 29: ...iles 139 000 km Replace engine oil and filter 90 000 Miles 144 000 km Replace engine oil and filter Replace engine air cleaner element Replace spark plugs Inspect front wheel bearings Clean and repack...

Page 30: ...change interval shown on schedule A 6 000 Miles or every other interval shown on schedule B 6 000 Miles Check engine coolant level hoses and clamps Lubricate steering linkage EMISSION CONTROL SYSTEM M...

Page 31: ...ace engine air cleaner element and air pump filter Drain and refill automatic transmission fluid Replace filter and adjust bands Drain and refill transfer case fluid Clean and lubricate crankcase inle...

Page 32: ...matic transmission fluid Replace filter and adjust bands Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings Lubricate tie rod ends every 3 000 miles 5 000 km Inspect front wheel...

Page 33: ...t air filter 5 9L Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings Flush and replace engine coolant Lubricate tie rod ends every 3 000 miles 5 000 km Inspect front w...

Page 34: ...bearings 4x2 82 500 Miles 132 000 km Replace oxygen sensor 5 9L only 84 000 Miles 134 000 km Change engine oil Replace engine oil filter Inspect engine air cleaner element and air pump filter replace...

Page 35: ...First is Schedule A It lists all the scheduled maintenance to be performed under normal operat ing conditions Second is Schedule B It is a schedule for vehicles that are operated under the conditions...

Page 36: ...s 52 500 Miles 84 000 km or at 42 months Change engine oil and filter Drain crankcase breather canister if equipped 60 000 Miles 96 000 km or at 48 months Change engine oil and filter Drain crankcase...

Page 37: ...anister if equipped Drain and refill automatic transmission fluid Replace filter and adjust bands Inspect fan hub Inspect damper Inspect front wheel bearings Clean and repack if required 4x2 Inspect w...

Page 38: ...r if equipped Replace fuel filter and clean water in fuel sen sor 56 250 Miles 90 000 km Change engine oil and filter Drain crankcase breather canister if equipped 60 000 Miles 96 000 km Change engine...

Page 39: ...breather canister if equipped Inspect drive belts replace as necessary Replace fuel filter and clean water in fuel sensor 116 250 Miles 186 000 km Change engine oil and filter Drain crankcase breathe...

Page 40: ...booster vehicle charging system can result 2 When using another vehicle as a booster source park the booster vehicle within cable reach Turn off all accessories set the parking brake place the automa...

Page 41: ...ECURE 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 10 Support the vehicle in the raised position with jack...

Page 42: ...e front end tow ing method SAFETY PRECAUTIONS CAUTION The following safety precautions must be observed when towing a vehicle Secure loose and protruding parts Always use a safety chain system that is...

Page 43: ...all lug nuts on wheel attaching studs to retain brake drums or rotors RAMP ANGLE If a vehicle with flat bed towing equipment is used the approach ramp angle should not exceed 15 degrees TOWING WHEN KE...

Page 44: ...spension and steering linkage adjustments An alignment is essential for efficient steering good directional stability and to minimize tire wear The most important measurements of an alignment are cast...

Page 45: ...The wheel toe position is the final front wheel alignment adjustment DIAGNOSIS AND TESTING PRE ALIGNMENT Before starting wheel alignment the following inspection and necessary corrections must be com...

Page 46: ...should be the final adjustment 1 Start the engine and turn wheels both ways before straightening the wheels Center and secure the steering wheel and turn off engine 2 Loosen the tie rod adjustment sl...

Page 47: ...Fig 4 Chassis Measurement 1 GAUGE HOLE 2 HANGER BOLT 3 HANGER BOLT 4 GAUGE HOLE 2 4 WHEEL ALIGNMENT BR BE WHEEL ALIGNMENT Continued...

Page 48: ...correct angle Be sure the axle is not bent or twisted Road test the vehicle and make left and right turn Observe the steering wheel return to center position Low caster will cause poor steering wheel...

Page 49: ...4 7 3 33 0 50 4 x 2 10 500 154 7 3 58 0 50 4 x 4 6 400 118 7 2 86 Not Set 4 x 4 6 400 134 7 3 04 Not Set 4 x 4 6 600 138 7 3 19 Not Set 4 x 4 6 600 154 7 3 37 Not Set 4 x 4 8 800 134 7 2 68 Not Set 4...

Page 50: ...12 REMOVAL 12 INSTALLATION 12 UPPER BALL JOINT DIAGNOSIS AND TESTING 12 UPPER BALL JOINT 12 UPPER CONTROL ARM REMOVAL 13 INSTALLATION 13 FRONT 2WD DESCRIPTION The independent front suspension IFS is c...

Page 51: ...replaceable The lower suspension arms bolt to the lower frame brackets and pivot through bushings these bushings are not replaceable The suspension arms have lube for life riveted ball studs SPECIFICA...

Page 52: ...1500 251N m 185 ft lbs HD 2500 3500 380 N m 280 ft lbs 4 Install the rotor onto hub bearing wheel studs 5 Install the caliper adapter assembly Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER...

Page 53: ...r suspension arm 4 Position indicator plunger against the bottom of the steering knuckle lower ball joint boss NOTE The dial Indicator plunger must be perpen dicular to the machined surface of the ste...

Page 54: ...be caused 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 malfunct...

Page 55: ...and caliper assembly Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION 8 Install the tire and wheel assembly Refer to 22 TIRES WHEELS WHEELS STANDARD PRO CEDURE 9 Remove the support and lowe...

Page 56: ...upper suspension arm bracket and remove arm from vehicle Fig 7 INSTALLATION 1 Position the upper suspension arm on the bracket and install the pivot bar bolts Tighten to 169 N m 125 ft lbs 2 Install t...

Page 57: ...of Fig 1 Shock absorbers Coil springs Upper and lower suspension arms Stabilizer bar Track bar Steering Knuckles Hub Bearing Ball Joints Jounce Bumpers CAUTION Components attached with a nut and cot...

Page 58: ...Arm Upper Axle Nut 163 120 Suspension Arm Upper Frame Nut 163 120 Stabilizer Bar Clamp Bolt 54 40 Stabilizer Bar Link Upper Nut 37 27 Stabilizer Bar Link Lower Nut 47 35 Track Bar Ball Stud Nut 95 70...

Page 59: ...rame and steering knuckle if equipped 7 Back off the hub bearing mounting bolts 1 4 inch each Fig 4 Then tap the bolts with a hammer to loosen the hub bearing from the steering knuckle 8 Remove the hu...

Page 60: ...SPEED SENSOR REMOVAL 6 Back off the hub bearing mounting bolts 1 4 inch each Fig 8 Then tap the bolts with a hammer to loosen the hub bearing from the steering knuckle 7 Remove the hub bearing mounti...

Page 61: ...eed sensor the brake shield must be positioned on the hub bearing Fig 12 7 Align the rotor hub with the drive shaft and start the shaft into the rotor hub splines NOTE Position wheel speed sensor wire...

Page 62: ...LLATION 1500 1 Apply a liberal quantity of anti seize compound to splines of the front drive shaft 2 Insert the bolts Fig 13 through back side of the steering knuckle 3 Position the brake shield Fig 1...

Page 63: ...le tube yokes INSTALLATION 1 Position the steering knuckle on the ball studs 2 Install and tighten lower ball stud nut to 108 N m 80 ft lbs torque Advance nut to next slot to line up hole and install...

Page 64: ...s 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 shoul...

Page 65: ...ll 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...

Page 66: ...be perpendicular to the ball joint end cap 4 Turn the front wheel 180 to the right and record the dial indicator reading Repeat this step three times and record all readings 5 If any of the readings...

Page 67: ...163 N m 120 ft lbs Tighten nut at frame bracket to 163 N m 120 ft lbs LOWER BALL JOINT REMOVAL 1 Remove lower snap ring from the lower ball joint Fig 23 Fig 20 Track Bar 1 AXLE BRACKET 2 FRAME BRACKE...

Page 68: ...all stud Fig 27 Fig 24 Lower Ball Joint Removal 1 SPECIAL TOOL C4212 F 2 SPECIAL TOOL 8445 3 3 SPECIAL TOOL 8445 1 Fig 25 Lower Ball Joint Install 1 SPECIAL TOOL C4212 F 2 SPECIAL TOOL 8445 2 3 BALL J...

Page 69: ...rt 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...

Page 70: ...g shock 3 Replace shock SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Shock Absorber Lower Nut 136 100 Shock Absorber Upper Nut 136 100 Spring Clamp Nuts 6 010 10 500...

Page 71: ...g 1 3 Remove the bolt and nut from the axle bracket 4 Remove the rear shock absorber from the vehi cle INSTALLATION 1 Position the shock absorber in the brackets 2 Install the bolts through the bracke...

Page 72: ...bolt hole in rear bracket Install bolt and nut 5 Tighten the spring front and rear eye pivot bolt snug do not torque 6 Install spring clamp bolts and the retaining nuts 7 Align the auxiliary spring w...

Page 73: ...er nuts and retain ers Fig 6 4 Remove stabilizer bar and replace worn cracked or distorted bushings 5 Remove links upper mounting nuts and bolts and remove links INSTALLATION 1 Install link into frame...

Page 74: ...vibra tion Tubular propeller shafts are balanced by the man ufacturer with weights spot welded to the tube Use the exact replacement parts when installing the propeller shafts The use of the correct r...

Page 75: ...ASE 2 FRONT PROPELLER SHAFT 3 FRONT AXLE 4 UNIVERSAL JOINT CLAMP Fig 2 Rear Propeller Shaft with Center Bearing 1 CENTER BEARING 2 REAR AXLE 3 TRANSMISSION TRANSFER 4 REAR PROPELLER SHAFT 3 2 PROPELLE...

Page 76: ...low frequency vibration Refer to 5 BRAKES DIAGNOSIS AND TESTING Driveline vibration can also result from loose or damaged engine mounts Propeller shaft vibration increases as the vehicle speed is inc...

Page 77: ...h the following procedure 1 Raise the vehicle 2 Clean all the foreign material from the propel ler shaft and the universal joints 3 Inspect the propeller shaft for missing balance weights broken welds...

Page 78: ...axle are within specifications Correct as necessary and re measure propeller shaft runout 8 Replace the propeller shaft if the runout still exceeds the limits RUNOUT SPECIFICATIONS Front of Shaft 0 02...

Page 79: ...record measurement This measurement will give you the pinion shaft or Input Yoke Angle B 7 Subtract smaller figure from larger C minus B to obtain axle Input Operating Angle Refer to rules given belo...

Page 80: ...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 13 Universal Joint Angle Two Piece Shaft 1 YOKES MUST BE IN SAME PLANE BR BE PROPELLER SHAFT 3 7 PROPELLER...

Page 81: ...5 Remove the bolts holding the propeller shaft to the transfer case companion flange 6 Remove the propeller shaft INSTALLATION 1 Position front propeller shaft under vehicle with rear universal joint...

Page 82: ...r Corporate axles 8 Slide the slip yoke off of the transmission or transfer case output shaft and remove the propeller shaft Fig 16 INSTALLATION 1 Slide the slip yoke onto the transmission or transfer...

Page 83: ...splitter 4 Position Bearing Splitter Tool 1130 between slinger and shaft CAUTION Do not damage shaft spline during removal of center bearing 5 Set shaft in press and press bearing off the shaft INSTA...

Page 84: ...se fitting if equipped pointing up 6 Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing...

Page 85: ...tained by nuts at the hub bearings The hub bearings are bolted to the steering knuckle at the outboard end of the axle tube yoke The hub bearings are serviced as an assembly The axles are equipped wit...

Page 86: ...rect backlash tooth contact worn damaged gears or the carrier housing not having the proper offset and squareness Gear noise usually happens at a specific speed range The noise can also occur during a...

Page 87: ...a worn U joint or by worn side gear thrust washers A worn pinion shaft bore will also cause low speed knock VIBRATION Vibration at the rear of the vehicle is usually caused by Damaged drive shaft Miss...

Page 88: ...operation 3 Replace broken shaft and avoid or correct erratic clutch operation 4 Grabbing clutch 4 Replace broken shaft and inspect and repair clutch as necessary Differential Cracked 1 Improper adju...

Page 89: ...acklash is correct Axle Noise 1 Insufficient lubricant 1 Fill differential with the correct fluid type and quantity 2 Improper ring gear and pinion adjustment 2 Check ring gear and pinion contact patt...

Page 90: ...d sensors if equipped Refer to group 5 Brakes for proper proce dures 12 Install the brake calipers and rotors Refer to Group 5 Brakes for proper procedures 13 Connect the vent hose to the tube fitting...

Page 91: ...0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 2 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 1 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004...

Page 92: ...ock and the arbor bar with the scooter block against the pinion height block Fig 9 When the dial probe contacts the arbor bar the dial pointer will turn clockwise Bring dial pointer back to zero again...

Page 93: ...he shim used on the ring gear side of the differential case Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear side of the dif f...

Page 94: ...side of the housing and record the dial indicator reading Fig 16 12 Add 0 38 mm 0 015 in to the zero end play total This total represents the thickness of shims Fig 12 Seat Pinion Gear Side Dummy Bea...

Page 95: ...m thickness required on the pinion side of the housing 23 Rotate dial indicator out of the way on pilot stud 24 Remove differential case and dummy bearings from the housing 25 Install the selected sid...

Page 96: ...RN The ring and pinion gear contact patterns will show if the pinion depth is correct It will also show if the ring gear backlash has been adjusted correctly The backlash can be adjusted within specif...

Page 97: ...Fig 21 Gear Tooth Contact Patterns 3 24 FRONT AXLE 216FBI BR BE FRONT AXLE 216FBI Continued...

Page 98: ...1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearing 2 4 N m 15 35 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Plug Fill Hole 34 25 Differential Cover Bolts 41 30 Bearing Cap Bolts 1...

Page 99: ...288 B DIAL INDICATOR C 3339 INSTALLER BEARING C 3716 A INSTALLER CUP D 146 HANDLE DRIVE C 4171 INSTALLER CUP D 144 REMOVER CUP D 147 REMOVER CUP D 149 INSTALLER BEARING D 156 3 26 FRONT AXLE 216FBI BR...

Page 100: ...OKE W 162 D INSTALLER BEARING W 262 INSTALLER SEAL 5041 PULLER PRESS C 293 PA BLOCK ADAPTERS C 293 40 BLOCK ADAPTER C 293 18 ADAPTER PLUG C 293 3 HOLDER YOKE 6719A PINION DEPTH SET 6730 BR BE FRONT AX...

Page 101: ...7 Install wheel and tire assembly 8 Remove support and lower the vehicle AXLE SHAFTS INTERMEDIATE REMOVAL 1 Remove vacuum shift motor housing 2 Remove outer axle shaft 3 Remove inner axle shaft seal...

Page 102: ...g 26 3 Install axle shafts and hub bearings AXLE VACUUM MOTOR DESCRIPTION The disconnect axle control system consists of Shift motor Indicator switch Vacuum switch Vacuum harness Fig 27 Fig 24 Bearing...

Page 103: ...llar connects the axle intermediate shaft to the axle shaft to sup ply engine power to both front wheels In two wheel drive mode the shift collar is disengaged from the intermediate shaft and the inte...

Page 104: ...DIAGNOSIS AND TESTING VACUUM MOTOR AXLE VACUUM SHIFT MOTOR BR BE FRONT AXLE 216FBI 3 31 AXLE VACUUM MOTOR Continued...

Page 105: ...AXLE VACUUM SHIFT MOTOR CONT D 3 32 FRONT AXLE 216FBI BR BE AXLE VACUUM MOTOR Continued...

Page 106: ...nt through indicator switch mounting hole 4 Install indicator switch electrical connector and vacuum harness SINGLE CARDAN UNIVERSAL JOINTS REMOVAL Single cardan U joint components are not service abl...

Page 107: ...assemblies 3 Remove brake calipers and rotors Refer to Brakes for procedure 4 Mark the propeller shaft and pinion yoke for installation reference 5 Remove propeller shaft from the yoke 6 Rotate pinio...

Page 108: ...n 6 8 N m 5 ft lbs until proper rotating torque is achieved 6 Installation propeller shaft with reference marks aligned 7 Check and add gear lubricant to axle if neces sary 8 Install brake rotors and...

Page 109: ...the indicator plunger against the opposite side of the housing Fig 38 and zero the dial indicator 11 Spread the housing enough to remove the case from the housing Measure the distance with the dial i...

Page 110: ...ly in two places 180 apart 6 Lubricate all differential components with hypoid gear lubricant INSTALLATION NOTE If replacement differential bearings or differ ential case are being installed different...

Page 111: ...tighten bearing cap bolts to 109 N m 80 ft lbs 8 Install axle shafts 9 Install the hub bearings 10 Apply a bead of Mopar Silicone Rubber Seal ant or equivalent to the housing cover Fig 45 Install the...

Page 112: ...tag shims to indicate location INSTALLATION 1 Install differential preload shims on differential case in their original locations 2 Install differential bearings with Installer D 156 with Handle C 41...

Page 113: ...rom the pinion shaft with Puller C 452 and Flange Wrench C 3281 Fig 49 10 Remove pinion gear from housing Fig 50 11 Remove pinion seal with a pry bar or slide hammer mounted screw 12 Remove front pini...

Page 114: ...Pinion Bearing Cup 1 REMOVER 2 HANDLE Fig 52 Rear Pinion Bearing Cup 1 DRIVER 2 HANDLE Fig 53 Collapsible Spacer 1 COLLAPSIBLE SPACER 2 SHOULDER 3 PINION GEAR 4 OIL SLINGER 5 REAR BEARING BR BE FRONT...

Page 115: ...side surface of bearing cups 2 Install rear pinion bearing cup with Installer D 146 and Handle C 4171 Fig 55 and verify cup is seated 3 Install front pinion bearing cup with Installer D 144 and Handle...

Page 116: ...t Fig 59 9 Install pinion gear in housing 10 Install yoke with Installer W 162 D and Yoke Holder 6719A Fig 60 Fig 57 Pinion Seal Installer 1 HANDLE 2 INSTALLER Fig 58 Rear Pinion Bearing 1 PRESS 2 INS...

Page 117: ...ew Bearings 2 to 5 N m 15 to 35 in lbs 14 Invert differential case in a vise and start two ring gear bolts This will provide case to ring gear bolt hole alignment 15 Install new ring gear bolts and al...

Page 118: ...ned by nuts at the hub bearings The hub bearings are bolted to the steering knuckle at the outboard end of the axle tube yoke The hub bearings are serviced as an assembly The axles are equipped with A...

Page 119: ...t backlash tooth contact worn damaged gears or the carrier housing not having the proper offset and squareness Gear noise usually happens at a specific speed range The noise can also occur during a sp...

Page 120: ...a worn U joint or by worn side gear thrust washers A worn pinion shaft bore will also cause low speed knock VIBRATION Vibration at the rear of the vehicle is usually caused by Damaged drive shaft Miss...

Page 121: ...operation 3 Replace broken shaft and avoid or correct erratic clutch operation 4 Grabbing clutch 4 Replace broken shaft and inspect and repair clutch as necessary Differential Cracked 1 Improper adju...

Page 122: ...c clutch operation 3 Ice spotted pavement 3 Replace gears and examine remaining parts for damage 4 Improper adjustments 4 Replace gears and examine remaining parts for damage Ensure ring gear backlash...

Page 123: ...the steer ing knuckles and tighten the nuts to 88 N m 65 ft lbs torque 11 Install the ABS wheel speed sensors if equipped Refer to group 5 Brakes for proper proce dures 12 Install the brake calipers a...

Page 124: ...004 1 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 2 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 3 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 0 007 4 0 0 001 0 002 0 003 0 004 0 005 0 006...

Page 125: ...ock and the arbor bar with the scooter block against the pinion height block Fig 9 When the dial probe contacts the arbor bar the dial pointer will turn clockwise Bring dial pointer back to zero again...

Page 126: ...he shim used on the ring gear side of the differential case Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear side of the dif f...

Page 127: ...side of the housing and record the dial indicator reading Fig 16 12 Add 0 38 mm 0 015 in to the zero end play total This total represents the thickness of shims Fig 12 Seat Pinion Gear Side Dummy Bea...

Page 128: ...thickness required on the pinion side of the housing 23 Rotate dial indicator out of the way on pilot stud 24 Remove differential case and dummy bearings from the housing 25 Install the selected side...

Page 129: ...RN The ring and pinion gear contact patterns will show if the pinion depth is correct It will also show if the ring gear backlash has been adjusted correctly The backlash can be adjusted within specif...

Page 130: ...Fig 21 Gear Tooth Contact Patterns BR BE FRONT AXLE 248FBI 3 57 FRONT AXLE 248FBI Continued...

Page 131: ...1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearing 1 7 4 N m 15 35 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 34 25 Differential Cover Bolts 41 30 Bearing Cap Bolt...

Page 132: ...SET C 3339 INSTALLER FLANGE C 3718 HANDLE DRIVE C 4171 INSTALLER BEARING C 4190 INSTALLER CUP C 111 INSTALLER CUP C 146 REMOVER CUP D 158 REMOVER CUP D 162 PULLER PRESS C 293 PA BR BE FRONT AXLE 248F...

Page 133: ...dust shield and hub bearing on knuckle 4 Install hub bearing bolts and tighten to 170 N m 125 ft lbs 5 Install axle washer and nut tighten nut to 237 N m 175 ft lbs Align nut to next cotter pin hole a...

Page 134: ...tor housing AXLE SHAFT SEALS REMOVAL 1 Remove hub bearings and axle shafts 2 Remove axle shaft seal from the differential housing with a long drift or punch Be careful not to damage housing 3 Clean th...

Page 135: ...r connects the axle intermediate shaft to the axle shaft to sup ply engine power to both front wheels In two wheel drive mode the shift collar is disengaged from the intermediate shaft and the interme...

Page 136: ...DIAGNOSIS AND TESTING VACUUM MOTOR AXLE VACUUM SHIFT MOTOR BR BE FRONT AXLE 248FBI 3 63 AXLE VACUUM MOTOR Continued...

Page 137: ...AXLE VACUUM SHIFT MOTOR CONT D 3 64 FRONT AXLE 248FBI BR BE AXLE VACUUM MOTOR Continued...

Page 138: ...through indicator switch mounting hole 4 Install indicator switch electrical connector and vacuum harness SINGLE CARDAN UNIVERSAL JOINTS REMOVAL Single cardan U joint components are not service able...

Page 139: ...calipers and rotors 4 Mark the propeller shaft and pinion yoke for installation reference 5 Remove the propeller shaft from the yoke 6 Rotate the pinion gear three or four times 7 Measure the amount...

Page 140: ...ing torque is achieved 6 Align the installation reference marks and attach the propeller shaft to the yoke 7 Check and add lubricant to axle if necessary Refer to Lubricant Specifications in this sect...

Page 141: ...indicator plunger against the opposite side of the housing Fig 38 and zero the dial indicator 11 Spread the housing enough to remove the case from the housing Measure the distance with the dial indica...

Page 142: ...ly in two places 180 apart 6 Lubricate all differential components with hypoid gear lubricant INSTALLATION NOTE If replacement differential bearings or differ ential case are being installed different...

Page 143: ...tighten bearing cap bolts to 109 N m 80 ft lbs 8 Install axle shafts 9 Install the hub bearings 10 Apply a bead of Mopar Silicone Rubber Seal ant or equivalent to the housing cover Fig 45 Install the...

Page 144: ...46 INSTALLATION 1 Using tool C 4190 with handle C 4171 install differential side bearings Fig 47 2 Install differential case in axle housing Fig 45 Differential Cover 1 SEALANT SURFACE 2 SEALANT 3 SE...

Page 145: ...ke with Puller C 452 and Flange Wrench C 3281 Fig 49 10 Remove pinion gear from housing Fig 50 11 Remove pinion seal with a pry bar or screw mounted slide hammer 12 Remove oil slinger and front pinion...

Page 146: ...Pinion Bearing Cup 1 REMOVER 2 HANDLE Fig 52 Rear Pinion Bearing Cup 1 DRIVER 2 HANDLE Fig 53 Collapsible Spacer 1 COLLAPSIBLE SPACER 2 SHOULDER 3 PINION GEAR 4 OIL SLINGER 5 REAR BEARING BR BE FRONT...

Page 147: ...out side surface of bearing cups 2 Install rear pinion bearing cup with Installer D 111 and Handle C 4171 Fig 55 and verify cup is seated 3 Install front pinion bearing cup with Installer D 146 and Ha...

Page 148: ...t Fig 59 9 Install pinion gear in housing 10 Install yoke with Installer C 3718 and Yoke Holder 6719A Fig 60 Fig 57 Pinion Seal Installer 1 HANDLE 2 INSTALLER Fig 58 Rear Pinion Bearing 1 PRESS 2 INST...

Page 149: ...bs New Bearings 1 7 to 4 N m 15 to 35 in lbs 14 Invert differential case in a vise and start two ring gear bolts This will provide case to ring gear bolt hole alignment 15 Install new ring gear bolts...

Page 150: ...o tag The tags are attached to the differential housing by a cover bolt The rear wheel anti lock RWAL brake speed sen sor is attached to the top forward exterior of the dif ferential housing A seal is...

Page 151: ...Fig 1 9 1 4 Axle 3 78 REAR AXLE 9 1 4 BR BE REAR AXLE 9 1 4 Continued...

Page 152: ...R 24 SIDE GEAR 25 C LOCK 26 DIFFERENTIAL POSITIONS 27 THRUST WASHER 28 COVER 29 PLUG 30 COVER BOLT 31 WASHER 32 CLIP 33 SIDE GEAR 34 THRUST WASHER 35 DIFFERENTIAL BEARING CONE 36 C LOCK 37 BOLT 38 LOC...

Page 153: ...f unequal traction When one wheel looses traction the clutch packs transfer additional torque to the wheel having the most traction Trac loky differentials resist wheel spin on bumpy roads and provide...

Page 154: ...the vehicle Turn the vehicle sharply to the left and to the right This will load the bearings and change the noise level Where axle bearing damage is slight the noise is usually not noticeable at spee...

Page 155: ...eplace case and inspect gears and bearings for further damage Set ring gear backlash properly 3 Vehicle overloaded 3 Replace case and inspect gears and bearings for further damage Avoid excessive vehi...

Page 156: ...oose pinion bearings 5 Adjust pinion bearing 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 compone...

Page 157: ...inch the depth varies from the standard depth setting of a pinion marked with a 0 The next two numbers are the sequence number of the gear set The standard depth provides the best teeth contact patte...

Page 158: ...ke measurements with Pinion Gauge Set and Dial Indi cator C 3339 Fig 8 1 Assemble Pinion Height Block 6739 Pinion Block 8542 and rear pinion bearing onto Screw 6741 Fig 8 2 Insert assembled height gau...

Page 159: ...usting the bearing preload and ring gear backlash Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure Insufficient adjuster torque can result in excessive...

Page 160: ...RN The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the hous ing It will also show if the ring gear backlash has been adjusted correctly The backlash can be...

Page 161: ...Fig 14 Gear Tooth Contact Patterns 3 88 REAR AXLE 9 1 4 BR BE REAR AXLE 9 1 4 Continued...

Page 162: ...ft 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 t...

Page 163: ...2 mm 0 005 in Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearings 1 7 4 N m 15 35 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Differential...

Page 164: ...andle C 4171 Installer C 4076 B Handle C 4735 1 Remover C 4828 Puller C 452 Installer C 3860 A Installer C 3718 Wrench C 4164 Puller Press C 293 PA BR BE REAR AXLE 9 1 4 3 91 REAR AXLE 9 1 4 Continued...

Page 165: ...C 293 47 Plug C 293 3 Installer C 4213 Fixture 8136 Remover C 4309 Adapters C 293 37 Installer C 4310 Installer D 129 Installer C 3095 Trac lok Tools C 4487 3 92 REAR AXLE 9 1 4 BR BE REAR AXLE 9 1 4...

Page 166: ...ct surface for signs of brinelling galling and pitting INSTALLATION 1 Lubricate bearing bore and seal lip with gear lubricant Insert axle shaft through seal bearing and engage it into side gear spline...

Page 167: ...seal is installed to the correct depth 3 Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft 4 Install the axle shaft AXLE BEARINGS REMOVAL 1 Remove axle sha...

Page 168: ...ith holder and remove the pinion nut and washer 11 Remove the companion flange with Remover C 452 Fig 22 12 Remove pinion seal with a pry tool or slide hammer mounted screw INSTALLATION NOTE The outer...

Page 169: ...e vehicle 2 Remove lubricant fill hole plug from the differ ential housing cover 3 Remove differential housing cover and drain the lubricant from the housing 4 Clean the housing cavity with a flushing...

Page 170: ...emove the differential side gears and thrust washers Fig 25 Reference Mark 1 REFERENCE MARKS 2 REFERENCE MARK 3 BEARING CAPS Fig 26 Threaded Adjuster 1 AXLE TUBE 2 BACKING PLATE 3 TOOL C 4164 Fig 27 P...

Page 171: ...s to 41 N m 30 ft lbs torque 8 Fill differential with lubricant to bottom of the fill plug hole Refer to the Lubricant Specifications for the quantity and type 9 Install the fill hole plug and lower t...

Page 172: ...e Fig 32 2 Remove ring gear if the ring gear is to be replaced The Trac loky differential can be serviced with the ring gear installed 3 Remove pinion shaft roll pin 4 Remove pinion shaft with a drift...

Page 173: ...r 12 Rotate differential case until the pinion gears can be removed 13 Remove pinion gears from differential case 14 Remove Forcing Screw Step Plate and Threaded Adapter 15 Remove top side gear clutch...

Page 174: ...packs on the side gear hubs 3 Install clutch pack and side gear in the ring gear side of the differential case Fig 41 Be sure clutch pack retaining clips remain in position and are seated in the case...

Page 175: ...t 13 Remove Forcing Screw Step Plate and Threaded Adapter 14 Install pinion shaft and align holes in shaft and case 15 Install and seat pinion shaft roll pin in differ ential case Peen the edge of the...

Page 176: ...2 Remove wheel and tire assemblies 3 Mark companion flange and propeller shaft for installation reference 4 Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody 5...

Page 177: ...companion flange from the pinion with Remover C 452 Fig 46 14 Remove the pinion from housing Fig 47 15 Remove pinion seal with a pry tool or slide hammer mounted screw 16 Remove oil slinger if equippe...

Page 178: ...up 2 Install rear pinion bearing cup Fig 52 with Installer C 4308 and Driver Handle C 4171 and ver ify cup is seated 3 Apply Mopar Door Ease or stick lubricant to outside surface of bearing cup 4 Inst...

Page 179: ...earing Cup 1 INSTALLER 2 HANDLE Fig 53 Front Pinion Bearing Cup 1 INSTALLER 2 HANDLE Fig 54 Pinion Seal 1 HANDLE 2 DIFFERENTIAL HOUSING 3 INSTALLER Fig 55 Rear Pinion Bearing 1 PRESS 2 INSTALLER 3 PIN...

Page 180: ...ver exceed spec ified preload 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 desi...

Page 181: ...bolts can fracture causing extensive damage 22 Install differential in axle housing and verify gear mesh and contact pattern 23 Install axle shafts 24 Install wheel and tire assemblies 25 Install dif...

Page 182: ...n and service without removing the complete axle from the vehicle A small stamped metal axle gear ratio identification tag is attached to the housing cover via one of the cover bolts This tag also ide...

Page 183: ...s generated by the side gears as torque is applied through the ring gear Fig 3 The Trac loky design provides the differential action needed for turning corners and for driving straight ahead during pe...

Page 184: ...aring noise The pitch of differen tial bearing noise is also constant and varies only with vehicle speed Axle shaft bearings produce noise and vibration when worn or damaged The noise generally change...

Page 185: ...lace case and inspect gears and bearings for further damage Set ring gear backlash properly 3 Vehicle overloaded 3 Replace case and inspect gears and bearings for further damage Avoid excessive vehicl...

Page 186: ...nd 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 ring gear 7 Measure ring gear run out Re...

Page 187: ...ting from the cen ter line of the ring gear to the back face of the pinion is 127 mm 5 00 in The standard depth provides the best gear tooth contact pattern Refer to Back lash and Contact Pattern in t...

Page 188: ...s 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 6736 and rear pinion bearing on...

Page 189: ...RING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side bearing cones The proper shim thickness can be...

Page 190: ...sition the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 14 10 Push and hold differential case to pinion gear side of the housing and zero dial indicator Fig 15 11 Push...

Page 191: ...13 18 Position the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 14 19 Push and hold differential case toward pinion gear and zero the dial indicator Fig 17 Fig 14 Dif...

Page 192: ...he housing 31 Rotate the differential case several times to seat the side bearings 32 Position the indicator plunger against a ring gear tooth Fig 19 33 Push and hold ring gear upward while not allowi...

Page 193: ...the turning resistance of the pinion This will provide a more distinct contact pat tern 3 With a boxed end wrench on the ring gear bolt rotate the differential case one complete revolution in both di...

Page 194: ...Fig 21 Gear Tooth Contact Patterns BR BE REAR AXLE 248RBI 3 121 REAR AXLE 248RBI Continued...

Page 195: ...N m 10 20 in lbs Pinion Bearing Preload New Bearings 2 3 5 1 N m 20 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 34 25 Differential Cover Bolts 41 30 Bearing Cap Bolts...

Page 196: ...6719A Puller C 452 Installer 8108 Spreader W 129 B Pilot Studs C 3288 B Dial Indicator C 3339 Puller Press C 293 PA Adapters C 293 37 Installer C 4190 Handle C 4171 BR BE REAR AXLE 248RBI 3 123 REAR...

Page 197: ...r D 158 Remover D 162 Adapters C 293 37 Installer D 111 Installer D 146 Installer C 3095 A Installer C 3718 Trac lok Tools 8139 Trac lok Tools C 4487 Gauge Set 6730 3 124 REAR AXLE 248RBI BR BE REAR A...

Page 198: ...grease seal contact axle tube threads during installtion 9 Install outer axle bearing 10 Install hub bearing adjustment nut with Socket DD 1241 JD 11 Tighten adjustment nut to 163 190 N m 120 140 ft...

Page 199: ...plus an addi tional 0 56 N m 5 in lbs Fig 25 CAUTION Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque If preload torque is exceede...

Page 200: ...ial bearing caps 8 Position Spreader W 129 B with the tool dowel pins seated in the locating holes Fig 27 9 Install the hold down clamps and tighten the tool turnbuckle finger tight 10 Install a Pilot...

Page 201: ...s and thrust washers 2 Install the pinion mate gears and thrust wash ers 3 Install the pinion gear mate shaft 4 Align the hole in the pinion gear mate shaft with the hole in the differential case 5 In...

Page 202: ...indica tor 3 Spread the housing enough to install the case in the housing Measure the distance with the dial indicator CAUTION Do not spread over 0 50 mm 0 020 in If the housing is over spread it cou...

Page 203: ...If the chatter persists clutch damage could have occurred DIFFERENTIAL TEST The differential can be tested without removing the differential case by measuring rotating torque Make sure brakes are not...

Page 204: ...ent adapter from turning Fig 36 Differential Case Holding Fixture 1 HOLDING FIXTURE 2 VISE 3 DIFFERENTIAL Fig 37 Pinion Shaft 1 PINION MATE SHAFT 2 SIDE GEAR 3 DRIFT 4 PINION MATE GEAR Fig 38 Step Pla...

Page 205: ...k retainer and clutch pack Keep plates in correct order during removal ASSEMBLY Clean all components in cleaning solvent Dry com ponents with compressed air Inspect clutch pack plates for wear scoring...

Page 206: ...ned 10 Rotate case with Turning Bar C 6960 2 until the pinion shaft holes in pinion gears align with holes in case It may be necessary to slightly tighten the forcing screw in order to install the pin...

Page 207: ...fferential case with Puller Press C 293 PA Adapters C 293 62 and Step Plate 8139 2 Fig 47 INSTALLATION 1 Using tool C 4190 with handle C 4171 install differential side bearings Fig 48 2 Install differ...

Page 208: ...ion yoke nut and washer 9 Using Remover C 452 and Wrench C 3281 remove the pinion yoke from pinion shaft Fig 50 10 Remove the pinion gear from housing Fig 51 Catch the pinion with your hand to prevent...

Page 209: ...aring Cup Removal 1 REMOVER 2 HANDLE Fig 53 Rear Bearing Cup Removal 1 DRIVER 2 HANDLE Fig 54 Collapsible Spacer 1 COLLAPSIBLE SPACER 2 SHOULDER 3 PINION GEAR 4 OIL SLINGER 5 REAR BEARING 3 136 REAR A...

Page 210: ...and Handle C 4171 Fig 56 Ensure cup is correctly seated 2 Apply Mopart Door Ease stick lubricant to out side surface of bearing cup Install the pinion front bearing cup with Installer D 146 and Handl...

Page 211: ...on the pinion gear Tighten the nut to 292 N m 215 ft lbs minimum Do not over tighten Maximum torque is 447 N m 330 ft lbs CAUTION Never loosen pinion gear nut to decrease pinion gear bearing preload t...

Page 212: ...al case 16 Using a brass drift slowly and evenly tap the exciter ring into position 17 Invert the differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignmen...

Page 213: ...service without removing the complete axle from the vehicle A small stamped metal axle gear ratio identification tag is attached to the housing cover via one of the cover bolts This tag also identifie...

Page 214: ...t attached to the outside wheel to rotate at a faster speed POWR LOKY DIFFERENTIAL The Powr loky clutches are engaged by two con current forces The first being the preload force exerted through Bellev...

Page 215: ...source of the noise If the bearing noise is heard during a coast the front pinion bearing is the source Worn or damaged differential bearings usually pro duce a low pitch noise Differential bearing n...

Page 216: ...lace case and inspect gears and bearings for further damage Set ring gear backlash properly 3 Vehicle overloaded 3 Replace case and inspect gears and bearings for further damage Avoid excessive vehicl...

Page 217: ...nd 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 ring gear 7 Measure ring gear run out Re...

Page 218: ...ing from the cen ter line of the ring gear to the back face of the pinion is 136 53 mm 5 375 in The standard depth pro vides the best gear tooth contact pattern Refer to Backlash and Contact Pattern i...

Page 219: ...s 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 6737 and rear pinion bearing on...

Page 220: ...RING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side bearing cones The proper shim thickness can be...

Page 221: ...sition the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 14 10 Push and hold differential case to pinion gear side of the housing and zero dial indicator Fig 15 11 Push...

Page 222: ...13 18 Position the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 14 19 Push and hold differential case toward pinion gear and zero the dial indicator Fig 17 Fig 14 Dif...

Page 223: ...he housing 31 Rotate the differential case several times to seat the side bearings 32 Position the indicator plunger against a ring gear tooth Fig 19 33 Push and hold ring gear upward while not allowi...

Page 224: ...the turning resistance of the pinion This will provide a more distinct contact pat tern 3 With a boxed end wrench on the ring gear bolt rotate the differential case one complete revolution in both di...

Page 225: ...Fig 21 Gear Tooth Contact Patterns 3 152 REAR AXLE 267RBI BR BE REAR AXLE 267RBI Continued...

Page 226: ...s 1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearings 2 3 5 1 N m 20 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 34 25 Differential Cover Bolts 47 35 Bearing Cap...

Page 227: ...452 Installer 8108 Spreader W 129 B Pilot Studs C 3288 B Dial Indicator C 3339 Puller Press C 293 PA Adapters C 293 62 Installer C 4190 Handle C 4171 Fixture 6963 A 3 154 REAR AXLE 267RBI BR BE REAR...

Page 228: ...D 162 Adapters C 293 62 Installer D 111 Installer D 146 Installer C 3095 A Installer C 3718 Trac lok Tools 8139 Trac lok Tools C 4487 Gauge Set 6730 Arbor Discs 6732 BR BE REAR AXLE 267RBI 3 155 REAR...

Page 229: ...xle tube for burrs roughness Remove all the rough contact surfaces from the axle tube 8 Carefully slide the hub onto the axle CAUTION Do not let grease seal contact axle tube threads during installtio...

Page 230: ...igned 6 Seat yoke on pinion shaft with Installer D 191 and Yoke Holder 6719 Fig 23 7 Remove the tools and install the pinion yoke washer and nut 8 Hold pinion yoke with Yoke Holder 6719 and tighten sh...

Page 231: ...ol dowel pins seated in the locating holes Fig 27 9 Install the hold down clamps and tighten the tool turnbuckle finger tight 10 Install a Pilot Stud C 3288 B at the left side of the differential hous...

Page 232: ...alled differential side bearing shim requirements may change Refer to Adjustments Differential Bearing Preload and Gear Backlash procedures to determine proper shim selection 1 Position Spreader W 129...

Page 233: ...ad of Mopar Silicone Rubber Seal ant or equivalent to the housing cover Fig 34 Install the housing cover within 5 minutes after applying the sealant 11 Install the cover and any identification tag Tig...

Page 234: ...e than 271 N m 200 ft lbs on either wheel the unit should be serviced DISASSEMBLY The Powr Loky differential has a two piece cross shaft and uses 2 disc and 3 plates for each clutch pack One plate and...

Page 235: ...36 Case Marked 1 REFERENCE MARKS Fig 38 Powr LokY Components 1 FLANGE HALF 2 CLUTCH RING 3 SIDE GEAR 4 PINION MATE GEAR 5 SCREW 6 BUTTON HALF 7 PINION MATE CROSS SHAFT 8 DISHED DISC 9 PLATE 10 DISHED...

Page 236: ...lugs enter the slots in the case Also ensure that the clutch pack bottoms out on the case 3 Install pinion mate shafts and pinion mate gears Fig 41 Make sure shafts are correctly installed according t...

Page 237: ...ller Press C 293 PA Adapters C 293 62 and Step Plate 8139 2 Fig 43 INSTALLATION 1 Using tool C 4190 with handle C 4171 install differential side bearings Fig 44 2 Install differential case in axle hou...

Page 238: ...remove pinion yoke nut and washer 9 Remove pinion yoke from pinion with Remover C 452 and Wrench C 3281 shaft Fig 46 10 Remove pinion gear from housing Fig 47 11 Remove pinion seal with a slide hammer...

Page 239: ...ll the pinion rear bearing cup with Installer C 111 and Handle C 4171 Fig 51 and verify cup is seated Fig 47 Remove Pinion Gear 1 RAWHIDE HAMMER Fig 48 Front Bearing Cup Removal 1 REMOVER 2 HANDLE Fig...

Page 240: ...ion gear mesh If ring and pinion gears are reused the pinion depth shim should not require replacement If the ring and pinion gears are replaced refer to Adjustments Pinion Gear Depth to select the pr...

Page 241: ...N m 8 in lbs 12 Invert the differential case 13 Position exciter ring on differential case 14 Using a brass drift slowly and evenly tap the exciter ring into position 15 Invert the differential case...

Page 242: ...removing the complete axle from the vehicle A small stamped metal axle gear ratio identification tag is attached to the housing cover via one of the cover bolts This tag also identifies the number of...

Page 243: ...ttached to the outside wheel to rotate at a faster speed TRAC LOKY DIFFERENTIAL The Trac loky clutches are engaged by two concur rent forces The first being the preload force exerted through Bellevill...

Page 244: ...urce Worn or damaged differential bearings usually pro duce a low pitch noise Differential bearing noise is similar to pinion bearing noise The pitch of differen tial bearing noise is also constant an...

Page 245: ...lace case and inspect gears and bearings for further damage Set ring gear backlash properly 3 Vehicle overloaded 3 Replace case and inspect gears and bearings for further damage Avoid excessive vehicl...

Page 246: ...ose pinion bearings 5 Adjust pinion bearing 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 componen...

Page 247: ...setting from the cen ter line of the ring gear to the back face of the pinion is 147 625 mm 5 812 in The standard depth pro vides the best teeth contact pattern Refer to Back lash and Contact Pattern...

Page 248: ...e Set 6730 and Dial Indicator C 3339 Fig 6 1 Assemble Pinion Height Block 6739 Pinion Block 6738 and rear pinion bearing onto Screw 6741 Fig 6 2 Insert assembled height gauge components rear bearing a...

Page 249: ...ts from the axle housing DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side beari...

Page 250: ...t stud Position the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 14 10 Push and hold differential case to pinion gear side of the housing and zero dial indicator Fig 1...

Page 251: ...he dial indicator plunger on a flat surface between the ring gear bolt heads Fig 14 19 Push and hold differential case toward pinion gear Fig 17 20 Zero dial indicator face to pointer Fig 17 Fig 14 Di...

Page 252: ...o seat the side bearings 32 Position the indicator plunger against a ring gear tooth Fig 19 33 Push and hold ring gear upward while not allowing the pinion gear to rotate 34 Zero dial indicator face t...

Page 253: ...to increase the turning resistance of the pinion This will provide a more distinct contact pat tern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential case one complete revolution...

Page 254: ...Fig 21 Gear Tooth Contact Pattern BR BE REAR AXLE 286RBI 3 181 REAR AXLE 286RBI Continued...

Page 255: ...bs Pinion Bearing Preload New Bearings 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fill Hole Plug 34 25 Differential Cover Bolts 47 35 Bearing Cap Bolts 108 80 Ring Ge...

Page 256: ...Bridge 938 Splitter Bearing 1130 Holder Yoke 6719 Gauge Pinion Depth Seting 6730 Puller C 452 Wrench C 3281 Dial Indicator Set C 3339 Handle C 4171 Installer C 4190 BR BE REAR AXLE 286RBI 3 183 REAR A...

Page 257: ...taller C 4308 Installer C 4204 Remover C 4307 Remover D 159 Installer D 187 B Installer D 191 Installer D 389 Spreader W 129 B Pilot Studs C 3288 B 3 184 REAR AXLE 286RBI BR BE REAR AXLE 286RBI Contin...

Page 258: ...nstall the hub bearing adjustment nut Use Socket DD 1241 JD to install the adjustment nut 10 Tighten the adjustment nut to 163 190 N m 120 140 ft lbs while rotating the wheel 11 Loosen the adjustment...

Page 259: ...lus a small amount for the drag the new seal will have Fig 25 NOTE The bearing rotating torque should be con stant during a complete revolution of the pinion If the rotating torque varies this indicat...

Page 260: ...of the differential housing Attach dial indicator to housing pilot stud Load the indicator plunger against the opposite side of the housing Fig 27 and zero the indicator 11 Spread the housing enough t...

Page 261: ...ferential case and mate shaft with a punch and hammer Fig 31 Peen the edge of the roll pin hole in the differential case slightly in two places 180 apart 6 Lubricate all differential components with h...

Page 262: ...sing Fig 32 6 Remove the spreader 7 Install bearing caps in their original locations Fig 33 and tighten bearing cap bolts to 109 N m 80 ft lbs 8 Install axle shafts 9 Install the hub bearings 10 Apply...

Page 263: ...l and read rotating torque Fig 35 6 If rotating torque is less than 22 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the unit should be serviced DISASSEMBLY The Trac Loky differential...

Page 264: ...e half Fig 39 Verify clutch plate lugs enter the slots in the case and clutch pack bottoms out in the case 4 Install pinion mate shafts and pinion mate gears Fig 40 Verify shafts are correctly install...

Page 265: ...differential side bearing preload and gear mesh back lash 1 Using tool C 4190 with handle C 4171 install differential side bearings Fig 43 2 Install differential in axle housing Fig 39 Clutch Pack 1 L...

Page 266: ...r installation alignment 7 Disconnect propeller shaft from pinion yoke Tie propeller shaft to underbody 8 Using Yoke Holder 6719 to hold yoke remove pinion yoke nut and washer 9 Remove pinion yoke fro...

Page 267: ...g 49 Place 4 adapter blocks so they do not damage the bearing cage 16 Remove the pinion depth shims from the pin ion gear shaft Record the total thickness of the depth shims Fig 45 Pinion Yoke Removal...

Page 268: ...ew pinion seal with an appropriate installer 8108 Fig 52 NOTE Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh If ring and...

Page 269: ...he desired rotating torque remove the pinion yoke and decrease the thickness of the solid shim pack if greater increase shim pack Changing the shim pack thick ness by 0 025 mm 0 001 in will change the...

Page 270: ...n fracture causing extensive damage 18 Install differential in housing and verify gear mesh and contact pattern 19 Install propeller shaft with reference marks aligned Fig 55 Pinion Gear Rotation Torq...

Page 271: ......

Page 272: ...OVAL 16 INSTALLATION 17 POWER BRAKE BOOSTER DIAGNOSIS AND TESTING 17 HYDRAULIC BOOSTER 17 STANDARD PROCEDURE 19 POWER BRAKE BOOSTER 19 REMOVAL 19 INSTALLATION 20 ROTORS DIAGNOSIS AND TESTING 20 DISC B...

Page 273: ...n 0 025 mm 0 001 in Mininium Front Rotor Thickness 1500 28 39 mm 1 117 in Minimum Front Rotor Thickness 2500 3500 33 90 mm 1 334 in Mininium Rear Rotor Thickness 2500 3500 28 39 mm 1 117 in DESCRIPTIO...

Page 274: ...Combination Valve Mounting Bolt 23 17 210 Combination Valve Brake Lines 21 16 190 Proportioning Valve Mounting Nuts 34 25 300 Proportioning Valve Brake Hose 31 23 276 Proportioning Valve Brake Lines...

Page 275: ...operated and connected to the rear brake trailing shoes Power brake assist is standard equipment A vacuum operated power brake booster is used on gas engine vehicles A hydraulic booster is used on die...

Page 276: ...to ensure proper operation DIAGNOSIS AND TESTING BASE BRAKE SYSTEM Base brake components consist of the brake shoes calipers wheel cylinders brake drums rotors brake lines master cylinder booster and...

Page 277: ...edal pulsation may be felt during ABS EBD activation BRAKE DRAG Brake drag occurs when the lining is in constant contact with the rotor or drum Drag can occur at one wheel all wheels fronts only or re...

Page 278: ...tire with internal damage such as a severe bruise cut or ply separation can cause pull and vibration BRAKE NOISES Some brake noise is common with rear drum brakes and on some disc brakes during the fi...

Page 279: ...cyl inder adapter The wrong adapter can lead to leak age or drawing air back into the system Use adapter provided with the equipment or Adapter 6921 BRAKE LINES STANDARD PROCEDURE DOUBLE INVERTED FLAR...

Page 280: ...draulic circuits A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shut tle forward or rearward in response to the pressure differential Movement of the s...

Page 281: ...hten to 19 23 N m 170 200 in lbs 3 Connect the pressure differential switch wire connector 4 Bleed base brake system Refer to 5 BRAKES HYDRAULIC MECHANICAL STAN DARD PROCEDURE DISC BRAKE CALIPERS REMO...

Page 282: ...piston WARNING NEVER ATTEMPT TO CATCH THE PIS TON AS IT LEAVES THE BORE THIS COULD RESULT IN PERSONAL INJURY 5 Remove the C clamp and block of wood from the caliper and clamp it over the dust boot of...

Page 283: ...eel caliper pistons The pistons seals seal grooves caliper bore and piston tolerances are different The bore can be lightly polished with a brake hone to remove very minor surface imperfections Fig 12...

Page 284: ...ease only CAUTION Use of alternative grease may cause damage to the boots seals 9 Install the boot seals into the caliper seal bores and center the seals in the bores 10 Install mounting bolt bushings...

Page 285: ...er to 22 TIRES WHEELS WHEELS STANDARD PRO CEDURE 8 Remove the supports and lower the vehicle 9 Verify a firm pedal before moving the vehicle FLUID DIAGNOSIS AND TESTING BRAKE FLUID CONTAMINATION Indic...

Page 286: ...ody in vise with brass protec tive jaws 3 Remove pins that retain reservoir to master cylinder Use hammer and pin punch to remove pins Fig 18 4 Loosen reservoir from grommets with pry tool Fig 19 5 Re...

Page 287: ...PS LIGHTING EXTERIOR BRAKE LAMP SWITCH REMOVAL 3 Remove switches from tabs on brake lamp switch bracket 4 Remove brake lamp switch bracket bolts and remove bracket Fig 23 5 Remove clip and washer atta...

Page 288: ...ring fluid level Check the brake fluid level Check all power steering hoses and lines for leaks and restrictions Check power steering pump pressure NOISES The hydraulic booster unit will produce certa...

Page 289: ...eal friction in booster 1 Replace booster 2 Faulty spool valve action 2 Replace booster 3 Restriction in booster return hose 3 Replace hose 4 Damaged input rod 4 Replace booster Excessive Brake Pedal...

Page 290: ...wait for foam to dis sipate and repeat steps 7 and 8 REMOVAL NOTE If the booster is being replaced because the power steering fluid is contaminated flush the power steering system before replacing the...

Page 291: ...h 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 Severely Scored Tapere...

Page 292: ...r assembly C3500 only Fig 31 REMOVAL 1500 2500 FRONT 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the caliper from the steering knuckle Refer to 5 BRAKES HYDRAULIC MEC...

Page 293: ...k 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 rotor onto the hub bearing wheel st...

Page 294: ...nd then tilt the top up and off the cal iper adapter Fig 35 6 Remove inboard brake shoe from the caliper adapter Fig 36 7 Remove outboard brake shoe from caliper adapter Fig 37 8 Remove the anti rattl...

Page 295: ...ve inboard brake shoe from the caliper adapter Fig 41 7 Remove outboard brake shoe from caliper adapter Fig 42 8 Remove the anti rattle springs from the caliper adapter Fig 43 and Fig 44 NOTE Anti rat...

Page 296: ...ole rotate adjuster star wheel to retract brake shoes 5 Vacuum brake components to remove brake lin ing dust 6 Remove shoe return springs with brake spring plier tool Fig 45 Fig 42 Outboard Brake Shoe...

Page 297: ...clip nuts securing brake drum to wheel studs 4 Remove brake drum 5 Vacuum brake components to remove brake lin ing dust 6 Unhook adjusting lever return spring from lever 7 Remove lever and return spr...

Page 298: ...shoe in adapter 6 Install outboard brake shoe in adapter 7 Tilt the bottom of the caliper over rotor and under adapter Then push the top of the caliper down onto the adapter 8 Install caliper Refer to...

Page 299: ...king brake cable into guide spring and insert cable into the backing plate 16 Adjust brake shoes to drum with brake gauge 17 Install wheel and tire assembly Refer to 22 TIRES WHEELS WHEELS STANDARD PR...

Page 300: ...ter vacuum hose connections A hissing noise indicates vacuum leak Correct any vacuum leak before proceeding 2 Stop engine and shift transmission into Neu tral 3 Pump brake pedal until all vacuum reser...

Page 301: ...bbles are no longer visible in fluid REMOVAL 1 Pump the brake pedal several times to deplete booster vacuum reserve 2 Remove brake lines from the master cylinder Fig 57 3 Remove mounting nuts from the...

Page 302: ...linder operation The cylinder bore can be lightly polished but only with crocus cloth Replace the cylinder if the bore is scored pitted or heavily corroded Honing the bore to restore the surface is no...

Page 303: ...n new support plate 4 Install parking brake cable in support plate 5 Install brake shoes and hardware 6 Install axle shaft Refer to 3 DIFFEREN TIAL DRIVELINE REAR AXLE 9 1 4 AXLE SHAFTS INSTALLATION 7...

Page 304: ...ing surface is indicated on the drum outer edge Generally a drum can be machined to a maximum of 1 52 mm 0 060 in oversize Always replace the drum if machining would cause drum diameter to exceed the...

Page 305: ...rify that left and right automatic adjuster levers and cables are properly connected 4 Insert brake gauge in drum Expand gauge until gauge inner legs contact drum braking surface Then lock gauge in po...

Page 306: ...The parking brakes are operated by a system of cables and levers attached to a primary and second ary shoe positioned within the drum section of the rotor The drum in hat design utilizes an independe...

Page 307: ...an applied position Parking brake release is accomplished by the hand release A parking brake switch is mounted on the parking brake lever and is actuated by movement of the lever The switch which is...

Page 308: ...2 Loosen adjusting nut to create slack in front cable 3 Remove the front cable from the cable connec tor 4 Compress cable end fitting at underbody bracket and remove the cable from the bracket 5 Lowe...

Page 309: ...7 Pull the right rear cable through the brake hose bracket and remove the cable retainers from the axle 8 Remove rear wheels and brake drums 9 Disconnect each cable from the park brake lever 10 Remov...

Page 310: ...the top hole of the bracket 7 Lock the left cable end fitting tabs into the frame bracket lower hole 8 Install the right rear cable into the tensioner cable bracket and lock the cable end fitting tabs...

Page 311: ...ner rod until the mark is no longer visible CAUTION Do not loosen or tighten the tensioner adjusting nut for any reason after completing adjustment 13 Lower the vehicle until the rear wheels are 15 20...

Page 312: ...e to access and snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle over the link age rod 5 Reach under the driver...

Page 313: ...rotor Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION 4 Install the disc brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS INSTALLATION 5 Install the tire and wheel...

Page 314: ...located between these two compo nents The clutch system provides the mechanical but still easily detachable link between the engine and the transmission The system is designed to ensure that the full...

Page 315: ...ND THE ENVIRONMENTAL SAFETY AGENCY EPA FOR THE HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS DIAGNOSTIC AND TESTING CLUTCH A road test and component inspection Fig 3 is recommended to determin...

Page 316: ...Fig 3 Clutch Components And Inspection BR BE CLUTCH 6 3 CLUTCH Continued...

Page 317: ...t is excessive Check condition of the clutch before installation A warped cover or diaphragm spring will cause grab and incomplete release or engagement Be careful when handling the cover and disc Imp...

Page 318: ...low minimum thickness specification 1 Improper flywheel machining Flywheel has excessive taper or excessive material removal 1 Replace flywheel Clutch disc cover and or diaphragm spring warped or dist...

Page 319: ...and lubricate a new bearing Clutch will not disengage properly 1 Low clutch fluid level 1 Replace hydraulic linkage assembly 2 Clutch cover loose 2 Follow proper bolt tightening procedure 3 Clutch dis...

Page 320: ...IONS CLUTCH TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Nut slave cylinder 19 26 14 19 170 230 Bolt clutch cover 5 16 in 23 17 Bolt clutch cover 3 8 in 41 30 Pivot release bearing 23 17 Screw...

Page 321: ...clutch cover will be reused mark position of cover on flywheel with paint or scriber Fig 8 5 Insert clutch alignment tool in clutch disc and into pilot bushing Tool will hold disc in place when cover...

Page 322: ...lts evenly and a few threads at a time Cover bolts must be tightened evenly and to specified torque to avoid distorting cover 8 Tighten clutch cover bolts to following 5 16 in diameter bolts to 23 N m...

Page 323: ...lled properly When the release lever is installed correctly the lever part number will be toward the bottom of the transmission and right side up There is also a stamped I in the lever which goes to t...

Page 324: ...ropriate size threaded rod that is 10 in 25 4 cm long Fig 14 The rod will be used to mount the dial indicator 4 Remove the release fork from the clutch hous ing 5 Reinstall the clutch housing Tighten...

Page 325: ...els in the direction needed to center the bore with the crank shaft centerline In the example TIR was 0 012 inch The dowels needed for correction would have an offset of 0 007 in Fig 17 Install the do...

Page 326: ...3 8 in diameter bolts 68 N m 50 ft lbs for 7 16 in diameter bolts 47 N m 35 ft lbs for V10 and diesel clutch housing bolts During final transmission installation install the shims between the clutch...

Page 327: ...ansmission and transfer case if equipped Refer to 21Transmission and Transfer Case for proper procedures CLUTCH RELEASE BEARING DESCRIPTION A conventional release bearing Fig 24 is used to engage and...

Page 328: ...side 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 transfe...

Page 329: ...bolted to the rear of the crankshaft The flywheel incorporates the ring gear around the outer circumference to mesh with the starter to permit engine cranking The rear face of the flywheel serves as...

Page 330: ...ent ref erence on the 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...

Page 331: ...aight during installation Do not allow bearing to become cocked Tap bearing into place until flush with edge of bearing bore Do not recess bearing 3 Install clutch cover and disc 4 Install clutch hous...

Page 332: ...e cylinder and an interconnecting fluid line 9 Fig 34 The clutch master cylinder push rod is connected to the clutch pedal The slave cylinder push rod is connected to the clutch release fork The maste...

Page 333: ...s serviced as an assembly only but it comes as two pieces to ease installation Once the clutch hydraulic line is connected to the slave cylinder it should not be disconnected The individual compo nent...

Page 334: ...5 N m 40 in lbs torque 8 Install the plastic clip securing the hydraulic line to the dash panel into the lower dash panel flange 9 Install the plastic clip securing the hydraulic line to the dash pan...

Page 335: ...ON The switch which is in circuit with the starter solenoid requires that the clutch pedal be fully depressed in order to start the engine Switch cir cuitry and operation is provided in section 8W of...

Page 336: ...ows the engine to reach normal oper ating temperature as quickly as possible It also maintains normal operating temperature and pre vents overheating The cooling system also provides a means of heat i...

Page 337: ...4 OPERATION HOSE CLAMPS The worm type hose clamp uses a specified torque value to maintain proper tension on a hose connec tion The spring type hose clamp applies constant ten sion on a hose connecti...

Page 338: ...Fig 3 Cooling System Circulation Diesel Engine BR BE COOLING 7 3 COOLING Continued...

Page 339: ...uld have been ordered with vehicle if add on or after market A C is installed If not maximum cooling system compo nents should be installed for model involved per manufacturer s specifications RECENT...

Page 340: ...r pressure cap from filler neck and check coolant level Push down on cap to disengage it from stop tabs Wipe inside of filler neck and examine lower inside sealing seat for nicks cracks paint dirt and...

Page 341: ...uctuation of gauge pointer indicates compression or combustion leakage into cooling system Because the vehicle is equipped with a catalytic converter do not remove spark plug cables or short out cylin...

Page 342: ...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...

Page 343: ...sary d Check coolant reserve overflow tank and tanks hoses for blockage Repair as necessary 8 Incorrect coolant concentration 8 Check coolant Refer to LUBRICATION MAINTENANCE FLUID TYPES DESCRIPTION 9...

Page 344: ...ought to a stop after heavy use engine still running 3 A normal condition No correction is necessary Gauge should return to normal range after vehicle is driven 4 Gauge reading high after re starting...

Page 345: ...IGNITION SYSTEM GAUGE MAY OR MAY NOT BE READING HIGH 1 Engine overheating 1 Check reason for overheating and repair as necessary 2 Freeze point of coolant not correct Mixture is too rich or too lean...

Page 346: ...gs 3 Remove heater hoses at both ends and check for obstructions 4 Heater hose kinked 4 Locate kinked area and repair as necessary 5 Water pump is not pumping water to through the heater core When the...

Page 347: ...with a heavy duty cooling system 1 None System operating normaly 2 Temperature gauge not connected 2 Connect gauge 3 Temperature gauge connected but not operating 3 Check gauge Refer Refer to 8 ELECT...

Page 348: ...Refer to 5 BRAKES HYDRAULIC MECHANICAL DIAGNOSIS AND TESTING TEMPERATURE GAUGE READING INCONSISTENT ERRATIC CYCLES OR FLUCTUATES 1 Heavy duty cooling system extream cold ambient outside temperature or...

Page 349: ...DITIONER PERFORMANCE COOLING SYSTEM SUSPECTED 1 Radiator and or A C condenser air flow obstructed 1 Remove obstruction and or clean 2 Thermal viscous fan drive not working 2 Check fan drive Refer to 7...

Page 350: ...K DRAIN PLUGS OR LOOSEN RADIATOR DRAIN COCK WITH SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR DO NOT WASTE reusable coolant If solution is clean drain coolant into a clean contai...

Page 351: ...rks If the coolant level is at or below the ADD mark fill the recovery bottle with a 50 50 mixture of antifreeze and water ONE QUART AT A TIME Repeat this pro cedure until the coolant level is at the...

Page 352: ...g This will soften scale and other deposits and aid flushing operation CAUTION Follow manufacturers instructions when using these products STANDARD PROCEDURE COOLANT SELECTION ADDITIVES The presence o...

Page 353: ...SPECIAL TOOLS COOLING Spanner Wrench 6958 Adapter Pins 8346 Pliers 6094 Pressure Tester 7700 A 7 18 COOLING BR BE COOLING Continued...

Page 354: ...L 5 9L DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine acces sories If specified tension is not maintained belt slippage may cause engine ove...

Page 355: ...coil mounting bracket has been tapped for coil mounting bolts tighten bolts to 5 N m 50 in lbs torque 5 Install drive belt Refer to 7 COOLING AC CESSORY DRIVE DRIVE BELTS INSTALLA TION 6 Check belt i...

Page 356: ...ly routed A used belt should be replaced if tensioner index ing arrow has moved to point A Fig 5 Tensioner travel stops at point A REMOVAL WARNING BECAUSE OF HIGH SPRING PRES SURE DO NOT ATTEMPT TO DI...

Page 357: ...bracket A dowel pin is located on back of tensioner Fig 7 Align this to dowel hole Fig 8 in tensioner mounting bracket Tighten bolt to 41 N m 30 ft lbs torque 3 Install drive belt Refer to 7 COOLING...

Page 358: ...not be met check for The wrong belt being installed incorrect length width Worn bearings on an engine accessory A C com pressor power steering pump water pump idler pul ley or generator A pulley on an...

Page 359: ...xcessive wear frayed cords or severe glazing Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable a...

Page 360: ...re seizure 3 Replace faulty component or bearing 4 Belt glazed or hardened from heat and excessive slippage 4 Replace belt LONGITUDAL BELT CRACKING 1 Belt has mistracked from pulley groove 1 Replace b...

Page 361: ...n tensile member and rubber matrix 4 Replace belt REMOVAL NOTE The belt routing schematics are published from the latest information available at the time of publication If anything differs between th...

Page 362: ...RIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts small cracks that run across the ribbed surface of the belt from rib to rib Fig 15 are considered normal These are not a rea...

Page 363: ...lley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Replace pulley Inspect belt 5 Belt rubber d...

Page 364: ...OISE Objectional squeal spueak or rumble is heard or felt while drive belt is in operation 1 Incorrect belt tension 1 Inspect Replace tensioner if necessary 2 Bearing noise 2 Locate and repair 3 Belt...

Page 365: ...heat due to water pump rotating in wrong direction Refer to Fig 17 Fig 18 for correct engine belt routing The correct belt with correct length must be used CAUTION If the pulley is to be removed from...

Page 366: ...ayed cords or severe glazing Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle Before re...

Page 367: ...lure seizure 3 Replace faulty component or bearing 4 Belt glazed or hardened from heat and excessive slippage 4 Replace belt LONGITUDAL BELT CRACKING 1 Belt has mistracked from pulley groove 1 Replace...

Page 368: ...ion with a belt tension gauge on vehicles equipped with an automatic belt tensioner Refer to Automatic Belt Tensioner in this group NOTE The belt routing schematics are published from the latest infor...

Page 369: ...he vacuum pump is a constant displacement vane type pump Vacuum is generated by four vanes mounted in the pump rotor The rotor is located in the pump housing and is pressed onto the pump shaft The vac...

Page 370: ...tput when necessary Simply disconnect the pump supply hose and connect a vacuum gauge to the outlet port for testing purposes With the engine running vacuum output should be a minimum of 25 inches dep...

Page 371: ...nd must not be seperated 9 Remove the remaining three power steering pump to adapter mounting nuts Fig 27 10 Gently remove the steering pump from the adapter Use caution not to damage the oil seal in...

Page 372: ...adhesive sealer to hold gasket in place 4 Insert pump assembly upper attaching bolt in mounting flange and gasket Use sealer or grease to hold bolt in place if necessary 5 Position pump assembly on en...

Page 373: ...pump connec tor and tighten line fitting 9 Connect steering pump pressure and return lines to pump Tighten pressure line fitting to 30 N m 22 ft lbs 10 Connect vacuum hose to vacuum pump 11 Connect b...

Page 374: ...THERMOSTAT 3 9L 5 2L 5 9L DESCRIPTION 49 OPERATION 49 DIAGNOSIS AND TESTING 49 THERMOSTAT 49 REMOVAL 49 INSTALLATION 50 ENGINE COOLANT THERMOSTAT 8 0L DESCRIPTION 52 OPERATION 52 DIAGNOSIS AND TESTING...

Page 375: ...rcent ethylene glycol will cause for mation of additive deposits in the system as the cor rosion inhibitive additives in ethylene glycol require the presence of water to dissolve The deposits act as i...

Page 376: ...to cover minor leaks and evaporation or boiling losses As the engine cools a vacuum is formed in the cooling system of both the radiator and engine Cool ant will then be drawn from the coolant tank a...

Page 377: ...ssembly if any of these conditions are found Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction 1 Disconnect negative battery cable from b...

Page 378: ...FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS CAUTION If fan blade assembly is replaced because of mechanical damage water pump and viscous fan drive should also be inspected These components could...

Page 379: ...A Snap On 36 MM Fan Wrench number SP346 from Snap On Cummins Diesel Tool Set number 2017DSP can be used Place a bar or screwdriver between the fan pulley bolts to prevent pulley from rotating 4 Remov...

Page 380: ...e heating element immersed in engine coolant The cord is attached to an engine compartment compo nent with tie straps The 3 9L and 5 9L gas powered engine has the block heater located on the right sid...

Page 381: ...AC electrical outlet with a grounded three wire extension cord provides the elec tricity needed to heat the element REMOVAL 1 Disconnect battery negative cable 2 Drain coolant from radiator and cylind...

Page 382: ...ting and faster warm up in low temperatures Connecting the power cord to a grounded 110 120 volt AC electrical outlet with a grounded three wire extension cord provides the elec tricity needed to heat...

Page 383: ...imes EGR solenoid on off times if equipped Leak Detection Pump operation if equipped Radiator fan relay on off times if equipped Target idle speed REMOVAL WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJ...

Page 384: ...ects low engine coolant temperature it will record a Diagnostic Trouble Code DTC in the PCM mem ory Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor he...

Page 385: ...acement is necessary use only an original equipment clamp with matching number or letter 7 Remove radiator upper hose clamp and upper hose at thermostat housing 8 Position wiring harness behind thermo...

Page 386: ...Conditioned vehicles Install generator Tighten bolts to 41 N m 30 ft lbs 8 Install support bracket generator mounting bracket to intake manifold Fig 16 Tighten bolts to 54 N m 40 ft lbs torque 9 Insta...

Page 387: ...additional infor mation If the powertrain control module PCM detects low engine coolant temperature it will record a Diagnostic Trouble Code DTC in the PCM mem ory Do not change a thermostat for lack...

Page 388: ...ors 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 and therm...

Page 389: ...pressure to force the valve to open DIAGNOSIS AND TESTING THERMOSTAT The cooling system used with the diesel engine provides the extra coolant capacity and extra cooling protection needed for higher G...

Page 390: ...AN OCCUR Do not waste reusable coolant If the solution is clean drain the coolant into a clean container for reuse 1 Disconnect the battery negative cables 2 Drain cooling system until coolant level i...

Page 391: ...e bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed DIAGNOSIS AND TESTING VISCOUS FAN DRIVE NOISE NOTE It is normal for fan noise to be louder roar ing when Th...

Page 392: ...o 79 C 135 to 175 F A definite decrease of fan flow noise roar ing should be noticed If not replace the defective viscous fan drive unit CAUTION Some engines equipped with serpentine drive belts have...

Page 393: ...ter of the fan shroud 2 Obtain a dial thermometer with an 8 inch stem or equivalent It should have a range of 18 to 105 C 0 to 220 F Insert thermometer through the hole in the shroud Be sure that ther...

Page 394: ...system 1 Idle engine until operating temperature is reached If the upper radiator hose is warm to the touch the thermostat is opening and coolant is flow ing to the radiator WARNING HOT PRESSURIZED C...

Page 395: ...he two radiator upper mounting bolts Fig 35 10 Lift radiator straight up and out of engine compartment The bottom of the radiator is equipped with two alignment dowels that fit into holes in the lower...

Page 396: ...ables 12 Position heater controls to full heat position 13 Fill cooling system with coolant Refer to 7 COOLING STANDARD PROCEDURE 14 Operate engine until it reaches normal tem perature Check cooling s...

Page 397: ...d remove tank 7 Remove the four fan shroud mounting bolts Fig 37 Position shroud rearward over the fan blades towards engine 8 Remove the two radiator upper mounting bolts Fig 38 9 Lift radiator strai...

Page 398: ...oler only on the V 10 gas engine and the 5 9L die sel engine combinations OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the...

Page 399: ...n shroud pull straight up The tank slips into T slots on the fan shroud Fig 40 The coolant recov ery reservoir does not require removal Disconnect the overflow hose from the radiator 6 Disconnect elec...

Page 400: ...hroud to flanges on sides of radi ator Install fan shroud mounting bolts Fig 41 Tighten bolts to 6 N m 50 in lbs torque 9 Install metal clips to top of fan shroud 10 Install coolant reserve overflow t...

Page 401: ...ESCAPE THROUGH THE COOLANT RESERVE OVERFLOW HOSE INTO RESERVE OVERFLOW TANK SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK...

Page 402: ...warms properly A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core REMOVAL The water pump on all models can be removed without discharg...

Page 403: ...ey from rotating 8 If water pump is being replaced do not unbolt fan blade assembly Fig 49 from the thermal control fan drive 9 Remove fan blade fan drive and fan shroud as an assembly from vehicle 10...

Page 404: ...ller rubbing the pump body Fig 49 Fan Blade and Viscous Fan Drive Typical 1 WATER PUMP BYPASS HOSE 2 FAN BLADE ASSEMBLY 3 VISCOUS FAN DRIVE 4 WATER PUMP AND PULLEY Fig 50 Belt Tensioner 3 9L V 6 or 5...

Page 405: ...heater core REMOVAL NOTE The water pump on all models can be removed without discharging the air conditioning system if equipped The water pump on all gas powered engines is bolted directly to the en...

Page 406: ...55 from the thermal control fan drive 8 Remove fan blade fan drive and fan shroud as an assembly from vehicle After removing fan blade fan drive assembly do not place the thermal viscous fan drive in...

Page 407: ...er fitting has been torqued position fitting as shown in Fig 59 When positioning fitting do not back off rotate counter clockwise Use a sealant on the fitting such as Mopart Thread Sealant With Teflon...

Page 408: ...a serpentine drive belt Fig 60 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 h...

Page 409: ...P BYPASS HOSE WITH AIR CONDITIONING If equipped with A C the generator and A C com pressor along with their common mounting bracket Fig 63 must be partially removed Removing the generator or A C compr...

Page 410: ...ve the tensioner mounting bolt Fig 65 and remove tensioner 10 Remove the engine oil dipstick tube mounting bolt at the side of the A C generator mounting bracket 11 Disconnect throttle body control ca...

Page 411: ...1 COOLANT RETURN TUBE 2 WATER PUMP 3 TUBE MOUNTING BOLT 4 O RING Fig 68 Bracket Bolts 3 9L V 6 or 5 2 5 9L V 8 LDC Gas 1 COOLANT TUBE MOUNTING BOLT 2 BRACKET MOUNTING BOLTS Fig 69 Bracket Bolts 5 9L...

Page 412: ...lamps to the center of hose 2 Install bypass hose to engine 3 Secure both hose clamps 4 Install generator A C mounting bracket assem bly to engine Tighten bolt number 1 Fig 63 to 41 N m 30 ft lbs torq...

Page 413: ...e to clip at radiator fan shroud 15 Connect wiring harness to A C compressor 16 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 17 Start and warm the engine Check for leaks INSTALLATION WATE...

Page 414: ...oler is located between the radiator and air conditioning condenser Fig 1 OPERATION The transmission oil is routed through the cooler where heat is removed from the transmission oil before returning t...

Page 415: ...From cooler line 6 Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines 8 Turn pump OFF 9 Disconnect CLEAR suction line from re...

Page 416: ...7 COOLING TRANSMISSION TRANS COOLER ASSEMBLY 21 Install the transmission oil cooler onto the vehicle Refer to 7 COOLING TRANSMISSION TRANS COOLER INSTALLATION 22 Disconnect CLEAR suction line from res...

Page 417: ...ng on the cooler outler tube until an audible click is heard Pull apart to verify connection 7 Connect battery negative cable 8 Start the engine and check all fittings for leaks 9 Check the fluid leve...

Page 418: ...be removed and an appropriate replacement hose installed to bridge the space between the transmis sion cooler line and the cooler fitting Failure to remove the drainback valve will prevent reverse fl...

Page 419: ...he snap ring 16 Turn pump ON for two to three minutes to flush cooler s and lines NOTE This flushes the main oil cooler core pas sages only 17 Turn pump OFF 18 Remove the thermostat cover from the oil...

Page 420: ...side of the engine Fig 6 The air to oil cooler is located in front of and to the left side of the radiator Fig 7 OPERATION The transmission oil is routed through the main cooler first then the auxili...

Page 421: ...m cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one quart container of Mopart ATF 4 type 9602 Automatic Transmission Fluid 12 Turn pump ON until all transmission fluid is removed f...

Page 422: ...mission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 26 Disconnect alligator clips from batte...

Page 423: ...matic trans mission Refer to 21 TRANSMISSION TRAN SAXLE AUTOMATIC 47RE FLUID STANDARD PROCEDURE INSTALLATION 1 Position oil cooler on bracket 2 Install mounting straps 3 Connect transmission oil lines...

Page 424: ...AKER 18 A PILLAR TWEETER SPEAKER REMOVAL 19 INSTALLATION 19 FRONT DOOR SPEAKER REMOVAL 20 INSTALLATION 20 REAR CAB SIDE PANEL SPEAKER REMOVAL 20 INSTALLATION 21 REAR DOOR SPEAKER REMOVAL 21 INSTALLATI...

Page 425: ...ls and integrates many of the additional electronic functions and features included on models with this option The RAZ radio receiver with a remote radio switch option is one of the features that the...

Page 426: ...4 Ground faulty 4 Check for continuity between radio chassis and a known good ground There should be continuity Repair ground if required 5 Radio faulty 5 Refer to Radio in the Diagnosis and Testing...

Page 427: ...panel antenna coaxial cable with an in line connector that is located behind the right end of the instrument panel The secondary coaxial cable is then routed behind the instrument panel to the back of...

Page 428: ...n A short length of coaxial cable serves as the pri mary antenna cable The center conductor of the cable is connected to the antenna mast receptacle The outer wire mesh of the cable is connected to an...

Page 429: ...nnect both battery cables the negative cable first Reconnect the battery negative cable and perform the test as follows 1 Connect one ohmmeter test lead to the vehicle fender Connect the other test le...

Page 430: ...wrench Special Tool C 4816 Fig 5 9 Remove the antenna adapter from the top of the fender 10 Lower the antenna body and cable assembly through the top of the fender 11 Pull the antenna body and cable o...

Page 431: ...GNOSIS AND TESTING RADIO CHOKE RELAY The filter choke and speaker relay is used to switch power to the individual speaker amplifiers used with the Infinity premium speaker package The choke and relay...

Page 432: ...filter choke and speaker relay wire harness connector 4 Reconnect the battery negative cable INSTRUMENT PANEL ANTENNA CABLE REMOVAL 1 Disconnect and isolate the battery negative cable 2 Reach under t...

Page 433: ...n authorized radio repair station See the latest War ranty Policies and Procedures manual for a current listing of authorized radio repair stations All vehicles are equipped with an Ignition Off Draw...

Page 434: ...position Check for battery voltage at the fused ignition switch output acc run fuse in the junction block If OK go to Step 5 If not OK repair the open fused ignition switch output acc run circuit to t...

Page 435: ...e used on this vehicle to control RFI or EMI noise include the fol lowing Radio antenna base ground Radio receiver chassis ground wire or strap Engine to body ground straps Cab to bed ground strap Hea...

Page 436: ...way from the factory installed vehicle wire harnesses whenever possible The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio SWR Fleet vehicles are available with an ext...

Page 437: ...rew that secures the cab to bed ground strap eyelet to the cab floor panel Tighten the screw to 3 9 N m 35 in lbs 3 Position the cab to bed ground strap to the front crossmember of the cargo bed 4 Ins...

Page 438: ...The switch on the right side is the volume control switch and has volume up and volume down functions The two switches are retained in mounting holes located on each side of the rear steering wheel t...

Page 439: ...ck Seek Up 4530 Ohms Left Black Seek Down 2050 Ohms Left Black Pre Set Station Advance 10 Ohms 3 Check for continuity between the ground cir cuit cavity of the remote radio switch wire harness connect...

Page 440: ...each front door There is also one full range 13 3 cen timeter 5 25 inch diameter speaker located in each rear cab side panel for the standard cab and the club cab models or in each rear door of the q...

Page 441: ...round In each case there should be no continuity If OK go to Step 3 If not OK repair the shorted speaker feed and or return circuit s to the speaker as required 3 If the inoperative speaker is an Infi...

Page 442: ...door mounted speaker on the same side of the vehicle as the inoperative speaker The meter should read between 2 5 and 4 ohms speaker resistance If OK replace the faulty front door mounted Infinity sp...

Page 443: ...connector to the front door wire harness connector 3 Position the speaker into the mounting hole in the front door inner panel 4 Install and tighten the four screws that secure the speaker to the fro...

Page 444: ...he mounting hole in the rear door inner panel far enough to access the door wire harness connector 5 Disconnect the door wire harness connector from the speaker connector receptacle 6 Remove the speak...

Page 445: ......

Page 446: ...several wire harnesses which are routed throughout the vehicle and retained by many different methods These circuits may be con nected to each other to the vehicle electrical system and to the chime w...

Page 447: ...ssion only The chimes will continue to sound for a duration of about two seconds each time the indicator is illuminated or until the ignition switch is turned to the Off position whichever occurs firs...

Page 448: ...it cavity and the seat belt switch sense circuit cavity of the seat belt switch connector receptacle There should be no continuity with the seat belt buckled Replace the faulty seat belt if required N...

Page 449: ...door ajar switch and the instrument panel wire harness connector Connector C1 for the headlamp switch Repair the driver door ajar switch sense circuit if required 2 Key in ignition switch sense circui...

Page 450: ...CTM Repair the fused ignition switch output circuit if required 4 Faulty CTM 4 Replace the faulty CTM if required NO WARNING CHIME SUPPORT FEATURES FOR EMIC BUT HARD WIRED CHIMES OK 1 Tone request si...

Page 451: ......

Page 452: ...e versions of the Central Timer Module CTM are available on this vehicle a base version Fig 1 a high line version Fig 2 and a premium version Whichever version of the CTM the vehicle is equipped with...

Page 453: ...nt Wipe Control All versions of the CTM provide control of the intermittent wipe delay and wipe after wash features Panic Mode The high line premium CTM pro vides support for the optional RKE system p...

Page 454: ...d received through a second connector and take out of the instrument panel wire harness The first ground cir cuit receives ground through a take out with an eye let terminal connector of the instrumen...

Page 455: ...N 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...

Page 456: ...IR 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...

Page 457: ...ING COVER INSTALLATION 6 Reconnect the battery negative cable COMMUNICATION DESCRIPTION CCD DATA BUS The Chrysler Collision Detection also referred to as CCD or C2 D data bus system is a multiplex sy...

Page 458: ...ND BUS CIRCUITS The two wires sometimes referred to as the twist ed pair that comprise the CCD data bus are the D1 circuit Bus and the D2 circuit Bus The 9D9 in D1 and D2 identify these as diagnostic...

Page 459: ...ot occur Voltage would go to 5 volts on one bus wire and 0 volts on the other bus wire The voltage drop through the termination resistor creates 2 51 volts on Bus and 2 49 volts on Bus The voltage dif...

Page 460: ...PRIORITY Messages can be broadcast almost simultaneously by modules over the CCD data bus Therefore all messages are defined and ranked by a predetermined priority When two CCD chips start a message a...

Page 461: ...s the ID code of the messages If the message is not for that particular module the message is sim ply ignored Once the module recognizes a message that it requires the rest of the message is monitored...

Page 462: ...s Monitor the RWAL brake system for proper oper ation Control the RWAL valve solenoids NOTE If the CAB needs to be replaced the rear axle type and tire revolutions per mile must be pro gramed into the...

Page 463: ...r harness 4 Connect the harnesses to the CAB and lock the connectors 5 Connect battery DATA LINK CONNECTOR DESCRIPTION DATA LINK CONNECTOR The data link connector is located at the lower edge of the i...

Page 464: ...CM regulates various engine and vehicle operations through different system components These compo nents are referred to as ECM Outputs The sensors and switches that provide inputs to the ECM are cons...

Page 465: ...le INSTALLATION Do not apply paint to back of ECM Poor ground will result 1 Clean ECM mounting points at engine block 2 Position ECM to engine block and install 3 mounting bolts Tighten bolts to 24 N...

Page 466: ...down ASD relay is energized by the PCM for approximately three seconds The fuel pump is energized through the fuel pump relay by the PCM The fuel pump will operate for approximately three seconds unle...

Page 467: ...s ignition timing by increasing and decreasing spark advance The PCM operates the A C compressor clutch through the clutch relay This happens if A C has been selected by the vehicle operator and reque...

Page 468: ...odule PCM has 2 main grounds Both of these grounds are referred to as power grounds All of the high current noisy electri cal devices are connected to these grounds as well as all of the sensor return...

Page 469: ...ection pump if equipped Malfunction indicator lamp Check engine lamp Driven through CCD circuits Overdrive indicator lamp if equipped Service Reminder Indicator SRI Lamp MAINT REQ D lamp Driven throug...

Page 470: ...upply supplies the required 5 volt power source to the oil pressure sensor supplies the required 5 volt power source for the Vehicle Speed Sensor VSS if equipped supplies the 5 volt power source to th...

Page 471: ...vehicle 2 Tighten bolts to 4 N m 35 in lbs 3 Check pin connectors in the PCM and the three 32 way connectors for corrosion or damage Repair as necessary 4 Install three 32 way connectors 5 Install cov...

Page 472: ...M DESCRIPTION A single 12 volt battery system is standard factory installed equipment on gasoline engine equipped models Models equipped with a diesel engine utilize two 12 volt batteries connected in...

Page 473: ...by the switching of any of the electrical components or circuits in the vehicle DIAGNOSIS AND TESTING BATTERY SYSTEM The battery starting and charging systems in the vehicle operate with one another...

Page 474: ...andard Procedures for the proper test procedures Charge the faulty battery as required 5 The electrical system ignition off draw is excessive 5 Refer to Standard Procedures for the proper test procedu...

Page 475: ...system as required 7 The charging system is faulty 7 Determine if the charging system is performing to specifications Refer to Charging System for the proper charging system diagnosis and testing pro...

Page 476: ...using a stiff bristle parts cleaning brush to remove any acid film Fig 2 Rinse the battery with clean water Ensure that the cleaning solution does not enter the battery cells through the vent holes If...

Page 477: ...storage battery Fig 4 is standard factory installed equipment on this model Refer to Battery Specifications for the proper specifications of the factory installed batteries available on this model Mal...

Page 478: ...r free electrons between the positive and negative plate groups This movement of electrons produces a flow of electrical current through the load device attached to the battery ter minals As the plate...

Page 479: ...t indicator but does have remov able cell caps perform the hydrometer test to deter mine the state of charge If the battery cell caps are not removable or a hydrometer is not available per form the op...

Page 480: ...THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BAT TERY PERSONAL INJURY AND OR VEHICLE DAM AGE MAY RESULT WARNING THE BATTERY CONTAINS SULFURIC ACID WHICH IS POISONOUS AND CAUSTIC AVOID...

Page 481: ...ers built into many battery chargers 2 Disconnect and isolate the battery negative cable Connect the battery charger leads Some bat tery chargers are equipped with polarity sensing cir cuitry This cir...

Page 482: ...ITH THE SKIN EYES OR CLOTHING IN THE EVENT OF CONTACT FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN WARNING IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS BE...

Page 483: ...H WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN WARNING IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFOR...

Page 484: ...removable cell caps WARNING IF THE BATTERY SHOWS SIGNS OF FREEZING LEAKING OR LOOSE POSTS DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHICLE...

Page 485: ...THE EVENT OF CONTACT FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN WARNING IF THE BATTERY IS EQUIPPED WITH REMOVABLE CELL CAPS BE CERTAIN THAT EACH OF THE CELL C...

Page 486: ...volts 0 18 7 If the voltmeter reading falls below 9 6 volts at a minimum battery temperature of 21 C 70 F the battery is faulty and must be replaced STANDARD PROCEDURE IGNITION OFF DRAW TEST The term...

Page 487: ...ghest amperage scale Connect the multi meter between the disconnected battery negative cable ter minal clamp and the battery negative terminal post Make sure that the doors remain closed so that the i...

Page 488: ...al post If nec essary use a battery terminal puller to remove the terminal clamp from the battery post 6 Remove the battery hold downs from the bat tery Refer to Battery Hold Downs in this group for t...

Page 489: ...ons OPERATION The battery holddown secures the battery in the battery tray This holddown is designed to prevent battery movement during the most extreme vehicle operation conditions Periodic removel a...

Page 490: ...he battery negative cable wire harness which may include portions of the wiring circuits for the generator and other com ponents on some models Refer to Wiring Diagrams in the index of this service ma...

Page 491: ...able terminal clamp pinch bolt and the other eyelet terminal is secured with a ground screw to the outer surface of the left frame rail below the battery DIESEL ENGINE The left battery positive cable...

Page 492: ...H A DIESEL ENGINE FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY The following operation will require a voltmeter accurate to 1 10 0 10 volt Before performing this test be certain that the following p...

Page 493: ...e reading is still above 0 2 volt replace the faulty battery positive cable NOTE If the vehicle is equipped with a dual battery system Step 3 must be performed on the driver side battery only Fig 21 F...

Page 494: ...erminal clamp pinch bolt hex nut 3 Disconnect the battery negative cable terminal clamp from the battery negative terminal post If necessary use a battery terminal puller to remove the terminal clamp...

Page 495: ...ner of the engine compartment A U nut held in a molded formation on each side of the battery tray pro vides anchor points for the battery hold down bolts The battery tray is secured on the outboard s...

Page 496: ...the vehicle is equipped with the optional vehicle speed control package the speed control servo must be removed from the left battery tray support to complete battery tray removal Refer to Speed Cont...

Page 497: ...anel Tighten the nuts to 15 8 N m 140 in lbs 10 If the left battery tray is being installed install the battery temperature sensor onto the left battery tray Refer to Battery Temperature Sensor in the...

Page 498: ...ture This temperature data along with data from monitored line voltage is used by the PCM to vary the battery charging rate This is done by cycling the ground path to control the strength of the roto...

Page 499: ...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 dr...

Page 500: ...harness from engine wire harness 3 Pry sensor straight up from battery tray mounting hole INSTALLATION The battery temperature sensor is located under the vehicle battery Fig 1 and is attached snappe...

Page 501: ...do not remove generator mounting bracket to engine bolt Fig 4 5 All Engines Remove upper generator mounting bolt and lower mounting bolt nut 6 Remove B terminal mounting nut at rear of generator Fig 5...

Page 502: ...d path 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 det...

Page 503: ...codes OPERATION The starting system components form two separate circuits A high amperage feed circuit that feeds the starter motor between 150 and 350 amperes 700 amperes diesel engine and a low ampe...

Page 504: ...S AND TESTING STARTING SYSTEM The battery starting and charging systems oper ate in conjunction with one another and must be tested as a complete system For correct starting charging system operation...

Page 505: ...Visually inspect ignition switch for indications of physical damage and loose or corroded wire harness connections Refer to Igni tion Switch and Key Lock Cylinder Clutch Pedal Position Switch If equi...

Page 506: ...e connector at starter solenoid If you probe battery positive terminal post and cable connector at starter solenoid you are reading com bined voltage drop in battery positive cable clamp to terminal p...

Page 507: ...erminal post and a good clean ground on engine block Fig 5 Rotate and hold ignition switch in Start position Observe voltmeter If reading is above 0 2 volt clean and tighten battery negative cable att...

Page 508: ...driver side battery positive cable clamp bolt Repeat test If reading is still above 0 2 volt replace faulty passenger side battery posi tive cable If resistance tests detect no feed circuit problems...

Page 509: ...ing Test Amperage Draw 73 Amperes 73 Amperes 200 Amperes Free Running Test Minimum Speed 3601 rpm 3601 rpm 3000 rpm Solenoid Closing Maximum Voltage Required 7 5 Volts 7 5 Volts 8 0 Volts Cranking Amp...

Page 510: ...overrunning clutch housing This electromechanical switch connects and disconnects the feed of battery voltage to the starter motor also engaging and disengaging the starter pinion gear with the start...

Page 511: ...onnect battery positive cable wire harness connector from solenoid terminal connector recepta cle 10 Remove starter motor 5 9L DIESEL ENGINE 1 Disconnect and isolate negative cables of both batteries...

Page 512: ...ctor recepta cle 6 Support starter motor and remove two bolts securing starter motor to engine 7 Remove starter motor from engine INSTALLATION 3 9L 5 2L 5 9L GASOLINE ENGINE 1 Connect wiring harness t...

Page 513: ...f an electromagnetic coil a resistor or diode and three two fixed and one mov able electrical contacts The movable common feed relay contact is held against one of the fixed contacts normally closed b...

Page 514: ...r a short If circuit is OK refer to Clutch Pedal Position Switch in 6 Clutch 5 The coil ground terminal 85 is connected to the electromagnet in the relay On vehicles with manual transmission it is gro...

Page 515: ......

Page 516: ...d in the lower left corner of the a c heater con trol unit face plate The heated mirror system helps the vehicle operator maintain outside rear view mir ror visibility during inclement operating condi...

Page 517: ...CT 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 DISAB...

Page 518: ...event during the same ignition switch cycle the heated mirror system electronic control logic and timer circuit is programmed to turn the system Off automatically after about five minutes When the ele...

Page 519: ...he power mirror wire harness The heating grid is then sandwiched between the back of the molded plastic mirror glass case and the mirror glass where it remains in direct contact with the back of the m...

Page 520: ...elect from two different levels of supplemental electrical seat heat ing or no seat heating to suit their individual com fort requirements The heated seat system for this vehicle includes the followin...

Page 521: ...if a failure occurs in the driver side heated seat and the passenger side heated seat switch indicator lamps will flash for a passenger side heated seat failure If a monitored heated seat system failu...

Page 522: ...itches can only be connected to the proper heated seat The momentary bidirectional rocker type heated seat switch provides a resistor multiplexed signal to the heated seat module Each switch has a cen...

Page 523: ...ules for the location of the proper heated seat module diagnosis and testing procedures Also refer to the Body Diagnostic Manual for additional diagno sis and testing procedures 2 Disconnect and isola...

Page 524: ...itches 5 Remove the heated seat switch bezel and both switches from the instrument panel as a unit 6 From the back of the heated seat switch bezel gently push the heated seat switch out through the fr...

Page 525: ...uts from the driver side and passenger side sensors The heated seat elements and sensors cannot be repaired If damaged or faulty the front seat cushion trim cover or front seat back trim cover assembl...

Page 526: ...2 way heated seat wire harness connector and the seat back frame There should be no continuity If OK go to Step 5 If not OK replace the faulty seat back trim cover unit 5 Test the seat wire harness be...

Page 527: ...The heated seat relay Fig 7 is located in the Junction Block JB on the left end of the instrument panel in the passenger compartment of the vehicle Refer to Wiring Diagrams for the location of com pl...

Page 528: ...panel 3 The heated seat relay is located on the forward side of the Junction Block JB just above the com bination flasher Fig 8 4 Grasp the heated seat relay firmly and pull it straight out from the J...

Page 529: ...eat switches receive battery current through a fused ignition switch output run circuit when the ignition switch is in the On position The ground side of each indi cator lamp is controlled by a separa...

Page 530: ...as required and replace the faulty fuse 5 Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output run fuse in the JB If OK go to Step 6 If not OK rep...

Page 531: ...tom of the connector receptacle and should be installed in the left mounting hole of the heated seat switch bezel The passenger side switch has the keyway located near the top of the connector recepta...

Page 532: ...wire harness con nectors splices and grounds Following are general descriptions of the remaining major components in the horn system OPERATION Each horn system is activated by a horn switch concealed...

Page 533: ...cle continues repeating at a very rapid rate producing the vibration and move ment of air that creates the sound that is directed through the horn outlet DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HO...

Page 534: ...parallel with the electromagnetic coil in the relay and helps to dissipate voltage spikes that are produced when the coil is de energized DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HORN RELAY The hor...

Page 535: ...he Power Distribution Center PDC Fig 3 3 See the fuse and relay layout label affixed to the underside of the PDC cover for horn relay iden tification and location 4 Remove the horn relay from the PDC...

Page 536: ...y between the metal steer ing column jacket and a good ground There should be continuity If OK go to Step 3 If not OK Refer to 19 STEERING COLUMN INSTALLATION for proper installation of the steering c...

Page 537: ......

Page 538: ...stem will be referred to as a distributor less ignition system DESCRIPTION V 6 V 8 The ignition systems used on the 3 9L V 6 the 5 2L V 8 and the 5 9L V 8 are basically identical OPERATION 8 0L V 10 T...

Page 539: ...ng 3 9L 5 2L 5 9L Engines if tapped bolts are used 5 50 Ignition Coil Mounting 3 9L 5 2L 5 9L Engines if nuts bolts are used 11 100 Ignition Coil Mounting 8 0L Engine 10 90 Spark Plugs all engines 41...

Page 540: ...rcuit for the coil within the ASD relay is controlled by the Powertrain Control Module PCM The PCM operates the ASD relay by switch ing its ground circuit on and off The ASD relay will be shut down me...

Page 541: ...Do not attach the other end of the jumper wire to the relay at this time WARNING DO NOT ALLOW OHMMETER TO CON TACT TERMINALS 85 OR 86 DURING THIS TEST DAMAGE TO OHMMETER MAY RESULT 7 Attach the other...

Page 542: ...Another function is to relate crankshaft position and Top Dead Center TDC of the number 1 cylinder Because the CMP is now used to relate crankshaft position the Crankshaft Position Sen sor CKP is no l...

Page 543: ...ling edge of the pulse ring shutter leaves the sync signal generator the following occurs The change of the magnetic field causes the sync sig nal voltage to switch low to 0 volts OPERATION 8 0L The C...

Page 544: ...y to remove camshaft position sensor 1 Remove air cleaner assembly 2 Disconnect negative cable from battery 3 Remove distributor cap from distributor two screws 4 Disconnect camshaft position sensor w...

Page 545: ...pry the sensor from the timing chain case cover in a rocking action with two small screw drivers 4 Remove the sensor from vehicle 5 Check condition of sensor o ring Fig 14 REPLACING WITH NEW SENSOR I...

Page 546: ...ever use an electric grinder to remove material from sensor 2 From the parts department obtain a peel and stick paper spacer Fig 13 These special paper spacers are of a certain thickness and are to be...

Page 547: ...directly in front of the sensor mounting hole opening on the timing gear cover Do not install sensor with gear positioned at low area Fig 16 or Fig 15 When the engine is started the sensor will be br...

Page 548: ...d Center TDC firing position 6 Attach a socket to the Crankshaft Vibration Damper mounting bolt 7 Slowly rotate engine clockwise as viewed from front until indicating mark on crankshaft vibration damp...

Page 549: ...is located in passenger com partment below and to left of steering column 2 Gain access to SET SYNC screen on DRB 3 Follow directions on DRB screen and start engine Bring to operating temperature engi...

Page 550: ...charred com pound Test the spring for insufficient tension Replace a rotor that displays any of these adverse conditions IGNITION COIL DESCRIPTION 3 9L 5 2L 5 9L A single ignition coil is used The coi...

Page 551: ...t sensors indicating the ignition key is ON but the engine is not running it will shut down the ASD circuit Base ignition timing is not adjustable on the 8 0L V 10 engine By controlling the coil groun...

Page 552: ...ting bracket INSTALLATION 3 9L 5 2L 5 9L The ignition coil is an epoxy filled type If the coil is replaced it must be replaced with the same type 1 Install the ignition coil to coil bracket If nuts an...

Page 553: ...mileage may be cleaned and reused if not otherwise defective carbon or oil fouled Also refer to Spark Plug Conditions CAUTION Never use a motorized wire wheel brush to clean the spark plugs Metallic...

Page 554: ...lectrode gap bridging may be traced to loose deposits in the combustion chamber These deposits accumulate on the spark plugs during continuous stop and go driving When the engine is suddenly subjected...

Page 555: ...gap will be consider ably in excess of 0 001 inch per 2000 miles of opera tion This suggests that a plug with a cooler heat range rating should be used Over advanced ignition timing detonation and coo...

Page 556: ...ND TESTING SPARK PLUG CABLES Cable routing is important on certain engines To prevent possible ignition crossfire be sure the cables are clipped into the plastic routing looms Try to pre vent any one...

Page 557: ...found in the SPARK PLUG CABLE RESISTANCE chart replace the cable Test all spark plug cables in this manner SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Pe...

Page 558: ...felt when a good connection is made between the plug cable and the distributor cap tower Fig 39 Engine Firing Order 3 9L V 6 Engine Fig 40 Engine Firing Order 5 2L 5 9L V 8 Engines Fig 41 Spark Plug C...

Page 559: ......

Page 560: ...TION INDICATOR LAMP MIL DESCRIPTION 24 OPERATION 24 ODOMETER DESCRIPTION 24 OPERATION 25 OIL PRESSURE GAUGE DESCRIPTION 25 OPERATION 26 OVERDRIVE OFF INDICATOR DESCRIPTION 27 OPERATION 27 SEATBELT IND...

Page 561: ...made at the back of the cluster housing through two take outs of the instrument panel wire harness each equipped with a self docking connector A single EMIC module is offered on this model This modul...

Page 562: ...cludes wiring dia grams proper wire and connector repair procedures further details on wire harness routing and reten tion as well as pin out and location views for the various wire harness connectors...

Page 563: ...of the shaft One of the coils has a fixed current flowing through it to maintain a constant magnetic field strength Current flow through the second coil changes which causes changes in its magnetic fi...

Page 564: ...ice reminder indica tor and the transmission overtemp indicator are automatically configured either electronically or mechanically The hard wired indicators are diagnosed using con ventional diagnosti...

Page 565: ...r illumination of the upshift indicator use a DRBIIIT scan tool to be certain that the instrument cluster has been programmed with the proper vehi cle equipment option settings PRELIMINARY DIAGNOSIS W...

Page 566: ...IAGNOSIS 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 The instru...

Page 567: ...d replace the faulty instrument cluster Following com pletion of the VFD walking segment test the actua tor test will proceed as described in Step 7 7 The instrument cluster will perform a bulb check...

Page 568: ...r C2 for the instrument cluster and the instrument panel wire harness connector Connector C1 for the CTM There should be conti nuity If OK replace the faulty instrument cluster If not OK repair the op...

Page 569: ...ed panel lamps dimmer switch signal circuit between the instrument cluster and the JB as required REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STE...

Page 570: ...nnect and isolate the battery negative cable 2 Remove the instrument cluster from the instru ment panel Refer to 8 ELECTRICAL INSTRU MENT CLUSTER REMOVAL 3 Remove the steering column opening cover fro...

Page 571: ...battery negative cable 2 Remove the instrument cluster from the instru ment panel Refer to 8 ELECTRICAL INSTRU MENT CLUSTER REMOVAL 3 Remove the six screws that secure the rear cover to the back of th...

Page 572: ...talled in the correct position Always use the correct bulb size and type for replacement An incorrect bulb size or type may overheat and cause damage to the instrument cluster the elec tronic circuit...

Page 573: ...se a DRBIIIT scan tool to program the instrument cluster with the proper vehicle equipment option setting to enable and or disable the upshift indicator lamp Refer to the appropriate diagnostic inform...

Page 574: ...e translucent outer layer of the overlay when it is illuminated from behind by a Light Emit ting Diode LED soldered onto the instrument clus ter electronic circuit board The airbag indicator is servic...

Page 575: ...on switch is turned to the On position the brake indicator is illu minated by the instrument cluster for about four sec onds as a bulb test Park Brake On If the park brake is applied or not fully rele...

Page 576: ...indicator is standard equipment on all instrument clusters The check gauges indicator is located on the lower edge of the instrument cluster overlay to the right of center The check gauges indi cator...

Page 577: ...optional speed control system this indicator is electronically disabled The cruise indica tor consists of the word CRUISE which appears in the lower portion of the odometer trip odometer Vac uum Fluor...

Page 578: ...ignition switch is in the On or Start positions The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position The instrum...

Page 579: ...an indication to the vehicle operator of the level of fuel in the fuel tank This gauge is controlled by the instrument cluster circuit board based upon the cluster programming and elec tronic messages...

Page 580: ...ing col umn Directly below each character on the face plate is a small rectangular window and behind these windows is a single movable red pointer The gear selector indicator graphics are white agains...

Page 581: ...s and grounds 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 AN...

Page 582: ...ent cluster transistor The instrument cluster will turn on the low fuel indicator for the following reasons Bulb Test Each time the ignition switch is turned to the On position the indicator is illumi...

Page 583: ...by the PCM ECM message For some DTC s if a problem does not recur the PCM or ECM will send a lamp off message automatically Other DTC s may require that a fault be repaired and the PCM or ECM be reset...

Page 584: ...nds the trip odometer will be reset to 000 0 kilometers miles The VFD must be display ing the trip odometer information in order for the trip odometer information to be reset Message Failure If the cl...

Page 585: ...8 psi for diesel engines the gauge needle is moved to the 0 kPa 0 psi graduation at the far left low end of the gauge scale the check gauges indicator is illumi nated and a single chime tone is genera...

Page 586: ...ve off lamp off message from the PCM or until the ignition switch is turned to the Off position whichever occurs first Actuator Test Each time the cluster is put through the actuator test the indicato...

Page 587: ...board The SRI is serviced as a unit with the instrument cluster OPERATION The Service Reminder Indicator SRI gives an indication to the vehicle operator when engine emis sions maintenance procedures...

Page 588: ...IFFERENTIAL DRIVELINE FRONT AXLE AXLE VACUUM MOTOR OPERATION The four wheel drive switch input to the instrument cluster circuitry can be diag nosed using conventional diagnostic tools and meth ods DI...

Page 589: ...te graphics appear blue green while the red graphics still appear red The orange gauge nee dle is internally illuminated Gauge illumination is provided by replaceable incandescent bulb and bulb holder...

Page 590: ...gauge needle will return to the far left low end of the scale Actuator Test Each time the cluster is put through the actuator test the gauge needle will be swept to several calibration points on the g...

Page 591: ...ignal indicators are located near the upper edge of the instrument cluster overlay between the speedometer and the tachometer Each turn signal indicator consists of a stenciled cutout of the Internati...

Page 592: ...rysler Collision Detection CCD data bus The upshift indicator bulb receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output st run circuit w...

Page 593: ...ional diesel engine the instru ment cluster is programmed to support the voltmeter gauge needle above the low end of normal graduation and suppress the check gauges indicator operation until ten secon...

Page 594: ...r lens behind the cutout in the opaque layer of the overlay causes the LOW WASHER text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by a Lig...

Page 595: ...ere should be continuity If OK go to Step 2 If not OK repair the open ground circuit to ground G100 as required 2 Remove the instrument cluster from the instru ment panel Check for continuity between...

Page 596: ...On position the indicator is illuminated for about two seconds as a bulb test Water In Fuel Lamp On Message Each time the cluster receives a water in fuel lamp on message from the ECM the indicator wi...

Page 597: ......

Page 598: ...LASHER DESCRIPTION 7 OPERATION 7 REMOVAL 8 INSTALLATION 8 DAYTIME RUNNING LAMP MODULE DESCRIPTION 9 OPERATION 9 REMOVAL 9 INSTALLATION 9 FOG LAMP DIAGNOSIS AND TESTING 9 FOG LAMP 9 REMOVAL 11 INSTALLA...

Page 599: ...rd of the two sides of the radiator grille opening The rear turn signal lamps are integral to the taillamp mod ules located on either side of the vehicle For pickup models the taillamp modules are sec...

Page 600: ...witch to the On position Actuate the turn signal switch or the hazard warning switch Observe the turn signal indicator lamp s in the instrument cluster If the flash rate is very high check for a turn...

Page 601: ...rt under the instrument panel CAUTION The switch can only be adjusted during initial installation If the switch is not adjusted prop erly a new switch must be installed OPERATION The brake lamp switch...

Page 602: ...plunger extended attach test leads to pins 1 and 2 Replace switch if meter indicates no continuity With switch plunger retracted attach test leads to pins 3 and 4 Replace switch if meter indicates no...

Page 603: ...s 5 Separate CHMSL from vehicle INSTALLATION 1 Position lamp at cab roof and connect wire con nector 2 Install screws holding CHMSL to roof panel Tighten securely 3 Connect the battery negative cable...

Page 604: ...nd turn signal circuit and hazard warning circuit Constant battery voltage and ground are supplied to the flasher so that it can perform the hazard warning function and ignition switched battery volta...

Page 605: ...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...

Page 606: ...r panel 3 Engage wire connector to DRLM 4 Connect the battery negative cable FOG LAMP DIAGNOSIS AND TESTING FOG LAMP CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITI...

Page 607: ...burned out bulb 5 Replace bulb FOG LAMPS ARE INOPERATIVE AND FOG LAMP INDICATOR LIGHT ALWAYS STAYS ON 1 Fog lamp DRL feed shorted to ground 1 Check wiring circuit from fog lamp DRL fuse to fog lamp Tr...

Page 608: ...EMOVAL 1 Disconnect and isolate the battery negative cable 2 Disengage fog lamp harness connector 3 Rotate bulb assembly counterclockwise and pull from lamp to separate Fig 9 INSTALLATION CAUTION Do n...

Page 609: ...Position fog lamp in fascia 2 Install screws attaching fog lamp to fascia 3 Connect wire connector to fog lamp 4 Check for proper operation and beam align ment 5 Connect the battery negative cable AD...

Page 610: ...ounding is provided by the lamp socket when it comes in contact with the metal body or through a separate ground wire Always begin any diagnosis by testing all of the fuses and circuit breakers in the...

Page 611: ...3 Test amperage draw of headlamp circuit 4 Both headlamp bulbs defective 4 Replace both headlamp bulbs HEADLAMPS FLASH RANDOMLY 1 Poor lighting circuit Z3 ground 1 Test for voltage drop across Z3 gro...

Page 612: ...lb to Multifunction switch is shorted to ground 1 Ground should be present according to Multifunction switch position Check wiring circuit from Multifunction switch to headlamp Trace short circuit in...

Page 613: ...d bulb life will result 1 Position bulb s in headlamp 2 Install retaining ring holding bulb s to head lamp 3 Connect wire connector to headlamp bulb s 4 Install battery tray if removed Refer to 8 ELEC...

Page 614: ...hat is secured by a ground screw to the left fender inner shield near the PDC in the engine compartment The coil ground terminal 85 is connected to the Central Timer Module CTM through the security re...

Page 615: ...e instrument panel The headlamp switch controls the parking lamps and the headlamps A separate switch in the module controls the interior lamps and instru ment cluster illumination This switch also co...

Page 616: ...ircuit terminal and the key in ignition switch sense circuit terminal of the head lamp switch There should be no continuity with the switch in the Off position and continuity with the switch in the pa...

Page 617: ...able HEADLAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove push in fastener attaching seal to radi ator closure panel 3 Remove park and turn signal lamp 4 Remove screws at...

Page 618: ...g downward on front bumper and releasing 6 Measure the distance from the center of head lamp lens to the floor Transfer measurement to the alignment screen with tape Use this line for up down adjustme...

Page 619: ...lens 3 Pull bulb from license plate lamp INSTALLATION 1 Install bulb in license plate lamp 2 Install license plate lamp lens 3 Connect the battery negative cable LICENSE PLATE LAMP UNIT REMOVAL 1 Disc...

Page 620: ...Display Symbol icon for Hazard Warning is applied to the top of the hazard warning switch push button The switch housing and its controls are constructed of molded black plastic A single connector rec...

Page 621: ...d position The multi function switch hazard warning circuitry simultaneously provides a signal to the hazard warning sense of the combina tion flasher to activate or deactivate the flasher out put and...

Page 622: ...ttent mode when the washer switch is actuated the CTM will operate the wiper motor at a fixed low speed for as long as the washer switch is depressed plus about three additional wipe cycles before the...

Page 623: ...rner lamps WIPER WASHER SWITCH POSITIONS CONTINUITY BETWEEN Off Pins 6 7 Delay Pins 1 2 4 Pins 8 9 Low Pins 4 6 High Pins 4 5 Wash Pins 3 4 Resistance between Pins 1 2 at Maximum delay position is bet...

Page 624: ...m below the steering column remove the one center screw that secures the lower outer shroud to the steering column housing 6 Remove the lower outer shroud from the steer ing column 7 From below the st...

Page 625: ...ever side of the upper inner shroud with the receptacles on the lower inner shroud and apply hand pressure to snap them together 9 From below the steering column install and tighten the two screws tha...

Page 626: ...TION 1 Install side marker socket from back of lamp 2 Install park turn signal socket in back of lamp 3 Install park turn signal lamp in vehicle 4 Install screw attaching the park lamp to head lamp mo...

Page 627: ...amp 5 Separate tail lamp from cargo box 6 Pull bulb from socket INSTALLATION CAB CHASSIS 1 Position tail lamp on vehicle 2 Engage tail lamp wire connector to body wire harness 3 Install nuts attaching...

Page 628: ...actuator The cancel actuator latches against the cancel cam rotation in the direction oppo site that which is signaled In other words if the left turn signal detent is selected the lobes of the cance...

Page 629: ...crew attaching underhood lamp to the inner hood panel Fig 33 6 Separate underhood lamp from vehicle INSTALLATION 1 Install bulb 2 Install lamp lens 3 Position the underhood lamp on the hood inner pane...

Page 630: ...PC194 LOW WASHER FLUID PC74 MAINTENANCE REQUIRED PC74 MESSAGE CENTER PC194 SEAT BELT PC74 LAMP BULB TURN SIGNAL PC194 UPSHIFT PC74 DOME 1004 GLOVE COMPARTMENT 1891 VANITY MIRROR LAMP P N 6501966 DOME...

Page 631: ...r door ajar switch from its wire harness connector Check for continuity between the ground circuit cavity of the driver door ajar switch wire harness connector and a good ground There should be contin...

Page 632: ...love box opening and behind the glove box lamp and switch mounting bracket to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing 6 While holding the retaining ta...

Page 633: ...plices and grounds OPERATION All reading and courtesy lamps located in the over head console are activated by the door jamb switches When all of the doors are closed these lamps can be individually ac...

Page 634: ...s 2 Rotate blade until lens pops out of lamp 3 Remove lens from housing 4 Remove bulb from lamp terminals INSTALLATION 1 Install bulb into lamp terminals 2 Place one side of lens into housing 3 Insure...

Page 635: ......

Page 636: ...to two rear mounting holes in the inner roof panel by two plastic hook formations that are integral to the over head console housing The front of the overhead con sole is secured to the two front moun...

Page 637: ...Fig 1 Overhead Console 8M 2 MESSAGE SYSTEMS BR BE OVERHEAD CONSOLE Continued...

Page 638: ...dings and in degrees 0 to 359 degrees North is 0 degrees East is 90 degrees South is 180 degrees and West is 270 degrees It will not display the head ings in minutes or seconds The self calibrating co...

Page 639: ...e is excessive magnetism near the com pass or the unit is faulty Repeat the calibration procedure at least one more time NOTE If the wrong direction is still indicated in the compass display the area...

Page 640: ...sole forward mounting screw proceed as follows 1 Be certain that the ignition switch is in the Off position before you begin the demagnetizing proce dure 2 Connect the degaussing tool to an electrical...

Page 641: ...or and locate the two overhead console latch tabs near the front of the bin Fig 4 3 While pulling gently downward on the front of the overhead console push the latch tabs forward until each latch is d...

Page 642: ...its pivot latch 5 From the face side of the overhead console housing remove the sunglasses storage bin from the overhead console COMPASS MINI TRIP LENS REMOVAL Overhead consoles equipped with the opti...

Page 643: ...r the cover plug forward far enough to engage the four forward mounting tabs in the overhead console unit 3 From the face of the overhead console align the rear mounting boss of the trip computer lens...

Page 644: ...hese inputs to calculate and display the requested data If the data displayed is incorrect perform the self diag nostic tests as described in this group If these tests prove inconclusive the use of a...

Page 645: ...ve cable Check for battery voltage at the fused B circuit cavity of the roof wire harness connector for the overhead console If OK go to Step 7 If not OK repair the open fused B circuit to the junctio...

Page 646: ...dule to the over head console housing Tighten the screws to 2 2 N m 20 in lbs 4 Install the overhead console onto the headliner Refer to Overhead Console in the Removal and Installation section of thi...

Page 647: ...or wire har ness connector and the overhead console wire har ness connector 2 Connect a jumper wire between the two termi nals in the body half of the ambient temperature sen sor wire harness connecto...

Page 648: ...screw that secures the ambient temperature sensor bracket to the inner hood reinforcement Tighten the screw to 5 6 N m 50 in lbs 3 Reconnect the wire harness connector to the ambient temperature senso...

Page 649: ......

Page 650: ...rsion of the power lock sys tem the power lock switches provide the only control over the operation of the power lock motors On mod els with the optional RKE system a high line or pre mium version of...

Page 651: ...pre mium CTM software is Flash compatible which means it can be reprogrammed using Flash repro gramming procedures However if any of the CTM hardware components are damaged or faulty the entire CTM u...

Page 652: ...etermine when an airbag has been deployed The CTM also monitors the state of the power lock system and the vehicle speed messages from the PCM in order to provide this feature If the airbag has been d...

Page 653: ...m which includes a high line or premium CTM Refer to 8 ELECTRICAL POWER LOCKS DIAGNOSIS AND TESTING POWER LOCK REMOTE KEYLESS ENTRY SYSTEM Refer to the appropriate wiring information The wiring inform...

Page 654: ...eatures automatic locks door lock inhibit enhanced accident response illuminated entry panic mode or RKE horn chirp further diag nosis should be performed using a DRBIIIt scan tool Refer to the approp...

Page 655: ...Refer to 23 BODY DOOR FRONT EXTERIOR HANDLE INSTALLATION 6 Reconnect the battery negative cable POWER LOCK MOTOR DESCRIPTION Models equipped with the optional power lock sys tem have a power operated...

Page 656: ...the polarity to check the motor operation in the opposite direction If OK repair the shorted or open circuits between the power lock motor and the power lock switch base CTM or the CTM high line or pr...

Page 657: ...ground feeds to the power lock motors to lock or unlock the door latches On models with a high line or premium version of the CTM the power lock switch controls battery cur rent signals to the lock a...

Page 658: ...TM high line or pre mium CTM as required If not OK replace the faulty power window and lock switch and bezel unit DRIVER SIDE LOCK SWITCH SWITCH POSITION CONTINUITY BETWEEN NEUTRAL 7 9 8 9 LOCK 7 9 8...

Page 659: ...er mirror system OPERATION AUTOMATIC DAY NIGHT MIRROR A switch located on the bottom of the automatic day night mirror housing allows the vehicle operator to select whether the automatic dimming featu...

Page 660: ...mirror Fig 1 Connect the battery negative cable Turn the ignition switch to the On position Check for battery voltage at the fused igni tion switch output run start circuit cavity of the automatic day...

Page 661: ...and mounted to the upper flag area of the driver side door trim panel OPERATION The switch knob is rotated clockwise right mirror control or counterclockwise left mirror control to select the mirror...

Page 662: ...ted mirror relay in the heater and air conditioner control only when the ignition switch is in the On position and the heated mirror system is turned on Refer to 8 ELECTRICAL HEATED MIRRORS DESCRIP TI...

Page 663: ...do not respond as indicated in the chart replace the faulty power mirror assembly If the power mirror s do respond as indicated in the chart repair the cir cuits between the power mirror and the powe...

Page 664: ...n 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 lum bar region of the spinal...

Page 665: ...his 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 moto...

Page 666: ...se shaft 5 If equipped install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat 6 Connect the battery negative cable LUMBAR CONT...

Page 667: ...le slats The more this grid is compressed the more the slats bow out ward against the center of the seat back padding providing additional lumbar support DIAGNOSIS TESTING POWER LUMBAR ADJUSTER Actuat...

Page 668: ...ses 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...

Page 669: ...m release shaft 5 If equipped install the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the front seat 6 Connect the battery negative cable RECL...

Page 670: ...the power seat switch and a good ground There should be continuity If OK go to Step 5 If not OK repair the open ground circuit to ground as required 5 Test the power seat switch Refer to Power Seat S...

Page 671: ...ck the wire harness for the inoperative power seat motor s between the power seat switch and the motor for shorts or opens If the circuits check OK replace the faulty power seat adjuster and motors as...

Page 672: ...mation The wiring informa tion includes wiring diagrams proper wire and con nector repair procedures details of wire harness routing and retention connector pin out information and location views for...

Page 673: ...ssenger side window A Light Emitting Diode LED in the paddle of each switch is illuminated whenever the ignition switch is in the On position OPERATION The power window switch for the driver side fron...

Page 674: ...REMOVAL 1 Disconnect and isolate the battery negative cable 2 Using a wide flat bladed tool such as a trim stick gently pry the upper edge of the switch bezel at the front and the rear to release the...

Page 675: ...lices and grounds Before you proceed with this diagnosis confirm proper switch operation Refer to 8 ELECTRICAL POWER WINDOWS POWER WINDOW SWITCH DIAGNOSIS AND TESTING 1 Disconnect and isolate the batt...

Page 676: ...ADJUSTER REMOVAL 29 INSTALLATION 29 TURNING LOOP HEIGHT ADJUSTER KNOB REMOVAL 30 INSTALLATION 30 RESTRAINTS DESCRIPTION A dual front airbag system is standard factory in stalled safety equipment on t...

Page 677: ...the various wire harness connectors splices and grounds OPERATION The airbag system is referred to as a supplemental restraint system because it was designed and is intended to enhance the protection...

Page 678: ...the ACM as well as the retrieval or erasure of a DTC from the ACM requires the use of a DRBIIIt scan tool Refer to the appropriate diagnos tic information See the owner s manual in the vehicle glove b...

Page 679: ...nd non deployed driver or passenger airbags which are replaced on vehicles are to be returned If an airbag unit is faulty or damaged and non deployed refer to the parts return list in the current Daim...

Page 680: ...OR 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 PRECAU TIONS COULD RESULT...

Page 681: ...ive Diagnostic Trouble Code DTC and sends messages to the EMIC over the CCD data bus to turn on the airbag indicator Refer to 8 ELECTRICAL INSTRUMENT CLUSTER AIRBAG INDICATOR OPERATION If the airbag s...

Page 682: ...RESULT IN ACCI DENTAL INCOMPLETE OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJU RIES 1 Disconnect and isolate the battery negative cable If either of the airbags has not been deployed wait...

Page 683: ...POSSIBLE OCCUPANT INJU RIES 1 Carefully position the Airbag Control Module ACM the mounting bracket and the instrument panel center support bracket onto the floor panel transmission tunnel as a unit...

Page 684: ...hat secures the child tether anchor standard cab or child tether club quad cab to the cab back panel Fig 7 3 Remove the child tether anchor standard cab or child tether club quad cab from the cab back...

Page 685: ...On this model the rotating electrical components include the driver airbag the horn switch the speed control switches and the remote radio switches if the vehicle is so equipped The clockspring case i...

Page 686: ...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 DIS ABLE THE AIRBAG SYSTEM FAILURE TO TAKE...

Page 687: ...n remove the two outboard screws that secure the upper shroud to the lower outer shroud Fig 9 9 Press carefully inward on each side of the outer shrouds to release the snap features and remove the upp...

Page 688: ...5 Align the locking tabs on the gearshift lever side of the upper inner shroud with the receptacles on the lower inner shroud and apply hand pressure to snap them together 6 From below the steering co...

Page 689: ...nitrogen gas The inflator is sealed to the back of the airbag hous ing and a diffuser in the inflator directs all of the nitrogen gas into the airbag cushion causing the cushion to inflate As the cush...

Page 690: ...airbag has been deployed the clockspring and the steering column must be replaced Refer to 8 ELECTRICAL RESTRAINTS CLOCKSPRING REMOVAL Refer to 19 STEER ING COLUMN REMOVAL DISASSEMBLY The horn switch...

Page 691: ...tor on the back of the driver airbag housing Fig 11 4 Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the back of the driver airbag housing 5 Remove the upper...

Page 692: ...ANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT 1 Carefully position the...

Page 693: ...r to the horn switch feed pig tail wire connector which is located on the back of the driver airbag 4 Carefully position the driver airbag in the steering wheel Be certain that the clockspring pig tai...

Page 694: ...r to the seat back frame 3 Remove the retractor cover from the seat back frame 4 Remove the two screws that secure the seat belt retractor to the seat back frame Fig 16 5 Remove the front shoulder bel...

Page 695: ...ver onto the front seat back frame Refer to 23 BODY SEATS SEAT BACK COVER INSTALLATION FRONT SEAT BELT BUCKLE REMOVAL WARNING DURING AND FOLLOWING ANY SEAT BELT SERVICE CAREFULLY INSPECT ALL SEAT BELT...

Page 696: ...door is serviced only as a unit with the passenger airbag and includes the two passenger side heating and air con ditioning panel outlet housings and barrels OPERATION The passenger airbag is deployed...

Page 697: ...rbag pigtail wire connector from the instrument panel wire har ness Fig 17 6 Remove the two screws that secure the passen ger airbag front bracket to the instrument panel structural support Fig 18 7 R...

Page 698: ...er airbag onto the instrument panel 4 Align the five tabs and retainers on the upper edge and sides of the passenger airbag door with the receptacles in the instrument panel top cover 5 Using hand pre...

Page 699: ...y actuator is rotated to its clockwise stop the key actuator slot will be aligned with the Off indicator lamp the Off indicator is illuminated and the passenger airbag is disabled When the switch is r...

Page 700: ...tall and tighten the three screws that secure the passenger airbag on off switch to the face plate Tighten the screws to 2 2 N m 20 in lbs 3 Route the passenger airbag on off switch pigtail wires thro...

Page 701: ...from the door sill Refer to 23 BODY INTERIOR DOOR SILL TRIM REMOVAL 3 Remove the screw that secures the lower seat belt anchor plate to the quarter inner panel near the base of the C pillar Fig 23 4 U...

Page 702: ...HAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT ALWAYS REPLACE DAMAGED OR FAU...

Page 703: ...ut The seat belt switch receives ground through its pigtail wire connection to the body wire harness from another take out of the body wire harness An eyelet terminal connector on that ground take out...

Page 704: ...screw that secures the shoulder belt turning loop to the height adjuster 3 Remove the trim from the B pillar Refer to 23 BODY INTERIOR B PILLAR TRIM REMOVAL 4 Remove the screw that secures the upper...

Page 705: ...le trim tool Fig 25 INSTALLATION WARNING DURING AND FOLLOWING ANY SEAT BELT SERVICE CAREFULLY INSPECT ALL SEAT BELTS BUCKLES MOUNTING HARDWARE AND RETRACTORS FOR PROPER INSTALLATION OPERATION OR DAMAG...

Page 706: ...ission and a diesel engine This is a ser vo less system The controls consist of two steering wheel mounted switches The switches are labeled ON OFF RES ACCEL SET COAST and CANCEL The system is designe...

Page 707: ...by depressing the ON switch the Engine Control Module ECM allows a set speed to be stored in ECM RAM for speed con trol To store a set speed depress the SET switch while the vehicle is moving at a spe...

Page 708: ...servo engine vacuum pump and heating air con ditioning system for leaks 4 Verify operation of one way check valve and check it for leaks a Locate one way check valve The valve is located in vacuum li...

Page 709: ...Speed Control Servo Removal Installation 4 Using finger pressure only disconnect end of servo cable from throttle lever pin by pulling forward on connector while holding lever rearward Fig 3 DO NOT t...

Page 710: ...e body The solenoid valve body controls the application and release of vacuum to the dia phragm of the vacuum servo The servo unit cannot be repaired and is serviced only as a complete assem bly Power...

Page 711: ...lation in this group 5 Remove three bolts retaining servo servo mounting bracket to side of battery tray Fig 5 6 Position servo assembly to gain access to 2 servo mounting nuts Fig 5 or Fig 6 7 Remove...

Page 712: ...vacuum line at servo 11 Position battery tray with attached servo assembly to gain access to 2 servo mounting nuts Fig 5 or Fig 6 12 Remove 2 mounting nuts holding servo cable sleeve to bracket Fig 6...

Page 713: ...tive battery cable at battery drivers side battery 3 Remove battery holddown bolts Fig 11 4 If equipped pull up on battery heat shield to remove it Fig 12 5 Remove battery from vehicle 6 From under ve...

Page 714: ...d upward on lower tab for cover removal Fig 12 Battery Heat Shield 1 BATTERY HEAT SHIELD Fig 13 Battery Tray Lower Mounting Nuts 1 BATTERY TRAY 2 SPEED CONTROL SERVO Fig 14 Battery Tray Upper Mounting...

Page 715: ...tation of servo to bracket INSTALLATION V 6 V 8 ENGINES 1 Position servo to mounting bracket 2 Align hole in cable connector with hole in servo pin Install cable to servo retaining clip 3 Insert servo...

Page 716: ...ole in cable connector with hole in servo pin Install cable to servo retaining clip 3 Insert servo studs through holes in servo mounting bracket 4 Insert servo studs through holes in servo cable sleev...

Page 717: ...the vehicle may have decelerated at an extremely high rate If the actual speed is not within 20 mph of the set speedThe previous disengagement conditions are programmed for added safety Once the spee...

Page 718: ...L AIRBAG DEPLOYMENT AND POSSI BLE INJURY 1 Disconnect and isolate negative battery cable s 2 Remove airbag module Refer to 8 Restraint Systems for procedures 3 Remove switch to steering wheel mounting...

Page 719: ...ase of windshield The vacuum reservoir is not used if equipped with a die sel engine 1 Install vacuum reservoir and two mounting screws Tighten screws to 2 2 N m 20 in lbs torque 2 Connect vacuum supp...

Page 720: ...NTERIOR DOOR AJAR SWITCH DESCRIPTION Door Cylinder Lock Switch A door cylinder lock switch is located on the back of each front door lock cylinder This switch provides an input to the VTSS indicating...

Page 721: ...been enabled it cannot be disabled unless the PCM is replaced with a new unit The same VTSS engine no run feature enable logic will apply anytime the PCM is replaced with a new unit ARMING Passive ar...

Page 722: ...on the DRBIII scan tool 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 DIS...

Page 723: ...not OK repair the open fused B circuit between the JB and the Power Distribution Center PDC as required 3 Disconnect and isolate the battery negative cable Disconnect the body wire harness connector f...

Page 724: ...ing column opening A base version of the CTM is used on base models of this vehicle The base version of the CTM combines the functions of a chime module and an intermittent wipe module in a single uni...

Page 725: ...nergized Wipe After Wash Mode The internal circuitry of the CTM provides a wipe after wash feature which if the wipers are turned Off will operate the washer pump motor and the wipers for as long as t...

Page 726: ...at will occur depends upon the position of the wiper blades on the windshield at the moment that the Off position is selected If the wiper blades are in the down position on the windshield when the Of...

Page 727: ...If not OK repair the open fused ignition switch output circuit between the multi function switch and the JB as required 4 If the problem being diagnosed involves only the intermittent wipe feature go...

Page 728: ...proper wire and con nector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness con nectors splices and ground...

Page 729: ...er use compressed air to flush the washer system plumbing Compressed air pres sures are too great for the washer system plumbing components and will result in further system dam age Never use sharp in...

Page 730: ...lled in the mounting hole of the reservoir A small plastic float pivots on the end of a bracket that extends from the switch nipple formation Within the float is a small magnet which actuates the reed...

Page 731: ...he barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole 4 Reconnect the headlamp and dash wire harness connector for the washer fluid level switch to the swit...

Page 732: ...fully engaged with the under side of the cowl plenum cover grille panel 3 From the underside of the cowl plenum cover grille panel reconnect the washer hose to the washer nozzle fitting 4 Reinstall th...

Page 733: ...ight yel low plastic filler cap with a rubber seal and an Inter national Control and Display Symbol icon for Windshield Washer and the text Washer Fluid Only molded into it snaps over the open end of...

Page 734: ...e engine cooling system Refer to 7 COOLING STANDARD PROCEDURE REFILL ALL EXCEPT DIESEL ENGINE or Refer to 7 COOLING STANDARD PROCEDURE REFILL DIESEL ENGINE 8 Refill the washer reservoir with the washe...

Page 735: ...sition before attempting to install the wiper arms Turn the ignition switch to the On position and move the wiper control knob on the end of the multi function switch control stalk to its Off posi tio...

Page 736: ...est to the wiper pivot 1 Turn the wiper control knob on the end of the multi function switch control stalk to the On posi tion Cycle the wiper blades to a convenient working location on the windshield...

Page 737: ...ient PTC circuit breaker Pivots The two wiper pivots are secured to the ends of the wiper module bracket The crank arms that extend from the bottom of the pivot shafts each have a ball stud on their e...

Page 738: ...inputs and outputs through its PDC receptacle by five male spade type terminals that extend from the bottom of the relay base The ISO designation for each termi nal is molded into the base adjacent to...

Page 739: ...l coil is de energized and the Off position of the wiper control of the multi function switch is selected The wiper relay can be diagnosed using conven tional diagnostic tools and methods DIAGNOSIS AN...

Page 740: ...ween the PDC and the JB as required 5 The coil ground terminal 85 is connected to the output of the Central Timer Module CTM through the wiper motor relay control circuit There should be continuity be...

Page 741: ......

Page 742: ...VEHICLE THEFT SECURITY SYSTEM 8W 39 1 INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 CENTRAL TIMER...

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Page 744: ...all of their features and characteristics 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 bot...

Page 745: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION BR BE WIRING DIAGRAM INFORMATION Continued...

Page 746: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 BR BE 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued...

Page 747: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION BR BE WIRING DIAGRAM INFORMATION Continued...

Page 748: ...ND AROUND THE BATTERY WARNING ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOTH ING DIAGNOSIS AND TESTING WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrica...

Page 749: ...se the wiring dia grams to determine what the circuit is doing where the problem most likely is occurring and where the diagnosis will continue 4 Isolate the problem area 5 Repair the problem area 6 V...

Page 750: ...use blows the circuit with the short to 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 ba...

Page 751: ...tool 6932 push the terminal to remove it from the connector Fig 9 5 Repair or replace the terminal as necessary INSTALLATION 1 Reset the terminal locking tang PROBING TOOL PACKAGE 6807 TERMINAL PICK 6...

Page 752: ...ll on the wire to remove it from the connec tor 6 Repair or replace the terminal as necessary INSTALLATION 1 Reset the terminal locking tang 2 Insert the removed wire in the same cavity on the repair...

Page 753: ...harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 15 INSTALLATION 1 Remove the insulation from the wires in the harness O...

Page 754: ...d 2 Cut the repair wire to the proper length and remove one half 1 2 inch of insulation 3 Splice the repair wire to the wire harness 4 Insert the repaired wire into the connector 5 Install the connect...

Page 755: ...ace the strands of wire overlapping each other inside of the splice clip Fig 19 4 Using crimping tool Miller p n 8272 crimp the splice clip and wires together Fig 20 5 Solder the connection together u...

Page 756: ...ome Lamp 8W 44 Door Ajar Switches 8W 45 Door Lock Motors 8W 61 Door Window Lock Switches 8W 60 61 Driver Airbag 8W 43 Duty Cycle EVAP Purge Solenoid 8W 30 Component Page Electric Brake Provision 8W 54...

Page 757: ...tors 8W 60 Powertrain Control Module 8W 30 PTO Switch 8W 30 Quad High Beam Relay 8W 50 Radio Choke Relay 8W 47 Component Page Radio 8W 47 Remote Radio Switch 8W 47 Seat Belt Switch 8W 40 Seat Heat Int...

Page 758: ...Fuse 12 JB 8W 10 10 Fuse 12 PDC 8W 10 23 8 Fuse 13 JB 8W 10 10 Component Page Fuse 14 JB 8W 10 10 Fuse B PDC 8W 10 24 9 Fuse C PDC 8W 10 24 9 Fuse E PDC 8W 10 24 9 Fuse F PDC 8W 10 24 9 Fuse G PDC 8W...

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Page 786: ...12 JB 8W 12 14 Fuse 13 JB 8W 12 15 Fuse 14 JB 8W 12 16 Component Page Fuse 15 JB 8W 12 6 16 Fuse 16 JB 8W 12 6 16 Fuse 17 JB 8W 12 6 17 Fuse 18 JB 8W 12 6 17 Fuse 19 JB 8W 12 6 17 G100 8W 12 18 G200...

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Page 808: ...nt Connector No 1 8W 15 2 Joint Connector No 2 8W 15 9 Joint Connector No 3 8W 15 7 Joint Connector No 4 8W 15 3 Joint Connector No 5 8W 15 13 Joint Connector No 6 8W 15 4 Joint Connector No 8 8W 15 1...

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Page 826: ...8W 18 2 3 Engine Control Module 8W 18 3 4 Fuse 12 JB 8W 18 2 3 G105 8W 18 2 G107 8W 18 4 Component Page G200 8W 18 2 3 Joint Connector No 5 8W 18 2 3 Joint Connector No 7 8W 18 2 3 Junction Block 8W 1...

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Page 830: ...DC 8W 20 2 3 Fusible Link 8W 20 3 G113 8W 20 3 G114 8W 20 2 G115 8W 20 2 3 Component Page G116 8W 20 2 G117 8W 20 3 G118 8W 20 3 G120 8W 20 3 Generator 8W 20 2 3 Intake Air Heater Relay No 1 8W 20 3 I...

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Page 834: ...Pedal Position Switch 8W 21 2 Engine Starter Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Component Page Fuse 9 PDC 8W 21 2 G105 8W 21 3 Ignition Switch 8W 21 2 Park Neutral Position Switch 8W 21...

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Page 838: ...2 8W 30 36 37 G105 8W 30 2 16 20 21 Component Page G107 8W 30 34 36 G113 8W 30 14 34 G200 8W 30 16 37 Generator 8W 30 13 38 Idle Air Control Motor 8W 30 9 Ignition Coil 4 Pack 8W 30 28 Ignition Coil 6...

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Page 880: ...Cluster 8W 31 5 Joint Connector No 3 8W 31 5 Component Page Joint Connector No 4 8W 31 5 Leak Detection Pump 8W 31 2 Output Speed Sensor 8W 31 4 Overdrive Switch 8W 31 4 Power Distribution Center 8W...

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Page 886: ...ngine Control Module 8W 33 4 G100 8W 33 2 Joint Connector No 1 8W 33 4 Component Page Joint Connector No 4 8W 33 2 Left Speed Control Switch 8W 33 3 Powertrain Control Module 8W 33 2 4 Right Speed Con...

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Page 890: ...1 PDC 8W 34 2 G100 8W 34 3 G101 8W 34 2 G107 8W 34 2 G200 8W 34 3 Component Page Instrument Cluster 8W 34 2 Joint Connector No 1 8W 34 3 Joint Connector No 3 8W 34 2 Joint Connector No 4 8W 34 3 Joint...

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Page 894: ...3 G107 8W 35 3 G200 8W 35 4 Instrument Cluster 8W 35 3 Component Page Joint Connector No 1 8W 35 4 Joint Connector No 3 8W 35 3 Joint Connector No 4 8W 35 4 Joint Connector No 7 8W 35 3 Junction Bloc...

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Page 898: ...adlamp Beam Select Switch 8W 39 2 High Note Horn 8W 39 3 Horn Relay 8W 39 3 Component Page Horn Switch 8W 39 3 Joint Connector No 1 8W 39 2 3 Joint Connector No 3 8W 39 3 Joint Connector No 6 8W 39 3...

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Page 902: ...ment Cluster 8W 40 2 3 4 5 6 7 Integrated Electronic Module 8W 40 3 Component Page Joint Connector No 3 8W 40 6 Joint Connector No 4 8W 40 4 6 Joint Connector No 5 8W 40 5 Joint Connector No 7 8W 40 4...

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Page 910: ...Fuse L PDC 8W 41 3 G100 8W 41 2 G201 8W 41 3 High Note Horn 8W 41 2 Component Page Horn Relay 8W 41 2 Horn Switch 8W 41 2 Joint Connector No 1 8W 41 2 Joint Connector No 3 8W 41 2 Joint Connector No 6...

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Page 914: ...ower Motor Relay 8W 42 2 3 4 Blower Motor Resistor Block 8W 42 4 Fuse 2 JB 8W 42 2 Fuse 5 JB 8W 42 4 Fuse 11 JB 8W 42 5 Fuse 12 PDC 8W 42 3 Component Page Fuse J PDC 8W 42 5 G102 8W 42 2 3 G105 8W 42...

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Page 920: ...or 8W 43 3 Driver Airbag 8W 43 2 Fuse 18 JB 8W 43 2 Fuse 19 JB 8W 43 2 G100 8W 43 2 Component Page Instrument Cluster 8W 43 3 Joint Connector No 7 8W 43 3 Joint Connector No 8 8W 43 2 Junction Block 8...

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Page 924: ...44 2 G200 8W 44 3 G201 8W 44 2 4 6 Glove Box Lamp And Switch 8W 44 2 Component Page Headlamp Switch 8W 44 4 5 6 Ignition Switch 8W 44 5 Joint Connector No 4 8W 44 2 Joint Connector No 5 8W 44 2 6 Join...

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Page 930: ...8W 45 4 Ignition Switch 8W 45 10 7 8 Component Page Instrument Cluster 8W 45 8 Intermittent Wiper Switch 8W 45 9 Joint Connector No 1 8W 45 3 4 Joint Connector No 2 8W 45 9 Joint Connector No 3 8W 45...

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Page 940: ...3 Joint Connector No 6 8W 47 4 7 8 Joint Connector No 7 8W 47 2 4 Component Page Joint Connector No 8 8W 47 3 Junction Block 8W 47 2 3 7 Left Front Door Speaker 8W 47 5 7 8 9 Left Rear Speaker 8W 47...

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Page 950: ...9 4 Fuse 11 JB 8W 49 3 Fuse 12 JB 8W 49 2 3 6 G200 8W 49 2 5 G201 8W 49 3 6 Component Page Joint Connector No 1 8W 49 3 Joint Connector No 7 8W 49 4 Joint Connector No 8 8W 49 2 Junction Block 8W 49 2...

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Page 956: ...ector No 1 8W 50 4 5 13 Component Page Joint Connector No 3 8W 50 7 Joint Connector No 4 8W 50 12 7 Joint Connector No 5 8W 50 3 10 11 Joint Connector No 6 8W 50 2 3 Joint Connector No 8 8W 50 2 3 Jun...

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Page 970: ...ector No 1 8W 51 2 3 Joint Connector No 6 8W 51 3 Junction Block 8W 51 2 Component Page Left Back Up Lamp 8W 51 2 Left Front Fender Lamp 8W 51 6 Left License Lamp 8W 51 5 6 Left Rear Fender Lamp 8W 51...

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Page 976: ...n Switch 8W 52 2 Joint Connector No 3 8W 52 3 Component Page Joint Connector No 4 8W 52 3 Joint Connector No 6 8W 52 2 Junction Block 8W 52 2 3 Left Park Turn Signal Lamp 8W 52 3 Left Tail Stop Turn S...

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Page 980: ...tral Timer Module C1 8W 53 2 3 Intermittent Wiper Switch 8W 53 2 Joint Connector No 2 8W 53 3 Component Page Joint Connector No 6 8W 53 2 Junction Block 8W 53 3 Windshield Washer Pump 8W 53 2 Wiper Mo...

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Page 984: ...se 8 PDC 8W 54 2 3 G100 8W 54 4 G102 8W 54 2 G201 8W 54 3 Component Page Headlamp Switch 8W 54 2 Joint Connector No 1 8W 54 2 3 Joint Connector No 2 8W 54 2 3 Joint Connector No 6 8W 54 3 Park Neutral...

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Page 988: ...8W Cb 8W 60 2 Driver Door Window Lock Switch 8W 60 2 Driver Power Window Motor 8W 60 2 G300 8W 60 2 Component Page Junction Block 8W 60 2 Passenger Door Window Lock Switch 8W 60 2 Passenger Power Win...

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Page 990: ...4 Driver Door Lock Motor 8W 61 2 4 Driver Door Window Lock Switch 8W 61 2 3 Fuse 13 JB 8W 61 2 3 Component Page G301 8W 61 2 Junction Block 8W 61 2 3 Passenger Door Lock Motor 8W 61 2 4 Passenger Door...

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Page 994: ...W 62 3 G300 8W 62 2 3 Heated Mirror Relay 8W 62 3 Heated Mirror Switch 8W 62 3 Component Page Joint Connector No 5 8W 62 3 Left Power Mirror 8W 62 2 3 Power Mirror Switch 8W 62 2 Right Power Mirror 8W...

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Page 998: ...2 JB 8W 63 5 7 G201 8W 63 5 7 G300 8W 63 3 4 6 8 G301 8W 63 2 Component Page Heated Seat Relay 8W 63 5 7 Joint Connector No 5 8W 63 5 7 Joint Connector No 8 8W 63 5 7 Junction Block 8W 63 2 3 5 7 Pas...

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Page 1006: ...3 S176 8W 10 18 19 S177 8W 40 2 S179 8W 70 3 S180 8W 31 2 S181 8W 10 24 S182 8W 50 6 S183 8W 50 10 S184 8W 18 4 Component Page S202 8W 53 2 S203 8W 12 10 S203 8W 53 2 S204 8W 12 8 S207 8W 42 3 4 S209...

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Page 1014: ...21 C329 Club Cab 8W 80 21 C329 Standard Cab 8W 80 22 Component Page C329 Standard Cab 8W 80 22 C333 Club Cab 8W 80 22 C333 Club Cab 8W 80 22 C333 Standard Cab 8W 80 22 C333 Standard Cab 8W 80 23 C342...

Page 1015: ...ank Module Diesel 8W 80 44 Fuel Transfer Pump Diesel 8W 80 44 Component Page G300 8W 80 44 Generator 8W 80 45 Glove Box Lamp And Switch 8W 80 45 Headlamp Switch C1 8W 80 45 Headlamp Switch C2 8W 80 45...

Page 1016: ...b 8W 80 65 Component Page Passenger Power Seat Switch Club Cab 8W 80 65 Passenger Power Window Motor 8W 80 65 Power Mirror Switch 8W 80 65 Power Outlet 8W 80 66 Powertrain Control Module C1 Diesel 8W...

Page 1017: ...2 C90 22LG WT A C SELECT INPUT 3 C4 16TN LOW SPEED BLOWER MOTOR 4 C5 16LG M1 SPEED BLOWER MOTOR 5 C6 14LB M2 SPEED BLOWER MOTOR 6 C7 12BK TN HIGH SPEED BLOWER MOTOR 7 Z3 12BK OR GROUND A C HEATER TEMP...

Page 1018: ...WAY CAV CIRCUIT FUNCTION 1 Z13 12BK GROUND 2 B40 12LB TRAILER TOW BRAKE B 3 L76 12BK OR TRAILER TOW RELAY OUTPUT 4 A6 12RD OR FUSED B 5 L63 16DG RD LEFT TURN SIGNAL 6 L62 16BR RD RIGHT TURN SIGNAL 7...

Page 1019: ...ION SWITCH OUTPUT RUN START 2 Z3 20BK GROUND 3 L1 20VT BK BACK UP LAMP FEED BACK UP LAMP SWITCH M T BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L1 18VT BK BACK UP LAMP FEED 2 L10 18BR LG FUSED IGNITION SWITCH...

Page 1020: ...K BRAKE SWITCH SENSE 2 Z2 22BK LG GROUND 3 V32 22YL RD SPEED CONTROL SUPPLY 4 V30 22DB RD SPEED CONTROL BRAKE SWITCH OUTPUT 5 L50 16WT TN BRAKE LAMP SWITCH OUTPUT 6 F32 16PK DB FUSED B BRAKE PRESSURE...

Page 1021: ...8BK C114 BLACK AMBIENT TEMPERATURE SEN SOR SIDE CAV CIRCUIT 1 G31 20VT LG 2 G32 20BK VT C114 BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 G31 20VT LG 2 G32 20BK VT C125 DIESEL TRANSMISSION SIDE CAV CIRC...

Page 1022: ...LG A T 2 Z12 18BK TN M T 3 T125 18DB 4 D20 18DG 5 D21 18PK DB 6 D1 18VT BR 7 D2 18WT BK 8 G85 18OR BK 9 C22 18DB 10 K24 18GY BK 11 V40 18WT PK 12 Z12 18BK TN 13 S21 18YL BK 14 S22 18OR BK C126 DIESEL...

Page 1023: ...BK OR 10 L63 16DG RD 11 L1 18VT BK 12 A6 12RD OR 13 L62 16BR RD 14 A61 16DG BK GAS C129 CHASSIS HARNESS SIDE CAV CIRCUIT 1 B113 20RD VT 2 B114 20WT VT 3 Z13 12BK 4 B40 12LB 5 K4 20BK LB 6 K226 20DB WT...

Page 1024: ...BK LB A T 18 K4 18BK LB M T 19 C90 18LG WT 20 D21 18PK DB 21 C3 18DB BK 22 V37 18RD LG 23 K226 18DB WT 24 V36 18TN RD 25 Y128 18DG GY 26 T41 20BK WT A T 26 Z12 18BK TN M T 27 28 F18 18LG BK 29 K30 18P...

Page 1025: ...13 22DB OR 16 D20 20DG 17 D2 20WT BK 18 K4 22BK LB 19 C90 22LG WT 20 D21 20PK DB 21 C3 22DB BK 22 V37 22RD LG 23 K226 20DB WT 24 V36 20TN RD 25 Y128 18DG GY 26 T41 22BK WT 27 K31 20BR WT 28 F18 20LG B...

Page 1026: ...C90 18LG WT 20 D21 18PK DB 21 C3 18DB BK 22 V37 18RD LG 23 K226 18DB WT 24 V36 18TN RD 25 Y128 18DG GY 8 0L 26 T41 22BK WT A T 26 Z11 20BK WT M T 27 K31 18BR WT 28 F18 18LG BK 29 K30 18PK A T 30 A341...

Page 1027: ...WT BK 18 K4 22BK LB 19 C90 22LG WT 20 D21 20PK DB 21 C3 22DB BK 22 V37 22RD LG 23 K226 20DB WT 24 V36 18TN RD 25 Y128 18DG GY 8 0L 26 T41 22BK WT 27 K31 20BR WT 28 F18 20LG BK 29 K30 22PK A T 30 A341...

Page 1028: ...L39 20LB HIGHLINE 23 F15 22DB 24 25 F32 16PK DB 26 K4 22BK LB 27 L35 22BR YL DRL 27 L35 20BR YL EXCEPT DRL 28 29 V37 22RD LG 30 G11 20WT LG 31 Z9 16BK VT 32 X3 22BK RD 33 34 Z5 18BK DB 35 F33 16PK RD...

Page 1029: ...WT 66 L10 18BR LG 67 Z3 18BK OR 68 V10 16BR 69 70 71 72 73 74 C134 I P HARNESS SIDE CAV CIRCUIT 1 Y128 18DG GY 2 Y193 18WT LG 3 D220 20WT VT DIESEL 4 5 L3 14RD OR 6 7 8 Z12 18BK TN 9 10 D2 20WT BK 11...

Page 1030: ...6BR WT 40 V5 16DG 41 Z2 16BK LG 42 Z6 18BK PK 43 C90 22LG WT 44 A1 10RD 45 C1 12DG 46 47 G50 22RD DB 48 V30 22DB RD 49 50 A2 14PK BK 51 A41 14YL 52 53 V32 22YL RD 54 55 V18 22YL DG 56 V40 22WT PK 57 L...

Page 1031: ...M 21 X54 18VT 22 X56 18DB RD 23 X53 18DG 24 X55 18BR RD 25 P31 22PK DG HIGHLINE PREMIUM 26 P34 22PK BK HIGHLINE PREMIUM C203 BODY HARNESS SIDE CAV CIRCUIT 1 X58 18DB OR 2 X57 18BR LB 3 F37 16RD LB 4 F...

Page 1032: ...E2 22OR 2 Z3 22BK OR C205 NATURAL ASH RECEIVER LAMP SIDE CAV CIRCUIT 1 E2 22OR 2 Z3 20BK OR C206 HEATED SEATS BODY SIDE CAV CIRCUIT 1 P7 20LB BK 2 P137 20DG 3 P8 20LB WT 4 F235 16RD 5 P139 20WT 6 P138...

Page 1033: ...6 14LB C237 RESISTOR BLOCK SIDE CAV CIRCUIT 1 C5 16LG 2 Z2 20BK LG 3 4 5 6 C82 20YL OR 7 8 C7 12BK TN 9 10 11 C4 16TN 12 F15 20DB 13 14 C6 14LB C303 BODY HARNESS SIDE CAV CIRCUIT 1 Z2 16BK LG 2 F37 16...

Page 1034: ...L50 18WT TN 2 Z3 18BK OR 2 Z3 18BK OR 3 M1 18PK 3 M1 18PK 4 M3 18PK DB 4 M3 18PK DB 5 6 C329 CLUB CAB BLACK RIGHT BACK UP LAMP SIDE CAV CIRCUIT 1 L7 16BK YL 2 Z13 16BK 3 L62 16BR RD 4 L1 18VT BK C329...

Page 1035: ...L62 16BR RD 4 L1 18VT BK C333 CLUB CAB BLACK LEFT BACK UP LAMP SIDE CAV CIRCUIT 1 L7 16BK YL 2 Z13 16BK 3 L63 16BR RD 4 L1 18VT BK C333 CLUB CAB BLACK CHASSIS HARNESS SIDE CAV CIRCUIT 1 L7 18BK YL 2 Z...

Page 1036: ...IRCUIT 1 Z13 18BK 2 L7 18BK YL C342 BLACK CHASSIS HARNESS SIDE CAV CIRCUIT 1 Z13 18BK 2 L7 16BK YL C343 GRAY FENDER LAMP SIDE CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL C343 BLACK LICENSE LAMP SIDE CAV CIRCU...

Page 1037: ...IUM RADIO 10 P34 18PK BK BASE POWER LOCKS WINDOWS 10 P31 22PK DG HIGHLINE PREMIUM C345 RIGHT DOOR HARNESS SIDE CAV CIRCUIT 1 C16 20LB YL SLT 2 P70 20WT SLT 3 P72 20YL BK SLT 4 X54 20VT STANDARD RADIO...

Page 1038: ...TN BK PREMIUM RADIO 16 X94 18TN VT PREMIUM RADIO C346 RIGHT DOOR HARNESS SIDE CAV CIRCUIT 1 F35 18RD 2 Q16 14BR WT 3 Q26 14VT WT 4 P33 18OR BK 5 X82 20LB RD 6 P35 18OR VT 7 P36 19PK VT 8 G73 20LG OR 9...

Page 1039: ...36 18PK VT 8 G73 20LG OR HIGHLINE PREMIUM 9 Z2 18BK LG BASE 10 P34 20PK BK POWER LOCKS WIN DOWS 11 X13 16BK RD PREMIUM RADIO 12 X81 20YL BK 13 X51 18BR YL PREMIUM RADIO 14 X57 18BR LB PREMIUM RADIO 15...

Page 1040: ...3 WHITE VISOR MIRROR SIDE CAV CIRCUIT 1 M1 20PK 2 Z4 20BK C353 WHITE OVERHEAD CONSOLE SIDE CAV CIRCUIT 1 M1 20PK 2 Z3 20BK C358 NATURAL OVERHEAD CONSOLE SIDE CAV CIRCUIT 1 G69 22BK 2 3 D1 20VT BR 4 D2...

Page 1041: ...20LB BK 2 P137 20DG 3 P8 20LB WT 4 F235 16RD 5 P139 20WT 6 P138 20VT LG 7 Z2 16BK LG 8 F37 16RD LB 9 G10 22LG RD 10 P140 20VT BK C360 CLUB CAB BODY HARNESS SIDE CAV CIRCUIT 1 Z2 16BK LG 2 F37 16RD LB...

Page 1042: ...C361 REAR DOOR HARNESS SIDE CAV CIRCUIT 1 2 X57 18BR LB 3 X51 18BR YL 4 5 6 C364 BODY HARNESS SIDE CAV CIRCUIT 1 2 X92 18TN BK PREMIUM RADIO 2 X58 18DB OR STANDARD RADIO 3 X94 18TN VT PREMIUM RADIO 3...

Page 1043: ...IT FUNCTION A K6 18VT WT 5V SUPPLY B K14 18BK DB SENSOR GROUND C K124 18GY CAMSHAFT POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR GAS EXCEPT 8 0L GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K44 18TN YL CAMSHA...

Page 1044: ...NTER HIGH MOUNTED STOP LAMP NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 Z3 18BK OR GROUND CENTER HIGH MOUNTED STOP LAMP NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L50 1...

Page 1045: ...IMER MODULE C2 18 WAY CAV CIRCUIT FUNCTION 1 P33 22OR BK DOOR LOCK DRIVER 2 M11 22PK LB COURTESY LAMP SWITCH OUTPUT 3 Z3 18BK OR GROUND 4 P30 22OR DG PASSENGER DOOR LOCK SWITCH OUTPUT 5 F12 22DB WT FU...

Page 1046: ...DIO CONTROL MUX CLUTCH PEDAL POSITION SWITCH M T BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T141 14YL RD FUSED IGNITION SWITCH OUTPUT START 2 A41 14YL FUSED IGNITION SWITCH OUTPUT START CONTROLLER ANTILOCK BR...

Page 1047: ...CRANKSHAFT POSITION SENSOR SIGNAL 2 K4 20BK LB SENSOR GROUND 3 K6 20VT WT 5V SUPPLY CRANKSHAFT POSITION SENSOR GAS EXCEPT 8 0L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K24 18GY BK CRANKSHAFT POSITION SENSO...

Page 1048: ...BK GROUND 2 L10 18BR LG FUSED IGNITION SWITCH OUTPUT RUN 3 G34 20RD GY HIGH BEAM INDICATOR DRIVER 4 G11 20WT LG PARK BRAKE SWITCH SENSE 5 6 L3 18RD OR DIMMER SWITCH HIGH BEAM OUTPUT 7 Z1 18BK GROUND 8...

Page 1049: ...WITCH SENSE DRIVER DOOR LOCK MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P34 20PK BK DOOR UNLOCK DRIVER 2 P33 20OR BK DOOR LOCK DRIVER DRIVER DOOR WINDOW LOCK SWITCH BLUE 11 WAY CAV CIRCUIT FUNCTION 1 Q1...

Page 1050: ...GNITION SWITCH OUTPUT RUN 5 P139 20WT LEFT SEAT HIGH HEAT LED DRIVER 6 P7 20LB BK DRIVER HEATED SEAT SWITCH DRIVER LUMBAR MOTOR 2 WAY CAV CIRCUIT FUNCTION 1 P106 16DG WT LUMBAR MOTOR FORWARD 2 P107 16...

Page 1051: ...T LEFT SEAT REAR DOWN DRIVER POWER SEAT REAR VERTICAL MOTOR STANDARD CAB 2 WAY CAV CIRCUIT FUNCTION 1 P11 14YL WT LEFT SEAT REAR UP 2 P13 14RD WT LEFT SEAT REAR DOWN DRIVER POWER SEAT SWITCH CLUB CAB...

Page 1052: ...14YL LB LEFT SEAT HORIZONTAL FORWARD M P19 14YL LG LEFT SEAT FRONT UP N P21 14RD LG LEFT SEAT FRONT DOWN DRIVER POWER WINDOW MOTOR 2 WAY CAV CIRCUIT FUNCTION 1 Q11 16LB LEFT WINDOW DRIVER UP 2 Q21 16...

Page 1053: ...K DATA LINK FUEL INJECTOR PUMP 24 V32 18YL RD BRAKE SWITCH SENSE 25 H102 18LB BK ACCELERATOR PEDAL POSITION SENSOR SIGNAL 26 G113 18OR PTO SWITCH SENSE 27 28 K22 18OR DB ACCELERATOR PEDAL POSITION SEN...

Page 1054: ...LB SENSOR GROUND C G60 18GY BK ENGINE OIL PRESSURE SENSOR SIGNAL ENGINE OIL PRESSURE SENSOR GAS 2 WAY CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 2 G60 18GY OR ENGINE OIL PRESSURE SENSOR SIGNAL E...

Page 1055: ...40 14RD LG FUEL PUMP RELAY OUTPUT 8 K48 18DG FUEL INJECTION PUMP SYNC SIGNAL 9 FUEL INJECTOR NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K11 18WT DB FUEL INJECTOR NO 1 DRIVER 2 A142 16DG OR AUTOMATIC SHUT...

Page 1056: ...NO 6 DRIVER 2 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 7 5 2L 5 9L 8 0L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K26 18VT TN FUEL INJECTOR NO 7 DRIVER 2 A142 16DG OR AUTOMATIC SHUT DO...

Page 1057: ...L SENSOR SIGNAL 4 A61 16DG BK FUEL PUMP RELAY OUTPUT FUEL TANK MODULE DIESEL LT GRAY 4 WAY CAV CIRCUIT FUNCTION 1 2 K4 20BK LB SENSOR GROUND 3 K226 20DB WT FUEL LEVEL SENSOR SIGNAL 4 FUEL TRANSFER PUM...

Page 1058: ...HEADLAMP SWITCH OUTPUT 7 L39 22LB FOG LAMP SWITCH OUTPUT 8 E17 18YL BK DAY BRIGHTNESS SENSE 9 Z3 20BK OR GROUND 10 M22 22WT ILLUMINATED ENTRY SWITCH SENSE 11 M3 22PK DB CARGO LAMP DRIVER 12 M2 22YL CO...

Page 1059: ...CAV CIRCUIT FUNCTION 1 A142 14DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K19 16BK GY IGNITION COIL NO 1 DRIVER IGNITION COIL 4 PACK 8 0L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K17 18DB WT IGNITION COIL NO...

Page 1060: ...ITCH SENSE 4 Z2 20BK LG GROUND 5 Z3 20BK OR GROUND 6 F73 20YL FUSED B 7 8 G85 22OR BK DIESEL WAIT TO START WARNING INDICATOR DRIVER 9 D2 20WT BK CCD BUS 10 D1 20VT BR CCD BUS INSTRUMENT CLUSTER C2 10...

Page 1061: ...4 16VT WT DIMMER SWITCH LOW BEAM OUTPUT 6 L4 20VT WT DIMMER SWITCH LOW BEAM OUTPUT 7 L4 20VT WT DIMMER SWITCH LOW BEAM OUTPUT 8 L4 18VT WT DIMMER SWITCH LOW BEAM OUTPUT 9 L1 18VT BK BACK UP LAMP FEED...

Page 1062: ...UT DOWN RELAY OUTPUT SENSE 16 A142 14DG OR GAS AUTOMATIC SHUT DOWN RELAY OUTPUT SENSE 16 Z12 18BK TN DIESEL GROUND 17 Z12 18BK TN DIESEL GROUND 17 A142 14DG OR GAS AUTOMATIC SHUT DOWN RELAY OUTPUT SEN...

Page 1063: ...BR WASHER SWITCH SENSE 3 V10 16BR WASHER SWITCH SENSE 4 5 6 Z9 16BK VT GROUND 7 Z9 16BK VT EXCEPT BASE LOWLINE GROUND 8 G26 22LB KEY IN IGNITION SWITCH SENSE 9 G26 22LB KEY IN IGNITION SWITCH SENSE 10...

Page 1064: ...E2 22OR HEATED SEATS PANEL LAMPS FEED 6 G75 22TN BASE MIDLINE DRIVER DOOR AJAR SWITCH SENSE 7 E2 22OR HEATED SEATS PANEL LAMPS FEED 7 G75 22TN BASE MIDLINE DRIVER DOOR AJAR SWITCH SENSE 8 F14 18LG YL...

Page 1065: ...CC 14 G32 20BK VT SENSOR GROUND 15 JUNCTION BLOCK C2 NATURAL 6 WAY CAV CIRCUIT FUNCTION 1 A7 10RD BK FUSED B 2 L9 16BK VT FUSED FLASHER FEED 3 M1 20PK FUSED B 4 5 L60 18TN RIGHT TURN SIGNAL 6 JUNCTION...

Page 1066: ...FUSED IGNITION SWITCH OUTPUT RUN ACC 4 V6 16DB FUSED IGNITION SWITCH OUTPUT RUN ACC 5 6 M2 22YL COURTESY LAMPS DRIVER 7 E2 22OR PANEL LAMPS FEED 8 G5 22DB WT FUSED IGNITION SWITCH OUTPUT RUN START JUN...

Page 1067: ...SWITCH OUTPUT RUN START 3 A22 14BK OR FUSED IGNITION SWITCH OUTPUT RUN 4 F15 18DB FUSED IGNITION SWITCH OUTPUT RUN LEAK DETECTION PUMP GAS BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 T125 18DB GENERATOR SOU...

Page 1068: ...REAR SPEAKER 10 X57 18BR LB LEFT REAR SPEAKER LEFT FRONT DOOR SPEAKER STANDARD 2 WAY CAV CIRCUIT FUNCTION A X55 20BR RD LEFT FRONT SPEAKER B X53 20DG LEFT FRONT SPEAKER LEFT FRONT FENDER LAMP DUAL REA...

Page 1069: ...TCH LOW BEAM OUTPUT B L43 18VT QUAD HEADLAMP FUSED B C L3 20RD OR DIMMER SWITCH HIGH BEAM OUTPUT LEFT OUTBOARD IDENTIFICATION LAMP 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL HEADLAMP SWITCH OUTPUT 2 Z4 1...

Page 1070: ...R 2 WAY CAV CIRCUIT FUNCTION 1 X57 18BR LB AMPLIFIED LOW LEFT REAR SPEAKER 2 X51 18BR YL AMPLIFIED LOW LEFT REAR SPEAKER LEFT REAR SPEAKER STANDARD 2 DOOR 2 WAY CAV CIRCUIT FUNCTION A X57 18BR LB LEFT...

Page 1071: ...NAL LEFT TWEETER PREMIUM 2 WAY CAV CIRCUIT FUNCTION 1 X81 20YL BK AMPLIFIED HIGH LEFT FRONT SPEAKER 2 X83 20YL RD AMPLIFIED HIGH LEFT FRONT SPEAKER LEFT VISOR VANITY LAMP BLACK 2 WAY CAV CIRCUIT FUNCT...

Page 1072: ...PUT 6 V3 16BR WT LOW SPEED WIPER SWITCH OUTPUT 7 V49 16RD BK DRIVER LOW SPEED WIPER MOTOR DRIVER 8 V49 16RD BK DRIVER LOW SPEED WIPER MOTOR DRIVER 9 V3 16BR WT LOW SPEED WIPER SWITCH OUTPUT 10 11 L60...

Page 1073: ...COURTESY LAMPS DRIVER 7 Z2 20BK LG GROUND 8 D2 20WT BK CCD BUS 9 G32 22BK LB SENSOR GROUND 10 11 G69 22BK VTSS INDICATOR DRIVER 12 OXYGEN SENSOR 1 1 LEFT BANK UP 5 9L HD 8 0L 4 WAY CAV CIRCUIT FUNCTI...

Page 1074: ...SENSOR 1 2 DOWNSTREAM 3 9L 5 2L 4 WAY CAV CIRCUIT FUNCTION 1 A141 18DG WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K299 18BR WT OXYGEN SENSOR 1 2 HEATER CONTROL 3 K4 18BK LB SENSOR GROUND 4 K341 18OR BK OXY...

Page 1075: ...T BANK DOWN CALIFORNIA 4 WAY CAV CIRCUIT FUNCTION 1 A341 18DG YL OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT 2 Z11 18BK WT GROUND 3 K4 18BK LB SENSOR GROUND 4 K441 18OR TN OXYGEN SENSOR 2 2 SIGNAL PARK NEUT...

Page 1076: ...GER AIRBAG SQUIB LINE 2 3 R42 18BK YL PASSENGER AIRBAG LINE 1 4 R44 18DG YL PASSENGER AIRBAG LINE 2 PASSENGER CYLINDER LOCK SWITCH LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z2 20BK LG GROUND 2 G73 20LG OR...

Page 1077: ...TION 1 P130 16TN RIGHT SEAT HEATER B DRIVER 2 Z2 18BK LG GROUND 3 P144 20BK WT SEAT TEMPERATURE 5V SUPPLY 4 P142 20DB RIGHT SEAT TEMPERATURE SENSOR INPUT PASSENGER HEATED SEAT SWITCH BLUE 6 WAY CAV CI...

Page 1078: ...LG GROUND H F37 16RD LB FUSED B I J P12 16RD WT RIGHT SEAT REAR DOWN K P16 16LB RIGHT SEAT HORIZONTAL FORWARD L P14 16YL LB RIGHT SEAT HORIZONTAL REARWARD M P18 16YL LG RIGHT SEAT FRONT UP N P20 16RD...

Page 1079: ...IGNITION SWITCH OUTPUT RUN START 3 4 K4 18BK LB SENSOR GROUND 5 6 T41 18BK WT A T PARK NEUTRAL POSITION SWITCH SENSE 7 8 K24 18GY BK CRANKSHAFT POSITION SENSOR SIGNAL 9 10 11 12 13 14 15 16 17 18 19 2...

Page 1080: ...V SUPPLY 18 K44 18TN YL CAMSHAFT POSITION SENSOR SIGNAL 19 K39 18GY RD IDLE AIR CONTROL NO 1 DRIVER 20 K59 18VT BK IDLE AIR CONTROL NO 4 DRIVER 21 22 A14 16RD WT FUSED B 23 K22 18OR DB THROTTLE POSITI...

Page 1081: ...8VT A T TRANSMISSION TEMPERATURE SENSOR SIGNAL 2 K26 18VT TN 5 2L 5 9L 8 0L FUEL INJECTOR NO 7 DRIVER 3 K115 18TN BK 8 0L FUEL INJECTOR NO 9 DRIVER 4 K11 18WT DB FUEL INJECTOR NO 1 DRIVER 5 K13 18YL W...

Page 1082: ...T DOWN RELAY CONTROL 4 V36 18TN RD SPEED CONTROL VACUUM SOLENOID CONTROL 5 V35 18LG RD SPEED CONTROL VENT SOLENOID CONTROL 6 7 8 9 10 11 V32 18YL RD SPEED CONTROL SUPPLY 12 A142 14DG OR AUTOMATIC SHUT...

Page 1083: ...SWITCH SENSE 15 K118 18PK YL BATTERY TEMPERATURE SENSOR SIGNAL 16 K299 18BR WT OXYGEN SENSOR 2 1 HEATER CONTROL 17 18 19 K31 18BR WT FUEL PUMP RELAY CONTROL 20 K52 18PK WT EVAPORATIVE EMISSION SOLENO...

Page 1084: ...N 1 D1 20VT BR CCD BUS 2 D2 20WT BK CCD BUS RADIO CHOKE RELAY BLACK 4 WAY CAV CIRCUIT FUNCTION 1 X60 16DG RD FUSED IGNITION SWITCH OUTPUT RUN ACC 2 X13 16BK RD RADIO CHOKE RELAY OUTPUT 3 X16 22LG ANTE...

Page 1085: ...LIFIED LOW RIGHT REAR SPEAKER 7 X13 16BK RD RADIO CHOKE RELAY OUTPUT 8 Z9 16BK VT GROUND 9 X52 18DB WT RIGHT REAR SPEAKER 10 X58 18DB OR RIGHT REAR SPEAKER RIGHT FRONT DOOR SPEAKER STANDARD 2 WAY CAV...

Page 1086: ...IRCUIT FUNCTION A L4 16VT WT QUAD HEADLAMP DIMMER SWITCH LOW BEAM OUTPUT A L44 18VT RD EXCEPT QUAD HEAD LAMP FUSED B B L4 16VT WT EXCEPT QUAD HEAD LAMP DIMMER SWITCH LOW BEAM OUTPUT B L44 18VT RD QUAD...

Page 1087: ...2 WAY CAV CIRCUIT FUNCTION 1 X92 18TN BK AMPLIFIED LOW RIGHT REAR SPEAKER 2 X94 18TN VT AMPLIFIED LOW RIGHT REAR SPEAKER RIGHT REAR SPEAKER 4 DOOR PREMIUM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X57 18BR...

Page 1088: ...L PARK LAMP RELAY OUTPUT 3 L62 18DG BR RIGHT TURN SIGNAL RIGHT TWEETER PREMIUM 2 WAY CAV CIRCUIT FUNCTION 1 X80 20LB BK AMPLIFIED HIGH RIGHT FRONT SPEAKER 2 X82 20LB RD AMPLIFIED HIGH RIGHT FRONT SPEA...

Page 1089: ...SWITCH 10 P138 20VT LG RIGHT SEAT LOW HEAT LED DRIVER 11 P140 20VT BK RIGHT SEAT HIGH HEAT LED DRIVER 12 P137 20DG LEFT SEAT LOW HEAT LED DRIVER 13 Z2 18BK LG GROUND 14 P139 20WT LEFT SEAT HIGH HEAT...

Page 1090: ...ISSION CONTROL RELAY OUTPUT 2 K7 18OR 5V SUPPLY 3 K4 18BK LB SENSOR GROUND 4 T25 18LG WT GOVERNOR PRESSURE SENSOR SIGNAL 5 K88 18VT WT GOVERNOR PRESSURE SOLENOID CONTROL 6 T60 18BR 3 4 SHIFT SOLENOID...

Page 1091: ...K1 18DG RD WATER IN FUEL SENSOR SIGNAL WIPER MOTOR 4 WAY CAV CIRCUIT FUNCTION 1 V4 16RD YL WIPER SWITCH HIGH SPEED OUTPUT 2 V5 16DG WIPER PARK SWITCH SENSE 3 V6 16DB FUSED IGNITION SWITCH OUTPUT RUN A...

Page 1092: ...Accelerator Pedal Position Sensor Diesel Left Front of Engine 10 11 Aftermarket Trailer Tow Connector Rear of Vehicle N S Airbag Control Module Center of I P at Airbag Control Module 23 Ambient Temper...

Page 1093: ...sition Sensor V10 Front of Engine 6 Camshaft Position Sensor Diesel Left Front of Engine 10 Cargo Lamp No 1 BK Rear of Lamp N S Cargo Lamp No 2 BK Rear of Lamp N S Center High Mounted Stop Lamp No 1 B...

Page 1094: ...17 Electric Brake Provision Bottom Left of Instrument Panel N S Engine Control Module Diesel Left Side Engine 12 Engine Coolant Temperature Sensor Diesel BK Left Front of Cylinder Head Diesel 10 Engin...

Page 1095: ...anel 23 26 Heated Mirror Switch Center of Instrument Panel 25 High Note Horn BK Front Bumper Right Support 17 Idle Air Control Motor BK On Throttle Body 9 Ignition Coil GY Right Front of Engine 4 5 9...

Page 1096: ...ind Front of Headliner 20 Left Outboard Headlamp BL At Headlamp N S Left Outboard Identification Lamp BK Behind Front of Headliner 20 Left Park Turn Signal Lamp BK At Lamp N S Left Power Mirror BK In...

Page 1097: ...Door 19 Passenger Heated Seat Switch BL Center of Instrument Panel N S Passenger Heated Seat Module Under Seat N S Passenger Lumbar Motor Under Seat N S Passenger Power Seat Front Vertical Motor Unde...

Page 1098: ...Switch Steering Wheel N S Right Tail Stop Turn Signal Lamp BK At Rear Bumper 21 Right Tweeter Right A Pillar N S Right Visor Vanity Lamp BK Right A Pillar N S Seat Belt Switch Above Left Rear Speaker...

Page 1099: ...Fig 1 ENGINE COMPARTMENT GAS Fig 2 ENGINE COMPARTMENT DIESEL ENGINE 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1100: ...Fig 3 3 9 5 2 5 9 LITER ENGINE BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 CONNECTOR GROUND LOCATIONS Continued...

Page 1101: ...Fig 4 5 2 5 9 LITER ENGINE 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1102: ...Fig 5 3 9 LITER ENGINE BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 CONNECTOR GROUND LOCATIONS Continued...

Page 1103: ...Fig 6 8 0 LITER ENGINE 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1104: ...Fig 7 GENERATOR GAS ENGINE Fig 8 GENERATOR DIESEL ENGINE BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 CONNECTOR GROUND LOCATIONS Continued...

Page 1105: ...Fig 9 IGNITION COIL GAS ENGINE 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1106: ...Fig 10 DIESEL COMPONENTS BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 CONNECTOR GROUND LOCATIONS Continued...

Page 1107: ...Fig 11 ACCELERATOR PEDAL POSITION SENSOR Fig 12 ENGINE CONTROL MODULE 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1108: ...Fig 13 TRANSMISSION CONNECTORS BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 CONNECTOR GROUND LOCATIONS Continued...

Page 1109: ...Fig 14 LEFT SIDE ENGINE COMPARTMENT 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1110: ...Fig 15 UNDER HOOD BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 CONNECTOR GROUND LOCATIONS Continued...

Page 1111: ...Fig 16 UNDER HOOD 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1112: ...Fig 17 RIGHT FENDER SHIELD BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 CONNECTOR GROUND LOCATIONS Continued...

Page 1113: ...Fig 18 CENTER HIGH MOUNTED STOP LAMP 8W 90 22 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1114: ...Fig 19 DOOR BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 23 CONNECTOR GROUND LOCATIONS Continued...

Page 1115: ...Fig 20 OVERHEAD CONSOLE 8W 90 24 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1116: ...Fig 21 TAIL LAMPS BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 25 CONNECTOR GROUND LOCATIONS Continued...

Page 1117: ...Fig 22 FRAME RAIL 8W 90 26 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1118: ...Fig 23 INSTRUMENT PANEL BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 27 CONNECTOR GROUND LOCATIONS Continued...

Page 1119: ...Fig 24 STEERING COLUMN 8W 90 28 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1120: ...Fig 25 INSTRUMENT PANEL BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 29 CONNECTOR GROUND LOCATIONS Continued...

Page 1121: ...Fig 26 INSTRUMENT PANEL 8W 90 30 8W 90 CONNECTOR GROUND LOCATIONS BR BE CONNECTOR GROUND LOCATIONS Continued...

Page 1122: ...Fig 27 LEFT COWL BR BE 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 31 CONNECTOR GROUND LOCATIONS Continued...

Page 1123: ......

Page 1124: ...Harness Near Left Wheel Speed Sensor 7 S111 Transmission Harness Near T O to A C Low Pressure Switch 2 S112 Headlamp and Dash Harness Near Antilock Brake Controller 7 S113 Headlamp and Dash Harness Ne...

Page 1125: ...Module N S S167 Diesel Engine Harness Near Fuel Transfer Pump N S S168 Diesel Engine Harness Near T O to Engine Coolant Temoerature Sensor N S S170 Diesel Engine Harness In T O to Engine Control Modul...

Page 1126: ...ead Console Harness At Roof Lamps 9 S325 Overhead Console Harness At Roof Lamps 9 S326 Overhead Console Harness At Roof Lamps 9 S327 Power Seat Harness Near Switch N S S328 Power Seat Harness Near T O...

Page 1127: ...Fig 2 DASH PANEL DIESEL ENGINE Fig 1 DASH PANEL GAS ENGINES 8W 95 4 8W 95 SPLICE LOCATIONS BR BE SPLICE LOCATIONS Continued...

Page 1128: ...Fig 3 3 9 5 2 5 9 LITER ENGINE BR BE 8W 95 SPLICE LOCATIONS 8W 95 5 SPLICE LOCATIONS Continued...

Page 1129: ...Fig 4 8 0 LITER ENGINE 8W 95 6 8W 95 SPLICE LOCATIONS BR BE SPLICE LOCATIONS Continued...

Page 1130: ...Fig 5 5 2 5 9 LITER ENGINE BR BE 8W 95 SPLICE LOCATIONS 8W 95 7 SPLICE LOCATIONS Continued...

Page 1131: ...Fig 6 LEFT SIDE TRANSMISSION 8 0 LITER ENGINE 8W 95 8 8W 95 SPLICE LOCATIONS BR BE SPLICE LOCATIONS Continued...

Page 1132: ...Fig 7 LEFT SIDE ENGINE COMPARTMENT BR BE 8W 95 SPLICE LOCATIONS 8W 95 9 SPLICE LOCATIONS Continued...

Page 1133: ...Fig 8 RIGHT FENDER SIDE SHIELD Fig 9 OVERHEAD CONSOLE 8W 95 10 8W 95 SPLICE LOCATIONS BR BE SPLICE LOCATIONS Continued...

Page 1134: ...Fig 10 LEFT COWL PANEL Fig 11 CHASSIS BR BE 8W 95 SPLICE LOCATIONS 8W 95 11 SPLICE LOCATIONS Continued...

Page 1135: ...Fig 12 INSTRUMENT PANEL 8W 95 12 8W 95 SPLICE LOCATIONS BR BE SPLICE LOCATIONS Continued...

Page 1136: ...s Blade type fuses Cartridge fuses Circuit splice blocks Flashers Relays Following are general descriptions of the major components in the power distribution system See the owner s manual in the vehic...

Page 1137: ...diates from the heating element caus ing the spring clips to expand Once the spring clips expand far enough to release the heating element the spring loaded housing forces the knob and heat ing elemen...

Page 1138: ...nt 5 Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and using a gentle rocking motion pull the pliers and the receptacle base out of the mount 6 Pull the receptacl...

Page 1139: ...rent levels resulting from a faulty generator or faulty charging system control circuits If the current rating of the fuse is exceeded the fuse conductor melts to open the generator output circuit con...

Page 1140: ...ircuit fuse The IOD fuse serves no useful purpose to the dealer technician in the ser vice or diagnosis of any vehicle system or condition other than the same purpose as that of any other standard cir...

Page 1141: ...plastic JB housing has integral mount ing brackets that are secured with two screws to the left instrument panel end bracket The left end of the instrument panel cover has a snap fit fuse access panel...

Page 1142: ...stru ment panel steering column opening to position the JB onto the left instrument panel end bracket 2 Reach through the outboard side of the instru ment panel steering column opening to install and...

Page 1143: ...e PDC and head lamp and dash wire harness unit must be replaced 1 Disconnect and isolate the battery negative cable 2 Disconnect each of the headlamp and dash wire harness connectors Refer to Connecto...

Page 1144: ...the screw that secures the engine wire harness in line connector to the PDC Tighten the screw until a distinct audible click is heard 10 Install and latch the cover onto the PDC 11 Engage each of the...

Page 1145: ...tic protective cap from the power outlet receptacle Check for continuity between the inside circumference of the power outlet recepta cle and a good ground There should be continuity If OK go to Step...

Page 1146: ...r receptacle 3 Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount 4 Press firmly on the cigar lighte...

Page 1147: ......

Page 1148: ...CYLINDER HEAD DESCRIPTION 22 OPERATION 22 DIAGNOSIS AND TESTING 22 CYLINDER HEAD GASKET FAILURE 22 REMOVAL 23 CLEANING 23 INSPECTION 23 INSTALLATION 23 CYLINDER HEAD COVER S REMOVAL 24 CLEANING 24 IN...

Page 1149: ...45 DIAGNOSIS AND TESTING 47 ENGINE OIL PRESSURE 47 ENGINE OIL LEAKS 47 OIL STANDARD PROCEDURE 47 ENGINE OIL 47 OIL FILTER REMOVAL 48 INSTALLATION 48 OIL PAN REMOVAL 48 CLEANING 49 INSPECTION 49 INSTAL...

Page 1150: ...mining the causes of malfunctions not detected and remedied by routine maintenance These malfunctions may be classified as either mechanical e g a strange noise or performance e g engine idles rough a...

Page 1151: ...l 2 Perform fuel pressure test and if necessary inspect fuel injector s and driver circuits Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP DIAGNOSIS AND TESTING 3 Low or no engine compression 3 Perfo...

Page 1152: ...ed 5 Check for correct firing order or replace spark plug cables Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CABLE DIAGNOSIS AND TESTING 6 Faulty coil 6 Test and replace if necessary Refer to 8...

Page 1153: ...ace 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...

Page 1154: ...ogged 8 Inspect suction tube and clean or replace if necessary 9 Oil pump cover warped or cracked 9 Install new oil pump OIL LEAKS 1 Misaligned or deteriorated gaskets 1 Replace gasket 2 Loose fastene...

Page 1155: ...l 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 Thi...

Page 1156: ...p Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa...

Page 1157: ...that remain steady with shaft rotation no further inspection can be done until dis assembled Refer to the service Diagnosis Mechani cal under the Oil Leak row for components inspections on possible ca...

Page 1158: ...CAUTION Be sure that the tapped holes maintain the original center line Damaged or worn threads can be repaired Essen tially this repair consists of Drilling out worn or damaged threads Tapping the h...

Page 1159: ...er steel gaskets REMOVAL 1 Disconnect the negative cable from the battery 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Remove the upper crossmember and top core support 4 Remove the...

Page 1160: ...r cap and wiring 17 Install the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 18 Using a new gasket install throttle body Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BOD...

Page 1161: ...mm 1 5605 1 5615 in Bearing to Journal Clearance Standard 0 0254 0 0762 mm 0 001 0 003 in Max Allowable 0 127 mm 0 005 in DESCRIPTION SPECIFICATION End Play 0 051 0 254 mm 0 002 0 010 in CONNECTING R...

Page 1162: ...5 Valve Seat Runout Max 0 0762 mm 0 003 in Valve Seat Width Finish Intake 1 016 1 542 mm DESCRIPTION SPECIFICATION 0 040 0 060 in Exhaust 1 524 2 032 mm 0 040 0 060 in Valve Face Angle 43 25 43 75 Val...

Page 1163: ...Out of Flat Max 0 0381 mm 0 0015 in Inner Rotor Thickness Min 20 955 mm 0 825 in DESCRIPTION SPECIFICATION Outer Rotor Clearance Max 0 3556 mm 0 014 in Outer Rotor Diameter Min 62 7126 mm 2 469 in Ou...

Page 1164: ...s 52 BBDC Duration 248 Intake Valve Closes 50 ABDC Opens 10 BTDC Duration 240 Valve Overlap 26 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CHART OS US Item Identification Location of Identificati...

Page 1165: ...Pan Bolts 24 215 Oil Pan Drain Plug 34 25 Oil Pump Mounting Bolts 41 30 Oil Pump Cover Bolts 11 95 Rear Insulator to Bracket 68 50 DESCRIPTION N m In Ft Lbs Lbs Through Bolt 2WD Rear Insulator to Cro...

Page 1166: ...ngine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A Adapter 6633 Adapter 6716A Valve Guide Sleeve C 3973 Dial Indicator C 3339 Puller C 3688 Front Oil Seal Installer 6635 Camshaft Holde...

Page 1167: ...2 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 Pressure Tester Kit 7700 Bloc Chek Kit C 3685 A 9 20 ENGINE...

Page 1168: ...throttle body and replace as necessary 7 The housing cover is equipped with three 3 spring clips Fig 4 and is hinged at rear with plastic tabs Unlatch clips from top of air cleaner housing and tilt ho...

Page 1169: ...acket Possible indications of the cylinder head gasket leaking between adjacent cylinders are Loss of engine power Engine misfiring Poor fuel economy Possible indications of the cylinder head gasket l...

Page 1170: ...o 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 17 Remove intake manifold and throttle body as an assembly Discard the flange side gaskets and the front and rear cross over gaskets 18 Remove e...

Page 1171: ...cleaner 22 Install the heat shields Tighten the bolts to 41 N m 30 ft lbs torque 23 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 24 Connect the battery negative cable CYLINDER HEAD COVER...

Page 1172: ...ator 2 Attach dial indicator Tool C 3339 to cylinder head and set it at right angles to valve stem being measured Fig 10 3 Move valve to and from the indicator The total dial indicator reading should...

Page 1173: ...ONTACT SURFACE VALVES Inspect the remaining margin after the valves are refaced Fig 12 Valves with less than 1 190 mm 0 047 in margin should be discarded VALVE SEATS CAUTION DO NOT un shroud valves du...

Page 1174: ...will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Refer to specifications to obtain specified height and allowable tensions Discard the...

Page 1175: ...LEANING Clean cylinder block thoroughly and check all core hole plugs for evidence of leakage INSPECTION Examine block for cracks or fractures The cylinder walls should be checked for out of round and...

Page 1176: ...camshaft to aid in removal of the camshaft Remove camshaft being careful not to damage cam bearings with the cam lobes INSTALLATION CAMSHAFT BEARINGS 1 Install new camshaft bearings with Camshaft Bear...

Page 1177: ...with timing marks on an exact imaginary center line through both camshaft and crankshaft bores 7 Place timing chain around both sprockets Fig 20 Camshaft Holding Tool C 3509 Installed Position 1 SPEC...

Page 1178: ...alternate from one bank to another because connect ing rods and pistons are not interchangeable from one bank to another The bearing caps are not interchangeable and should be marked at removal to en...

Page 1179: ...block and oil pan sealing Fig 26 Apply enough sealant so that a small amount is squeezed out Withdraw nozzle and wipe excess seal ant off the oil pan seal groove 11 Install new front crankshaft oil s...

Page 1180: ...LOCATION CHART ITEM MEASUREMENT IDENTIFICATION ROD U S 0 025 mm R1 R2 R3 ect 0 001 in indicates rod journal No 1 2 and 3 MAIN U S 0 025 mm M1 M2 M3 or M4 0 001 in indicates main journal No 1 2 3 and...

Page 1181: ...battery 2 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 3 If front seal is suspected of leaking check front oil seal alignment to crankshaft The seal installa tion a...

Page 1182: ...nstalled with crankshaft removed from engine or with crankshaft installed When a new upper seal is installed install a new lower seal The lower seal half can be installed only with the rear main beari...

Page 1183: ...he kit Install the new seal with the white paint facing toward the rear of the engine 4 Install the new lower rear bearing oil seal into the bearing cap with the white paint facing toward the rear of...

Page 1184: ...Withdraw nozzle and wipe excess seal ant off the oil pan seal groove 10 Immediately install the oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION DISTRIBUTOR BUSHING REMOVAL 1 Remove distrib...

Page 1185: ...is in the tappet Inspect the rocker arm push rod sockets and push rod ends for wear 3 Valve tappet noise ranges from light noise to a heavy click A light noise is usually caused by exces sive leak dow...

Page 1186: ...tappet CLEANING Clean tappet with a suitable solvent Rinse in hot water and blow dry with a clean shop rag or com pressed air INSTALLATION 1 Lubricate tappets 2 Install tappets and push rods in their...

Page 1187: ...3 9087 3 9092 3 9098 3 9103 B 99 294 99 306 99 320 99 333 3 9092 3 9097 3 9103 3 9108 C 99 306 99 319 99 333 99 345 3 9097 3 9102 3 9108 3 9113 D 99 319 99 332 99 346 99 358 3 9102 3 9107 3 9113 3 91...

Page 1188: ...own in cylinder bore using a hammer handle At the same time guide connecting rod into position on crankshaft journal 7 The notch or groove on top of piston must be pointing toward front of engine The...

Page 1189: ...Arrange second compression ring 90 clock wise from the oil ring rail gap Fig 44 VIBRATION DAMPER REMOVAL 1 Disconnect the negative cable from the battery 2 Remove fan and fan drive Refer to 7 COOL ING...

Page 1190: ...icle on hoist 5 Lift the engine SLIGHTLY and remove the thru bolt and nut Fig 47 6 Remove engine support bracket cushion bolts Fig 47 Remove the support bracket cushion and heat shields INSTALLATION 1...

Page 1191: ...e bolts holding the support cushion to the transmission support bracket Remove the sup port cushion 6 If necessary remove the bolts holding the transmission support bracket to the transmission INSTALL...

Page 1192: ...f each main bearing The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals Each connecting rod bearing has half a hole in it oil passes through...

Page 1193: ...CONNECTING ROD BEARINGS 13 OIL INTAKE 14 OIL PUMP 15 OIL FILTER 16 CRANKSHAFT 17 FROM OIL PUMP 18 OIL TO FILTER 19 OIL FROM FILTER TO SYSTEM 20 PASSAGE TO CAMSHAFT REAR BEARING 21 RIGHT OIL GALLERY 22...

Page 1194: ...f test pressure 9 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 bes...

Page 1195: ...ivalent oil filter be used 1 Position a drain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise to remove it from the cylinder block...

Page 1196: ...s Tighten the bolts to 24 N m 215 in lbs torque 8 Remove the dowels Install the remaining oil pan bolts Tighten these bolts to 24 N m 215 in lbs torque 9 Lower the engine into the support cushion brac...

Page 1197: ...fully for damage or wear CLEANING Use only mild solvents to clean the oil pump Do not use any abrasive material to clean the oil pump housing or rotors INSPECTION Mating surface of the oil pump cover...

Page 1198: ...replace pump assembly Fig 64 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper The relief valve spring...

Page 1199: ...fold Fig 66 is a single plane design with equal length runners This mani fold uses a separate plenum pan and gasket there fore the plenum gasket is servicable It also uses separate flange gaskets and...

Page 1200: ...11 Disconnect the coil wires 12 Disconnect the heat indicator sending unit wire 13 Disconnect the heater hoses and bypass hose 14 Remove the closed crankcase ventilation and evaporation control system...

Page 1201: ...n on the cylinder block and cylinder heads After intake manifold is in place inspect to make sure seals are in place 7 Install the intake manifold bolts and tighten as follows Fig 70 Step 1 Tighten bo...

Page 1202: ...nect the negative cable from the battery 2 Raise and support the vehicle 3 Disconnect the exhaust pipe from the exhaust manifold Refer to 11 EXHAUST SYSTEM EX HAUST PIPE REMOVAL 4 Lower the vehicle 5...

Page 1203: ...chain case cover and cylinder block are clean and free from burrs 2 Using a new cover gasket carefully install chain case cover to avoid damaging oil pan gasket Use a small amount of Mopart GEN II Si...

Page 1204: ...eel arm presses on the timing chain maintaining the correct chain tension TIMING BELT CHAIN AND SPROCKETS REMOVAL 1 Disconnect battery negative cable 2 Drain cooling system Refer to 7 COOLING STANDARD...

Page 1205: ...175 mm 1 8 inch INSTALLATION 1 If tensioner assembly is being replaced install tensioner and mounting bolts Torque bolts to 24 N m 210 in lbs 2 Place both camshaft sprocket and crankshaft sprocket on...

Page 1206: ...5 ROCKER ARM ADJUSTER ASSEMBLY REMOVAL 85 INSTALLATION 85 ENGINE BLOCK CLEANING 86 INSPECTION 86 CAMSHAFT BEARINGS IN BLOCK REMOVAL 86 INSTALLATION 87 CONNECTING ROD BEARINGS STANDARD PROCEDURE 88 CON...

Page 1207: ...TALLATION 113 TIMING BELT CHAIN COVER S REMOVAL 113 INSTALLATION 113 TIMING BELT CHAIN AND SPROCKETS REMOVAL 114 INSPECTION 114 INSTALLATION 115 ENGINE 5 2L DESCRIPTION The 5 2 Liter 318 CID eight cyl...

Page 1208: ...1 Charge Replace Battery Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY STANDARD PROCEDURE Check charging system Refer to 8 ELECTRICAL CHARGING DIAGNOSIS AND TESTING 2 Corroded or loose battery connect...

Page 1209: ...REMOVAL ENGINE STALLS OR ROUGH IDLE 1 Carbon build up on throttle plate 1 Remove throttle body and de carbon Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BODY REMOVAL 2 Engine idle speed too low 2...

Page 1210: ...Y VALVES LIFTERS 1 High or low oil level in crankcase 1 Check for correct oil level Adjust oil level by draining or adding as needed 2 Thin or diluted oil 2 Change oil Refer to 9 ENGINE LUBRICATION OI...

Page 1211: ...3 Thin or diluted oil 3 Change oil to correct viscosity 4 Excessive main bearing clearance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check crankshaft thrust...

Page 1212: ...tion 1 Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS DESCRIPTION for correct operation 2 Defective valve stem seal s 2 Repair or replace seal s 3 Worn or broken piston rings 3 Hone cylinder bore...

Page 1213: ...l 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 Thi...

Page 1214: ...p Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa...

Page 1215: ...oil and coolant Can be used on threaded and machined parts under all temperatures This mate rial is used on engines with multi layer steel MLS cylinder head gaskets This material also will pre vent c...

Page 1216: ...as removing light scuffing scoring and scratches Usually a few strokes will clean up a bore and maintain the required lim its CAUTION DO NOT use rigid type hones to remove cylinder wall glaze 2 Deglaz...

Page 1217: ...o converter bolts Auto matic transmission equipped vehicles 30 Remove transmission bell housing to engine block bolts 31 Lower the vehicle 32 Install an engine lifting fixture 33 Separate engine from...

Page 1218: ...iator lower hose 30 Connect the transmission oil cooler lines to the radiator 31 Install the fan shroud 32 Install the fan Refer to 7 COOLING EN GINE RADIATOR FAN INSTALLATION 33 Connect the radiator...

Page 1219: ...mm 1 984 1 985 in No 3 50 013 50 038 mm 1 969 1 970 in No 4 49 606 49 632 mm 1 953 1 954 in DESCRIPTION SPECIFICATION No 5 39 688 39 713 mm 1 5625 1 5635 in Bearing Journal Diameter No 1 50 749 50 77...

Page 1220: ...shing Press Fit Bushing to Bore Interference 0 0127 0 3556 mm 0 0005 0 0140 in Shaft to Bushing Clearance 0 0178 0 0686 mm 0 0007 0 0027 in DESCRIPTION SPECIFICATION CYLINDER HEAD Valve Seat Angle 44...

Page 1221: ...ENGINE OIL PUMP Clearance over Rotors Max 0 0381 mm 0 0015 in DESCRIPTION SPECIFICATION Inner Rotor Thickness Min 20 955 mm 0 825 in Outer Rotor Clearance Max 0 3556 mm 0 014 in Outer Rotor Diameter...

Page 1222: ...Closes ATDC 61 Opens BBDC 10 Duration 250 Valve Overlap 31 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CHART U S O S Item Identification Identification Location U S Rod R or M R 1 4 ect Milled f...

Page 1223: ...ts Refer to Procedure Oil Pan Bolts 24 215 Oil Pan Drain Plug 34 25 Oil Pump Mounting Bolts 41 30 Oil Pump Cover Bolts 11 95 Rear Insulator to Bracket Through 68 50 Bolt 2WD Rear Insulator to Crossmem...

Page 1224: ...Engine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A Adaptor 6633 Adaptor 6716A Valve Guide Sleeve C 3973 Dial Indicator C 3339 Puller C 3688 Puller 1026 Crankshaft Damper Removal Inser...

Page 1225: ...older C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 Pressure Tester...

Page 1226: ...linder head gasket leaking between adjacent cylinders are Loss of engine power Engine misfiring Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adj...

Page 1227: ...rs and gaskets Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 14 Remove intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL and throttle body as an assembly Dis card th...

Page 1228: ...ion system 20 Connect the evaporation control system 21 Install the air cleaner 22 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 23 Connect the negative cable to the battery 24 Start engin...

Page 1229: ...indicator reading should not exceed 0 432 mm 0 017 in Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored VALVE GUIDES Service v...

Page 1230: ...ONTACT SURFACE VALVES Inspect the remaining margin after the valves are refaced Fig 11 Valves with less than 1 190 mm 0 047 in margin should be discarded VALVE SEATS CAUTION DO NOT un shroud valves du...

Page 1231: ...will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Refer to specifications to obtain specified height and allowable tensions Discard the...

Page 1232: ...normal 41 27 to 42 86 mm 1 5 8 to 1 11 16 inch 8 Install cylinder head Refer to 9 ENGINE CYLINDER HEAD INSTALLATION ROCKER ARM ADJUSTER ASSEMBLY REMOVAL 1 Remove cylinder head cover and gasket Refer...

Page 1233: ...lat dowel to posi tion properly 4 If plug is too low remove oil pan and No 4 main bearing cap Use suitable flat dowel to position properly Coat outside diameter of plug with Mopart Stud and Bearing Mo...

Page 1234: ...full register with oil passages from the main bearing If the camshaft bearing shell oil holes are not in exact alignment remove and install them correctly Install a new core hole plug at the rear of c...

Page 1235: ...ed grooves in the rods and caps Limits of taper or out of round on any crankshaft journals should be held to 0 025 mm 0 001 in Bearings are available in 0 025 mm 0 001 in 0 051 mm 0 002 in 0 076 mm 0...

Page 1236: ...gn ment dowel and cap bolts DO NOT remove excess material after assembly DO NOT strike rear cap more than 2 times for proper engagement 9 Clean and oil all cap bolts Install all main bearing caps Inst...

Page 1237: ...ions Main Bearing Undersize Availability List 0 25 mm 0 001 inch 0 051 mm 0 002 inch 0 076 mm 0 003 inch 0 254 mm 0 010 inch 0 305 mm 0 012 inch REMOVAL 1 Remove the oil pan Refer to 9 ENGINE LU BRICA...

Page 1238: ...he oil seal to pry the oil seal outward Be careful not to damage the crankshaft seal bore of cover INSTALLATION 1 Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635...

Page 1239: ...IL PAN REMOVAL 2 Remove the oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 3 Remove the rear main bearing cap and discard the old lower seal INSTALLATION The service seal is a two piece Viton...

Page 1240: ...e new upper seal lips with engine oil To allow ease of installation of the seal loosen at least the two main bearing caps forward of the rear bearing cap 3 Rotate the new upper seal into the cylinder...

Page 1241: ...NGINE LUBRI CATION OIL PUMP INSTALLATION 9 Apply Mopart GEN II Silicone Rubber Adhe sive Sealant or equivalent at bearing cap to block joint to provide cap to block and oil pan sealing Apply enough se...

Page 1242: ...allow all of the air inside the tappets to be bled out TAPPET NOISE DIAGNOSIS 1 To determine source of tappet noise operate engine at idle with cylinder head covers removed 2 Feel each valve spring or...

Page 1243: ...ons 4 Remove intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 5 Remove yoke retainer and aligning yokes 6 Slide Hydraulic Tappet Remover Installer Tool C 4129 A through opening in c...

Page 1244: ...3 9087 3 9092 3 9098 3 9103 B 99 294 99 306 99 320 99 333 3 9092 3 9097 3 9103 3 9108 C 99 306 99 319 99 333 99 345 3 9097 3 9102 3 9108 3 9113 D 99 319 99 332 99 346 99 358 3 9102 3 9107 3 9113 3 91...

Page 1245: ...hammer handle At the same time guide connecting rod into position on crankshaft journal 7 The notch or groove on top of piston must be pointing toward front of engine The larger chamfer of the connect...

Page 1246: ...Fig 42 VIBRATION DAMPER REMOVAL 1 Disconnect the negative cable from the battery 2 Remove fan and fan drive Refer to 7 COOL ING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove the accessory drive be...

Page 1247: ...remove the thru bolt and nut Fig 45 6 Remove engine support bracket cushion bolts Fig 45 Remove the support bracket cushion and heat shields INSTALLATION 1 With engine raised SLIGHTLY position the en...

Page 1248: ...e bolts holding the support cushion to the transmission support bracket Remove the sup port cushion 6 If necessary remove the bolts holding the transmission support bracket to the transmission INSTALL...

Page 1249: ...f each main bearing The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals Each connecting rod bearing has half a hole in it oil passes through...

Page 1250: ...CONNECTING ROD BEARINGS 13 OIL INTAKE 14 OIL PUMP 15 OIL FILTER 16 CRANKSHAFT 17 FROM OIL PUMP 18 OIL TO FILTER 19 OIL FROM FILTER TO SYSTEM 20 PASSAGE TO CAMSHAFT REAR BEARING 21 RIGHT OIL GALLERY 22...

Page 1251: ...uitable test pressure that provide the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures 10 If the leakage occurs at the...

Page 1252: ...r poration recommends a Mopart or equivalent oil filter be used 1 Position a drain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise...

Page 1253: ...op of the dowel This will allow easier installation and removal with a screwdriver Fig 53 5 Install the dowels in the cylinder block Fig 54 6 Apply small amount of Mopart Silicone Rubber Adhesive Seal...

Page 1254: ...56 4 Wash all parts in a suitable solvent and inspect carefully for damage or wear INSPECTION Mating surface of the oil pump cover should be smooth Replace pump assembly if cover is scratched or groo...

Page 1255: ...and shaft into pump body If clearance between inner and outer rotors is 0 203 mm 0 008 inch or more replace shaft and both rotors Fig 61 Place a straightedge across the face of the pump between bolt...

Page 1256: ...against mating surface on No 5 main bearing cap Finger tighten pump attaching bolts Tighten attaching bolts to 41 N m 30 ft lbs torque 3 Install the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INST...

Page 1257: ...nnect the accelerator linkage Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE CONTROL CABLE REMOVAL and if so equipped the speed control and transmission kickdown cables 9 Remove the return spring 10...

Page 1258: ...ner joints An excessive amount of sealant is not required to ensure a leak proof seal However an excessive amount of sealant may reduce the effectiveness of the flange gasket The sealant should be app...

Page 1259: ...COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION Tighten generator mounting bolt to 41 N m 30 ft lbs torque 19 Install the air cleaner 20 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 21 C...

Page 1260: ...front bolt at each side 6 Remove the cover bolts 7 Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket INSTALLATION 1 Be sure mating surfaces of chain case cover...

Page 1261: ...ocket over cam shaft sprocket attaching bolt Apply torque in the direction of crankshaft rotation to take up slack 41 N m 30 ft lbs torque with cylinder head installed or 20 N m 15 ft lbs torque with...

Page 1262: ...ide both sprockets evenly over their respec tive shafts and use a straightedge to check alignment of timing marks Fig 75 6 Install the camshaft bolt Tighten the bolt to 68 N m 50 ft lbs torque 7 Check...

Page 1263: ...N 141 ROCKER ARM ADJUSTER ASSY REMOVAL 142 INSTALLATION 142 ENGINE BLOCK CLEANING 142 INSPECTION 142 CAMSHAFT BEARINGS IN BLOCK REMOVAL 143 INSTALLATION 144 CONNECTING ROD BEARINGS STANDARD PROCEDURE...

Page 1264: ...STALLATION 168 TIMING BELT CHAIN COVER S REMOVAL 169 INSTALLATION 169 TIMING BELT CHAIN AND SPROCKETS REMOVAL 170 INSPECTION 170 INSTALLATION 170 ENGINE 5 9L DESCRIPTION The 5 9 Liter 360 CID eight cy...

Page 1265: ...RT GASOLINE ENGINES CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT CRANK 1 Weak or dead battery 1 Charge Replace Battery Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY STANDARD PROCEDURE Check cha...

Page 1266: ...Faulty ignition cables 11 Replace any cracked or shorted cables 12 Faulty ignition coil 12 Test and replace as necessary Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL ENGINE STALLS OR...

Page 1267: ...GINE MECHANICAL DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES LIFTERS 1 High or low oil level in crankcase 1 Check for correct oil level Adjust oil level by draining or adding as n...

Page 1268: ...3 Thin or diluted oil 3 Change oil to correct viscosity 4 Excessive main bearing clearance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check crankshaft thrust...

Page 1269: ...ion 1 Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS DESCRIPTION for correct operation 2 Defective valve stem seal s 2 Repair or replace seal s 3 Worn or broken piston rings 3 Hone cylinder bores...

Page 1270: ...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...

Page 1271: ...Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa...

Page 1272: ...oil and coolant Can be used on threaded and machined parts under all temperatures This mate rial is used on engines with multi layer steel MLS cylinder head gaskets This material also will pre vent co...

Page 1273: ...s removing light scuffing scoring and scratches Usually a few strokes will clean up a bore and maintain the required lim its CAUTION DO NOT use rigid type hones to remove cylinder wall glaze 2 Deglazi...

Page 1274: ...converter bolts Auto matic transmission equipped vehicles 30 Remove transmission bell housing to engine block bolts 31 Lower the vehicle 32 Install an engine lifting fixture 33 Separate engine from t...

Page 1275: ...ator lower hose 30 Connect the transmission oil cooler lines to the radiator 31 Install the fan shroud 32 Install the fan Refer to 7 COOLING EN GINE RADIATOR FAN INSTALLATION 33 Connect the radiator u...

Page 1276: ...1 954 in No 5 39 688 39 713 mm 1 5625 1 5635 in DESCRIPTION SPECIFICATION Bearing Journal Diameter No 1 50 723 50 775 mm 1 997 1 999 in No 2 50 317 50 368 mm 1 981 1 983 in No 3 49 936 49 987 mm 1 96...

Page 1277: ...03 in Width Finish Intake 1 016 1 524 mm 0 040 0 060 in Exhaust 1 524 2 032 mm 0 060 0 080 in DESCRIPTION SPECIFICATION Valves Face Angle 43 25 43 75 Head Diameter Intake 47 752 mm 1 88 in Exhaust 41...

Page 1278: ...x 0 2032 mm 0 008 in PISTONS Clearance at Top of Skirt 0 013 0 038 mm 0 0005 0 0015 in Land Clearance Diam 0 508 0 660 mm 0 020 0 026 in DESCRIPTION SPECIFICATION Piston Length 81 03 mm 3 19 in Piston...

Page 1279: ...flat on 025 MM indicating No 2 No three 001 IN 3 main bearing crankshaft journal and or counterweight R 1 4 ect indicating No 1 4 connecting rod journal O S Cylinder A Following 508 mm Bores engine s...

Page 1280: ...il Pan Bolts 24 215 Oil Pan Drain Plug 34 25 Oil Pump Attaching Bolts 41 30 Oil Pump Cover Bolts 11 95 Rear Insulator to Bracket 68 50 Through Bolt 2WD Rear Insulator to Crossmember 41 30 Support Brac...

Page 1281: ...Engine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A Adaptor 6633 Adaptor 6716A Valve Guide Sleeve C 3973 Dial Indicator C 3339 Puller C 3688 Puller 1026 Crankshaft Damper Removal Inser...

Page 1282: ...lder C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 Pressure Tester...

Page 1283: ...indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are Engine overheating Loss of coolant Excessive steam white smoke emitting from exhaust Coolant foaming...

Page 1284: ...arm assemblies and push rods Identify to ensure installation in original locations 17 Remove the head bolts from each cylinder head and remove cylinder heads Discard the cylin der head gasket 18 Remov...

Page 1285: ...ilation system and evap oration control system from cylinder head cover 4 Remove cylinder head cover and gasket CLEANING Clean cylinder head cover gasket surface Clean head rail if necessary INSPECTIO...

Page 1286: ...e guides from standard to 0 381 mm 0 015 in Use a two step procedure so the valve guides are reamed true in relation to the valve seat Step 1 Ream to 0 0763 mm 0 003 inch Step 2 Ream to 0 381 mm 0 015...

Page 1287: ...ample the compression length of the spring to be tested is 1 5 16 in Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1 5 16 in mark on the threaded stud Be sure the...

Page 1288: ...h lubrication oil and insert them in cylinder head 5 If valves or seats are reground check valve stem height If valve is too long replace cylinder head 6 Install new seals on all valve guides Install...

Page 1289: ...vidence of leakage INSPECTION Examine block for cracks or fractures The cylinder walls should be checked for out of round and taper Refer to Honing Cylinder Bores in the Service Procedures portion of...

Page 1290: ...vers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 6 Remove timing case cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL and timing chain Refer to 9 ENGINE VALVE...

Page 1291: ...be installed in the same position from which it was removed When camshaft is replaced all of the tappets must be replaced 8 Install distributor and distributor drive shaft 9 Install push rods and tap...

Page 1292: ...the crankshaft 7 Using a suitable jack support the crankshaft 8 Identify main bearing caps before removal Remove main bearing caps and bearings one at a time 9 Lower the crankshaft out of the block 1...

Page 1293: ...e main bearing is located in the crankshaft main bore the other half of the matching bearing is located in the main bearing cap there are five main bearings Number three main bearing is flanged this f...

Page 1294: ...E LU BRICATION OIL PUMP INSTALLATION 5 Install the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 6 Start engine check for leaks CRANKSHAFT OIL SEAL FRONT DESCRIPTION The crankshaft rear...

Page 1295: ...CRANKSHAFT OIL SEAL REAR DESCRIPTION The crankshaft rear seal is a two piece viton seal The crankshaft front seal is a one piece viton seal with a steel housing The front seal is located in the engine...

Page 1296: ...lower seal lips with engine oil 6 Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine 7 Apply 5 mm 0 20 in drop of Mopart Gaske...

Page 1297: ...the rear of engine 5 Apply 5 mm 0 20 in drop of Mopart Gasket Maker or equivalent on each side of the rear main bearing cap Fig 31 DO NOT over apply sealant or allow the sealant to contact the rubber...

Page 1298: ...would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily LOW Low oil level may allow oil pump to take in air When air is fed to the tappets t...

Page 1299: ...with hydraulic valve tappet test oil until the tappet is completely submerged 5 Swing the weighted arm onto the push rod and pump the tappet plunger up and down to remove air When the air bubbles cea...

Page 1300: ...to heat treat The piston pins are press fit STANDARD PROCEDURE PISTON FITTING Piston and cylinder wall must be clean and dry Specified clearance between the piston and the cylin der wall is 0 013 0 0...

Page 1301: ...the rail gaps located properly Fig 38 3 Immerse the piston head and rings in clean engine oil Slide Piston Ring Compressor Tool C 385 over the piston and tighten with the special wrench part of Tool C...

Page 1302: ...t a stamped letter O an oval depression or the word TOP facing up d Measure side clearance between piston ring and ring land Clearance should be 0 074 0 097 mm 0 0029 0 0038 in for the compression rin...

Page 1303: ...the battery negative cable 2 Position fan to ensure clearance for radiator top tank and hose CAUTION DO NOT lift the engine by the intake manifold 3 Install engine support lifting fixture 4 Raise veh...

Page 1304: ...e rear of transmission and engine SLIGHTLY 5 Remove the bolts holding the support cushion to the transmission support bracket Remove the sup port cushion Fig 46 Positioning Engine Front Mounts 1 ENGIN...

Page 1305: ...main bear ing back up to the left side of the block and into the oil gallery on the left side of the engine Galleries extend downward from the main oil gal lery to the upper shell of each main bearin...

Page 1306: ...CONNECTING ROD BEARINGS 13 OIL INTAKE 14 OIL PUMP 15 OIL FILTER 16 CRANKSHAFT 17 FROM OIL PUMP 18 OIL TO FILTER 19 OIL FROM FILTER TO SYSTEM 20 PASSAGE TO CAMSHAFT REAR BEARING 21 RIGHT OIL GALLERY 22...

Page 1307: ...uitable test pressure that provide the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures 10 If the leakage occurs at the...

Page 1308: ...r poration recommends a Mopart or equivalent oil filter be used 1 Position a drain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise...

Page 1309: ...h a screwdriver Fig 53 5 Install the dowels in the cylinder block Fig 54 6 Apply small amount of Mopart Silicone Rubber Adhesive Sealant or equivalent in the corner of the cap and the cylinder block 7...

Page 1310: ...r wear INSPECTION Mating surface of the oil pump cover should be smooth Replace pump assembly if cover is scratched or grooved Lay a straightedge across the pump cover surface Fig 57 If a 0 038 mm 0 0...

Page 1311: ...0 203 mm 0 008 inch or more replace shaft and both rotors Fig 61 Place a straightedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm 0 004 inch or more can be inserted be...

Page 1312: ...sign with equal length runners and uses a separate plenum therefore the manifold does have a plenum gasket It also uses separate flange gaskets and front and rear cross over gaskets Extreme care must...

Page 1313: ...14 Remove the closed crankcase ventilation and evaporation control systems 15 Remove intake manifold bolts 16 Lift the intake manifold and throttle body out of the engine compartment as an assembly 1...

Page 1314: ...oles in the cylinder block 6 Carefully lower intake manifold into position on the cylinder block and cylinder heads After intake manifold is in place inspect to make sure seals are in place 7 Using a...

Page 1315: ...icle 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 6 Remove bolts nuts and washers attaching manifold to c...

Page 1316: ...al with the crankshaft 4 Position the special tool 6635 onto the crank shaft Fig 72 5 Tighten chain case cover bolts to 41 N m 30 ft lbs torque Tighten oil pan bolts to 24 N m 215 in lbs torque 6 Remo...

Page 1317: ...on With the cylinder heads removed apply 20 N m 15 ft lbs torque in the reverse direc tion Note the amount of chain movement Fig 74 4 Install a new timing chain if its movement exceeds 3 175 mm 1 8 in...

Page 1318: ...EANING 198 INSPECTION 198 INSTALLATION 198 ROCKER ARM ADJUSTER ASSY REMOVAL 200 INSTALLATION 200 ENGINE BLOCK CLEANING 200 INSPECTION 200 CAMSHAFT BEARINGS IN BLOCK REMOVAL 200 INSTALLATION 201 CONNEC...

Page 1319: ...TION 227 INSTALLATION 227 ENGINE 8 0L DESCRIPTION The 8 0 Liter 488 CID ten cylinder engine is a V Type lightweight single cam overhead valve engine with hydraulic roller tappets This engine is design...

Page 1320: ...RT GASOLINE ENGINES CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT CRANK 1 Weak or dead battery 1 Charge Replace Battery Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY STANDARD PROCEDURE Check cha...

Page 1321: ...Faulty ignition cables 11 Replace any cracked or shorted cables 12 Faulty ignition coil 12 Test and replace as necessary Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL ENGINE STALLS OR...

Page 1322: ...GINE MECHANICAL DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES LIFTERS 1 High or low oil level in crankcase 1 Check for correct oil level Adjust oil level by draining or adding as n...

Page 1323: ...3 Thin or diluted oil 3 Change oil to correct viscosity 4 Excessive main bearing clearance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check crankshaft thrust...

Page 1324: ...ion 1 Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS DESCRIPTION for correct operation 2 Defective valve stem seal s 2 Repair or replace seal s 3 Worn or broken piston rings 3 Hone cylinder bores...

Page 1325: ...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...

Page 1326: ...Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa...

Page 1327: ...place gaskets are used on the engine Care must be taken when applying form in place gaskets to assure obtaining the desired results Do not use form in place gasket material unless specified Bead size...

Page 1328: ...es maintain the original center line Damaged or worn threads can be repaired Essen tially this repair consists of Drilling out worn or damaged threads Tapping the hole with a special Heli Coil Tap or...

Page 1329: ...s Remove starter motor Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 32 Remove transmission 33 Lower vehicle CAUTION DO NOT lift the engine by the intake manifold 34 Install an engine lifting f...

Page 1330: ...IR CONDITIONING PLUMBING A C CONDENSER INSTALLATION 33 Install the A C compressor with the lines attached Refer to 24 HEATING AIR CONDI TIONING PLUMBING A C COMPRESSOR INSTALLATION 34 Install the serp...

Page 1331: ...FICATION CONNECTING RODS Piston Pin bore Diameter 24 940 24 978 mm 0 9819 0 9834 in Side Clearance 0 25 0 46 mm 0 010 0 018 in Total Weight Less Bearing 744 gms 26 24 oz CRANKSHAFT Rod Journal Diamete...

Page 1332: ...alled Height 41 66 mm 1 64 in Wire Diameter 4 50 mm 0 177 in DESCRIPTION SPECIFICATION HYDRAULIC TAPPETS Body Diameter 22 949 22 962 mm 0 9035 0 9040 in Clearance to bore 0 0203 0 0610 mm 0 0008 0 002...

Page 1333: ...ATDC 25 Opens BBDC 60 Duration 265 Intake Valve Closes ATDC 61 Opens BBDC 6 Duration 246 Valve Overlap 31 CRANKSHAFT JOURNAL MARKING LOCATION MEASURE MENT ITEM IDENTIFI CATION LOCATION OF IDENTIFI CA...

Page 1334: ...ator to Intake Manifold Bracket 41 30 Bolts Heat Shield Nuts 20 175 Hydraulic Tappet Yoke Retaining 22 16 DESCRIPTION N m Ft In Lbs Lbs Spider Bolts Intake Manifold Lower Bolts 54 40 Intake Manifold U...

Page 1335: ...sor Tool MD 998772A Valve Spring Compressor Screw Tool 6756 Black Valve Guide Sleeve Tool C6819 Silver Valve Guide Sleeve Tool C6818 Dial Indicator Tool C3339 Crankshaft Pulley Damper Installer Tool C...

Page 1336: ...nstaller Tool 6806 Front Oil Seal Installer Tool 6761 Camshaft Bearing Installer Tool C3132A Compression Ring Installer Tool C4184 Piston Ring Compressor Tool C385 Seal Installer Tool 6687 Crankshaft...

Page 1337: ...and remove cover from air cleaner housing 3 Remove air cleaner element from air cleaner cover 4 Before installing a new air cleaner element clean inside of air cleaner housing 5 If housing removal is...

Page 1338: ...Engine overheating Loss of coolant Excessive steam white smoke emitting from exhaust Coolant foaming CYLINDER TO CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking betwee...

Page 1339: ...cedure Refer to 14 FUEL SYSTEM FUEL DELIV ERY STANDARD PROCEDURE Disconnect the fuel line Refer to 14 FUEL SYSTEM FUEL DELIV ERY QUICK CONNECT FITTING STANDARD PROCEDURE 9 Disconnect accelerator link...

Page 1340: ...manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 6 Install the upper intake manifold onto the lower intake manifold Refer to 9 ENGINE MANI FOLDS INTAKE MANIFOLD INSTALLATION 7 Instal...

Page 1341: ...the right side head cover Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 4 Remove cylinder head cover bolts and stud bolts Remove the covers and gaskets Fig 12 The gasket may be used again CLEAN...

Page 1342: ...Sleeve Tool C 6818 over valve stem for the EXHAUST valve and install valve The special sleeve places the valve at the cor rect height for checking with a dial indicator 3 Attach Dial Indicator Tool C...

Page 1343: ...SPECIFICATION A SEAT WIDTH 1 016 1 524 mm INTAKE 0 040 0 060 in SEAT WIDTH 1 016 1 524 mm EXHAUST 0 040 0 060 in B FACE ANGLE INT and EXT 45 C SEAT ANGLE INT and EXT 44 D CONTACT SURFACE VALVES Inspec...

Page 1344: ...lowable tensions Discard the springs that do not meet specifications REMOVAL VALVE STEM SEALS NOTE This procedure is done with the cylinder head installed 1 Disconnect the negative cable from the batt...

Page 1345: ...em and install valve Fig 23 The special sleeve places the valve at the correct height for checking with a dial indicator 2 Attach dial indicator Tool C 3339 to cylinder head and set it at right angles...

Page 1346: ...ll air cleaner 13 Connect the negative cable to the battery 14 Road test vehicle and check for leaks INSTALLATION VALVES AND VALVE SPRINGS 1 Clean valves thoroughly Discard burned warped and cracked v...

Page 1347: ...e same order as removed 2 Install rocker arm assemblies in the same order as removed Tighten the rocker arm bolts to 28 N m 21 ft lbs torque 3 Install cylinder head cover and gasket Refer to 9 ENGINE...

Page 1348: ...proper adapter 2 Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing If the camshaft bearing shell oil holes are not in exact alignment rem...

Page 1349: ...r to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 16 Install the intake manifolds Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 17 Start engine and check for leaks CONNECTING R...

Page 1350: ...a new gasket 7 Install the timing chain cover with a new gas ket and oil seal 8 Prime oil pump by squirt oil in the oil filter mounting hole and filling the J trap of the front tim ing cover When oil...

Page 1351: ...d of 667 N 150 lbs f on crankshaft centerline driving No 3 main cap and thrust bearing against No 3 bulkhead Repeat procedure driving crankshaft forward to align rear flange of thrust bearings in a co...

Page 1352: ...e and check for leaks INSTALLATION FRONT OIL SEAL FRONT COVER REMOVED 1 Position the crankshaft front oil seal onto seal installer special tool 6806 2 Use tool 6761 to support timing chain cover when...

Page 1353: ...ne and check for leaks HYDRAULIC LIFTERS DIAGNOSIS AND TESTING HYDRAULIC TAPPETS Before disassembling any part of the engine to cor rect tappet noise check the oil pressure If vehicle has no oil press...

Page 1354: ...ll the tester cup with hydraulic valve tappet test oil until the tappet is completely submerged 5 Swing the weighted arm onto the push rod and pump the tappet plunger up and down to remove air When th...

Page 1355: ...ansion forces the pin bosses away from each other causing the piston to assume a more nearly round shape All pistons are machined to the same weight regardless of size to maintain piston balance The p...

Page 1356: ...Pistons and connecting rods must be removed from top of cylinder block When removing piston and connecting rod assemblies rotate crankshaft center the connecting rod in the cylinder bore and at BDC Be...

Page 1357: ...on into cylinder bore Be sure the piston and rod assemblies are installed in the proper orientation Fig 41 8 The notch groove or arrow on top of piston must be pointing toward front of engine The larg...

Page 1358: ...g Installation Tool C 4184 The compression rings must be installed with the identification mark face up toward top of piston and chamfer facing down An identification mark on the ring is a drill point...

Page 1359: ...FRONT REMOVAL INSTALLATION 1 Position the crankshaft pulley damper onto the crankshaft 2 Use Special Tool C 3688 Crankshaft Pulley Damper Installer to press the pulley damper onto the crankshaft Insta...

Page 1360: ...ve lifting fixture REAR MOUNT REMOVAL 1 Raise the vehicle on a hoist 2 Position a transmission jack in place 3 Remove support cushion stud nuts Fig 50 4 Raise rear of transmission and engine SLIGHTLY...

Page 1361: ...filter element the oil passes from the center outlet of the filter through an oil gal lery that channels the oil up to the tappet galleries which extends the entire length of block Galleries extend do...

Page 1362: ...rea of oil leak If the oil leak is found and identified repair per service manual instructions 4 If dye is not observed drive the vehicle at var ious speeds for approximately 24km 15 miles and repeat...

Page 1363: ...Fig 52 Engine Lubrication System 9 216 ENGINE 8 0L BR BE LUBRICATION Continued...

Page 1364: ...on a level surface and turn engine off 2 Hoist vehicle 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 Insp...

Page 1365: ...r onto adapter nipple When gasket makes contact with sealing surface Fig 55 hand tighten filter one full turn do not over tighten 3 Add oil Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE OIL PAN...

Page 1366: ...e to be slightly raised on 2WD vehicles 6 Install the oil pan bolts Fig 58 Tighten the bolts to as shown in Oil Pan Bolts Torque Chart 7 Remove the dowels Install the remaining 5 16 inch oil pan bolts...

Page 1367: ...3 246 inches or less replace rotor set Slide outer rotor into timing chain cover pump body Press rotor to the side with your fingers and measure clearance between rotor and pump body Fig 64 If clearan...

Page 1368: ...e spring should test between 100 and 109 N 22 5 and 24 5 pounds when compressed to 34 mm 1 11 32 inches Replace spring that fails to meet these specifications If oil pressure was low and pump is withi...

Page 1369: ...wer 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 PUT YOUR HA...

Page 1370: ...ld bolts and remove the manifold Fig 72 17 Discard the lower intake manifold gaskets Fig 73 CLEANING Clean manifold in solvent and blow dry with com pressed air Clean cylinder block front and rear gas...

Page 1371: ...el lines Refer to 14 FUEL SYS TEM FUEL DELIVERY QUICK CONNECT FIT TING STANDARD PROCEDURE 16 Using a new gasket install the air cleaner housing Tighten the nuts to 11 N m 96 in lbs torque Install the...

Page 1372: ...acket on to the exhaust manifold right side only 3 Position washers and exhaust heat shields onto the manifold stud bolts Fig 76 Be sure the tabs on the heat shields are hooked over the top of the exh...

Page 1373: ...78 6 Prime oil pump by squirting oil in the oil filter mounting hole and filling the J trap of the front tim ing cover When oil is running out install oil filter that has been filled with oil 7 Insta...

Page 1374: ...the crankshaft to prevent rotation 3 Hold a scale with dimensional reading even with the edge of a chain link With cylinder heads installed apply 14 N m 30 ft lbs torque in the reverse direction With...

Page 1375: ...camshaft bolt Tighten the bolt to 61 N m 45 ft lbs torque 6 Check camshaft end play The end play should be 0 051 0 152 mm 0 002 0 006 inch with a new thrust plate and up to 0 254 mm 0 010 inch with a...

Page 1376: ...ON 263 ENGINE BLOCK STANDARD PROCEDURE 263 CYLINDER BORE REFACING 263 CYLINDER BORE DE GLAZE 264 CYLINDER BORE REPAIR 265 CAM BORE REPAIR 267 INSPECTION 267 CAMSHAFT BEARINGS IN BLOCK REMOVAL 268 INSP...

Page 1377: ...L PRESSURE RELIEF VALVE REMOVAL 297 CLEANING 297 INSPECTION 297 INSTALLATION 298 OIL PRESSURE SENSOR SWITCH DESCRIPTION 298 OPERATION 298 REMOVAL 298 INSTALLATION 299 OIL PUMP REMOVAL 299 CLEANING 299...

Page 1378: ...ead o ring fittings at lubrication oil access points The engine is manufactured with the cylinders being a non sleeved type cylinder However one approved service method is to bore out the cylinders an...

Page 1379: ...ong bearings installed 10 Inspect and replace connecting rod or main bearings Check and replace piston cooling nozzles 11 Oil jet under piston bad fit into main carrier 11 Check oil jet position LUBRI...

Page 1380: ...broken engine mounts 1 Replace engine mounts 2 Damaged fan or improperly operating accessories 2 Check and replace the vibrating components 3 Improperly operating vibration damper 3 Inspect replace v...

Page 1381: ...nostic Trouble Codes DTC s active or multiple intermittent DTC s Refer to Powertrain Diagnostic Procedures Information Engine Control Module ECM not calibrated or ECM has incorrect calibration Refer t...

Page 1382: ...to Powertrain Diagnostic Procedures Information In very cold ambient temperatures engine block heater is malfunctioning if equipped Refer to 7 COOLING ENGINE ENGINE BLOCK HEATER REMOVAL Engine coolant...

Page 1383: ...ents for correct operation Intake manifold heater elements not functioning correctly in cold weather A diagnostic trouble code WILL NOT BE SET if heater elements are malfunctioning Refer to NTC tests...

Page 1384: ...ee 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 differe...

Page 1385: ...its original thread size STANDARD PROCEDURE HYDROSTATIC LOCK CAUTION DO NOT use the starter motor to rotate the crankshaft Severe damage could occur When an engine is suspected of hydrostatic lock reg...

Page 1386: ...ting bolts 26 Remove charge air cooler and A C condenser if equipped from vehicle 27 Disconnect engine block heater connector 28 Disconnect A C compressor electrical connec tors 29 Remove the passenge...

Page 1387: ...g 5 APPS Connector 1 APPS 2 TAB 3 PUSH FOR REMOVAL 4 APPS CONNECTOR Fig 6 Vacuum Pump Supply Hose 1 VACUUM CHECK VALVE 2 VACUUM SUPPLY LINE Fig 7 Fuel Return and Supply Line Quick Connect Locations 1...

Page 1388: ...pply hose 10 Connect the APPS connector Fig 5 11 Install the APPS assembly bracket to the cyl inder head bracket 12 Install the throttle linkage cover 13 Connect the power steering pressure and return...

Page 1389: ...EDURE 41 Start engine and inspect for engine oil cool ant and fuel leaks INSTALLATION CRANKCASE BREATHER VAPOR CANISTER 1 Position vapor canister with strap over stud on engine front cover Install ret...

Page 1390: ...ing Valve Opening Pressure 448 kPa 65 psi Oil Filter Bypass Pressure Setting 344 75 kPa 50 psi TORQUE TORQUE CHART 5 9L DIESEL ENGINE DESCRIPTION N m In Ft Lbs Lbs Connecting Rod Bolts Step 1 35 26 St...

Page 1391: ...essarily remove the top of the air cleaner housing for air cleaner element inspection on diesel engines The air cleaner filter housing is equipped with an air Filter Minder gauge Fig 11 This air flow...

Page 1392: ...as during a heavy rain or snow If this occurs allow the ele ment to dry out during normal engine operation Reset the rubber button on the top of the Filter Minder and retest after the element has dri...

Page 1393: ...om the cylinder head and heater pipe 8 Disconnect turbocharger oil drain tube at rub ber hose connection Cap off open ports to prevent intrusion of dirt or foreign material 9 Disconnect turbocharger o...

Page 1394: ...the air inlet housing 21 Remove the charge air cooler to air inlet hous ing pipe 22 Remove the air inlet housing and intake grid heater from the intake manifold cover 23 Remove the engine lift bracket...

Page 1395: ...rk each component so they can be installed in their original positions NOTE The 5 cylinder exhaust and the 6 cylinder intake and exhaust push rods are removed by lift ing them up and through the provi...

Page 1396: ...t water and blow dry with com pressed air CLEANING PUSHRODS Clean the pushrods in a suitable solvent Rinse in hot water and blow dry with compressed air If nec essary use a wire brush or wheel to remo...

Page 1397: ...duced diameter due to bolt stretching If the bolts are not damaged their free length should be measured using the cap screw stretch gauge provided with the replacement head gasket Place the head of th...

Page 1398: ...r head cover Fig 33 Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 10 Connect the IAT and MAP sensor connectors 11 Install the fuel filter canister assembly and torque mounting bol...

Page 1399: ...take grid heater wires 24 Fasten engine harness to front of cylinder head with bolt 25 Install engine harness ground wire and torque bolt to 24 N m 18 ft lbs 26 Connect engine coolant temperature sens...

Page 1400: ...r pattern to 24 N m 18 ft lbs 4 Connect both battery negative cables INTAKE EXHAUST VALVES SEATS DESCRIPTION The valves are made of heat resistant steel and have chrome plated stems to prevent scuffin...

Page 1401: ...ove the retainers springs valve seals if necessary and valves Fig 39 Arrange or number all components so they can be installed in their orig inal locations 8 Repeat the procedure on all cylinders to b...

Page 1402: ...e the valve stem diameter in three places as shown in Fig 41 Measure the cylinder head valve guide bore Fig 42 Subtract the corresponding valve stem diameter to obtain valve stem to guide clearance Me...

Page 1403: ...9 ENGINE CYLINDER HEAD INSTALLATION STANDARD PROCEDURE VALVE LASH ADJUSTMENT AND VERIFICATION NOTE To obtain accurate readings valve lash mea surements AND adjustments should only be per formed when...

Page 1404: ...pecifications If the measure ment falls within the limits adjustment resetting is not necessary If measurement finds the lash out side of the limits adjustment resetting is required VALVE LASH LIMIT C...

Page 1405: ...d in their original position 4 Remove the crankcase breather vapor canister and breather housing Fig 55 5 Using the crankshaft barring tool 7471 B Fig 51 rotate the engine to line up the mark on the p...

Page 1406: ...d install the collets h Release the spring tension and remove the compressor Verify that the collets are seated by tapping on the valve stem with a plastic hammer 10 Using the crankshaft barring tool...

Page 1407: ...ir original locations Fig 53 Tighten bolts to 36 N m 27 ft lbs torque Fig 54 Injector Clamp Removal Installation 1 DO NOT REMOVE 2 INJECTOR CLAMP Fig 55 Crankcase Breather Vapor Canister 1 ENGINE FRON...

Page 1408: ...negative cables 2 Remove cylinder head cover Fig 59 Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 3 Remove the rocker arm pedestal fasteners Fig 60 and remove rocker arm and pedestal...

Page 1409: ...r 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 63 Fig 64 Fi...

Page 1410: ...pedestals Fig 60 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 I...

Page 1411: ...e grit Flex hone and a mixture of equal parts of mineral spirits and SAE 30W engine oil to de glaze the bores 6 The crosshatch angle is a function of drill speed and how fast the hone is moved vertica...

Page 1412: ...ne to chamfer the edge of the bore Fig 72 CYLINDER BORE DIMENSION CHART DESCRIPTION MEASUREMENT BORING DIAMETER DIMENSION 1st REBORE 102 469 mm 4 0342 in 2nd REBORE 102 969 mm 4 0539 in HONING DIAMETE...

Page 1413: ...ng 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 sleeve into the bore as far as possible Using a sleeve driver...

Page 1414: ...size dimensions Intermediate and rear cam bores may be bored to 57 235 mm 0 013 mm 2 253 inch 0 0006 inch oversize A surface finish of 2 3 micrometers 92 microinch must be maintained Not more than 20...

Page 1415: ...n 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 C refrigerant if A C equipped Refer to 24 HEATING AIR CONDI...

Page 1416: ...EMOVAL 21 Remove the crankcase breather vapor canister from the gear housing cover Fig 84 22 Using Special Tool 7471 B Crankshaft Bar ring Tool rotate the crankshaft to bring the engine to TDC 1 23 Re...

Page 1417: ...r exhaust and the 6 cylinder intake and exhaust pushrods are removed by lifting them up and through the provided cowl panel access holes Remove the rubber plugs to expose these relief holes Fig 85 Cyl...

Page 1418: ...r band around the dowel rods Fig 88 to prevent the tap pets from dropping into the crankcase c Repeat this procedure for the remaining cyl inders 27 Verify that the camshaft timing marks are aligned w...

Page 1419: ...g and bores for signs of excessive wear 2 Measure the camshaft bushing and bores Fig 93 with a telescoping bore gauge and micrometer If out of specification Refer to 9 ENGINE ENGINE BLOCK CAMSHAFT BEA...

Page 1420: ...with fresh engine oil or suitable equivalent 2 Liberally coat the camshaft lobes journals and thrust washer with fresh engine oil or suitable equiv alent CAUTION When installing the camshaft Fig 91 DO...

Page 1421: ...luid reservoirs to the fan shroud 27 Connect the coolant recovery hose to the radi ator filler neck 28 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 29 I...

Page 1422: ...r Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to 176 N m 130 ft lbs torque Fig 101 MAIN BEARING BORE DIAMETER CHART ITEM MAIN BEARING BORE...

Page 1423: ...f fan shroud 8 Remove the fan shroud to radiator mounting bolts 9 Remove viscous fan drive assembly The fan drive nut has left handed threads Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 10 Remove c...

Page 1424: ...inside of the cover 5 Install the plastic seal pilot provided with seal kit into the crankshaft seal 6 Apply a bead of Mopart Silicone Rubber Adhe sive Sealant or equivalent to the gear housing cover...

Page 1425: ...in the crankshaft is excessively deep install the new seal 1 8 deeper into the retainer bore or obtain a crank shaft wear sleeve that is available in the aftermar ket 3 Install the seal pilot provided...

Page 1426: ...move the rear seal retainer and gasket Fig 111 14 Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch INSTALLATION 1 If using the old seal retainer it is recom...

Page 1427: ...ghten the bolts to 60 N m 44 ft lbs torque 10 Install the starter motor Refer to 8 ELECTRI CAL STARTING STARTER MOTOR INSTALLATION 11 Install the flywheel or converter drive plate Tighten bolts to 137...

Page 1428: ...of the cam shaft bore Fig 115 Again make sure the cap end goes in first and the open side faces up towards tap pets 2 Lower the tappet installation tool through the push rod hole Fig 119 and into the...

Page 1429: ...all scraping Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals The connecting rods Fig 125 are a split angle design constructed of micro alloy The...

Page 1430: ...ne to remove any burrs from the cylinder block head deck Zero the dial indicator to the cylinder block head deck 6 Move the dial indicator directly over the piston pin to eliminate any side to side mo...

Page 1431: ...0 508 0 609 mm C 0 020 0 024 in 6052 6155 0 813 0 914 mm A 0 032 0 036 in 6052 6155 0 711 0 813 mm B 0 028 0 032 in 6052 6155 0 609 0 711 mm C 0 024 0 028 in NOTE Use the table below when piston gradi...

Page 1432: ...piston must be replaced replace with the same part number grading that was removed CLEANING CAUTION DO NOT use bead blast to clean the pis tons DO NOT clean the pistons and rods in an acid tank Clean...

Page 1433: ...ill progress to breakage Measure the connecting rod pin bore Fig 132 The maximum diameter is 40 042 mm 1 5764 inch If out of limits replace the connecting rod Fig 128 Piston Skirt Diameter PISTON SKIR...

Page 1434: ...p of the block Carefully pull the connecting rod onto the crankshaft journal 8 Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts 9 The number stamped on the...

Page 1435: ...mm 0 014 0 0177 in INTERMEDIATE RING 0 85 1 15 mm 0 0334 0 0452 in OIL CONTROL RING 0 250 0 550 mm 0 0100 0 0215 in 4 The top surface of all of the rings are identified with the word TOP or the suppl...

Page 1436: ...ut of alignment replace the damper 3 Inspect the rubber member for deterioration or missing segments Fig 144 INSTALLATION 1 Install the crankshaft damper and bolts Fig 142 Tighten bolts to 125 N m 92...

Page 1437: ...and tighten to 149 N m 110 ft lbs torque 2 Install the thru bolt into the engine mount 3 Lower the engine while guiding the mount and thru bolt into the frame mounted support cushion brackets Fig 146...

Page 1438: ...sion 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 transmiss...

Page 1439: ...eceives filtered cooled and pressurized oil through a supply line from the filter head The oil lubricates the turbocharger and returns to the pan by way of a drain tube connecting the bottom of the tu...

Page 1440: ...n System 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 TO OIL SUMP 11 OIL DRAIN 12 OIL SUPPLY BR BE ENGINE 5 9L DIESEL 9 293 LUBR...

Page 1441: ...Fig 149 Lubrication System Circulation Cont d 9 294 ENGINE 5 9L DIESEL BR BE LUBRICATION Continued...

Page 1442: ...sition vehicle on level surface 2 With engine OFF allow approximately ten min utes for oil to settle to bottom of crankcase remove engine oil dipstick 3 Wipe dipstick clean 4 Replace dipstick and veri...

Page 1443: ...ent OIL FILTER REMOVAL 1 Clean the area around the oil filter head Remove the filter using a 90 95 mm filter wrench 2 Clean the gasket surface of the filter head The filter canister O Ring seal can st...

Page 1444: ...housing assembly with the starter motor attached and tighten bolts to 60 N m 44 ft lbs torque 5 Connect starter motor cables 6 Install transmission and transfer case if equipped 7 Lower vehicle 8 Ins...

Page 1445: ...sor has a 3 wire electrical function very much like the Manifold Absolute Pres sure MAP sensor on the gasoline powered engine Meaning different pressures relate to different output voltages A 5 volt s...

Page 1446: ...the pump from the bore in the cylinder block Fig 159 CLEANING Clean all parts in solvent and dry with compressed air Clean the old sealer residue from the back of the gear housing cover and front of t...

Page 1447: ...alled in the locating bore in the cylinder block 3 Install the pump Fig 159 Tighten the oil pump mounting bolts in two steps in the sequence shown in Fig 165 Step 1 Tighten to 5 N m 44 in lbs torque S...

Page 1448: ...be mounting bolt Fig 167 Position dipstick tube to the side 4 Disconnect the air grid heater power cables at the cable mounting studs Fig 168 5 Remove the four 4 air inlet housing mounting bolts Fig 1...

Page 1449: ...lbs torque 3 Install the high pressure fuel lines Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL LINES INSTALLATION 4 Install the high pressure fuel line support bracket to intake manifold cover bolts an...

Page 1450: ...he exhaust pipe from the turbo charger elbow Fig 170 4 Lower vehicle 5 Disconnect the turbocharger air inlet hose Fig 171 6 Disconnect the turbocharger oil supply line and the oil drain tube from the...

Page 1451: ...pe to the turbocharger With the clamp in position tighten the clamp nut to 8 N m 72 in lbs torque 8 Position the air inlet hose to the turbocharger Fig 171 Tighten the clamp to 8 N m 72 in lbs torque...

Page 1452: ...ve the gear housing and gasket Fig 177 21 Clean the gasket material from the cylinder block INSTALLATION 1 Install a new gasket and the gear housing Fig 177 Tighten the bolts to 24 N m 18 ft lbs torqu...

Page 1453: ...t hub assembly Fig 174 and tighten bolts to 24 N m 18 ft lbs torque 16 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 17 Install the cooling fan and shrou...

Page 1454: ...Apply a bead of Mopart Silicone Rubber Adhe sive Sealant or equivalent to the gear housing cover Be sure to surround all through holes 3 Using the seal pilot to align the cover Fig 183 install the co...

Page 1455: ...STALLATION 11 Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection 12 Install the coolant recovery bottle to the fan shroud and c...

Page 1456: ...STALLATION 11 MUFFLER 5 9L DIESEL REMOVAL 11 INSTALLATION 11 TAILPIPE 3 9L 5 2L 5 9L REMOVAL 11 INSPECTION 11 INSTALLATION 12 TAILPIPE 5 9L HEAVY DUTY 8 0L REMOVAL 12 INSPECTION 12 INSTALLATION 12 TAI...

Page 1457: ...ed to the exhaust pipe Fig 2 The exhaust system must be properly aligned to prevent stress leakage and body contact Minimum clearance between any exhaust component and the body or frame is 25 4 mm 1 0...

Page 1458: ...exhaust pipe resonator extension pipe if needed muffler and exhaust tailpipe The exhaust system must be properly aligned to prevent stress leakage and body contact The exhaust components should be ke...

Page 1459: ...ents disconnect the oxygen sensor connector s Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and or sensor DIAGNOSIS AND TESTING DIESEL ENGINE EXHAUST SYSTEM DIAGNOSIS...

Page 1460: ...nder the vehicle integral to the exhaust pipe s OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion cham bers during the exhaust stroke of the engine...

Page 1461: ...s during the exhaust stroke of the engine This process aids in reducing emissions output REMOVAL 1 Raise and support vehicle 2 Saturate the bolts and nuts with heat valve lubricant Allow 5 minutes for...

Page 1462: ...utes for penetration 3 Remove exhaust pipe to manifold bolts retain ers and nuts Fig 7 4 Remove the clamp nuts Fig 7 5 Remove the exhaust pipe INSPECTION Discard rusted clamps broken or worn supports...

Page 1463: ...tion 3 Remove exhaust pipe to manifold bolts retain ers and nuts Fig 8 4 Remove the clamp nuts Fig 9 Fig 10 5 Disconnect the exhaust pipe from the support hangers on the 5 9L Heavy Duty and the 8 0L e...

Page 1464: ...e battery negative cables 2 Raise and support the vehicle on a hoist 3 Saturate the bolts and nuts with heat valve lubricant Allow 5 minutes for penetration 4 Remove the exhaust pipe to extension pipe...

Page 1465: ...s 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 the heat can cause damage to other components REMOVAL...

Page 1466: ...3 Install the muffler into the tail pipe 4 Install the exhaust clamps align the exhaust system and tighten the exhaust clamps to 48 N m 35 ft lbs torque 5 Lower the vehicle 6 Connect the battery nega...

Page 1467: ...parts Fig 15 2 Connect the support hangers Fig 15 3 Position the exhaust tailpipe for proper clear ance with the underbody parts 4 Tighten all clamp nuts to 48 N m 35 ft lbs torque 5 Lower the vehicl...

Page 1468: ...e 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 sys...

Page 1469: ...ltered 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 21 A...

Page 1470: ...vehicle on hoist 3 Disconnect the exhaust pipe from the turbo charger elbow Fig 22 4 Lower vehicle 5 Disconnect the turbocharger air inlet hose Fig 23 6 Disconnect the turbocharger oil supply line an...

Page 1471: ...Zero the indicator at one end of travel b Move the impeller shaft fore and aft and record the measurement Allowable end play is 0 038 mm 0 0015 in MIN and 0 089 mm 0 0035 in MAX If the recorded measur...

Page 1472: ...charge air cooler and intake air grid heater The 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 pr...

Page 1473: ...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...

Page 1474: ...f A C equipped Refer to 24 HEATING AIR CONDITIONING PLUMBING A C CONDENSER INSTALLATION Recharge A C system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PRO CEDURE 5 Install the front suppor...

Page 1475: ......

Page 1476: ...LLATION 10 SPARE TIRE WINCH REMOVAL 10 INSTALLATION 10 TRAILER HITCH REMOVAL 10 INSTALLATION 10 TRANSFER CASE SKID PLATE REMOVAL 11 INSTALLATION 11 BUMPERS DESCRIPTION Bumpers are used at the front an...

Page 1477: ...pproximately a 19 mm 3 4 in gap between the lower portion of the front fender and the upper por tion of the front upper fascia Fig 3 The gap should ideally be 19 mm 3 4 in but it is more important to...

Page 1478: ...Remove screws attaching bottom of air deflec tor 4 Lift top of fascia upward to disengage from retaining clips on front bumper 5 Pull fascia from front bumper and separate from vehicle INSTALLATION 1...

Page 1479: ...vice 5 Remove nuts attaching bumper to inner bumper brackets Fig 7 6 Separate bumper from vehicle INSTALLATION 1 Support bumper on a suitable lifting device 2 Position bumper on vehicle 3 Install nuts...

Page 1480: ...mper on a suitable lifting device 2 Position rear bumper on vehicle 3 Engage license plate lamp wire connector to body wire harness if equipped 4 Install nuts attaching rear bumper to inner and outer...

Page 1481: ...driving conditions FRAME SERVICE SAFETY PRECAUTIONS AND WARNINGS WARNING USE EYE PROTECTION WHEN GRIND ING OR WELDING METAL SERIOUS EYE INJURY CAN RESULT BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING...

Page 1482: ...e components that have been damaged should be inspected for cracks before returning the vehicle to use If cracks are found in accessible frame com ponents perform the following procedures 1 Drill a ho...

Page 1483: ...Fig 10 Frame Dimensions 13 8 FRAME BUMPERS BR BE SPECIFICATIONS Continued...

Page 1484: ...m 30 ft lbs Skid plate to trans crossmember bolt 54 N m 40 ft lbs Spare tire winch bolt 27 N m 20 ft lbs Trailer hitch nut 108 N m 80 ft lbs CAB CHASSIS ADAPTER BRACKET REMOVAL 1 Remove bolts attachi...

Page 1485: ...s holding spare tire winch to spare crossmember 3 Insert winch tube into spare tire winch 4 Install cotter pin attaching winch tube to spare tire winch 5 Install spare tire TRAILER HITCH REMOVAL 1 Sup...

Page 1486: ...icle INSTALLATION 1 Position skid plate on vehicle 2 Install bolts holding skid plate to frame rails 3 Remove safety stands and lower vehicle Fig 14 Trailer Hitch 1 SPARE TIRE WINCH SUPPORT 2 FLAG BOL...

Page 1487: ......

Page 1488: ...ING UNIT SENSOR DESCRIPTION 7 OPERATION 7 DIAGNOSIS AND TESTING 8 FUEL GAUGE SENDING UNIT 8 REMOVAL 8 INSTALLATION 9 FUEL LINES DESCRIPTION 9 FUEL PUMP DESCRIPTION 9 OPERATION 9 DIAGNOSIS AND TESTING...

Page 1489: ...diagnostic procedure indicates to do so DIAGNOSIS AND TESTING FUEL PRESSURE LEAK DOWN TEST Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test Check Valve Operati...

Page 1490: ...ally indicates a defective check valve in the electric fuel pump The electric fuel pump is not serviced separately Replace the fuel pump module assembly The filter regulator may be replaced separately...

Page 1491: ...odule Locknut 24 44 18 32 Fuel Rail Mounting Bolts 3 9L 5 2L 5 9L Engines 23 200 Fuel Rail Mounting Bolts 8 0L Engine 15 136 Fuel Tank Mounting Nuts 41 30 Fuel Hose Clamps 1 15 SPECIAL TOOLS FUEL SYST...

Page 1492: ...to maintain some fuel pressure when the engine is not operating This will help to start the engine A second check valve is located at the outlet end of the electric fuel pump Refer to Fuel Pump Descr...

Page 1493: ...astic fuel tube 2 Install filter regulator to fuel tube Rotate fil ter regulator in fuel tube line Fig 8 until it is pointed to drivers side of vehicle Fig 4 or Fig 5 3 Tighten line clamp to fuel line...

Page 1494: ...om the Powertrain Control Module PCM The resistor track is used to vary the voltage depend ing on fuel tank float level As fuel level increases the float and arm move up which decreases voltage As fue...

Page 1495: ...e removed from vehicle The unit is part of the fuel pump module Refer to Fuel Pump Module Removal Installation for procedures Measure the resistance across the send ing unit terminals With float in up...

Page 1496: ...ply line pres sure engine warm when pump is not operational It is also used to keep the fuel supply line full of gaso line when pump is not operational After the vehicle has cooled down fuel pressure...

Page 1497: ...Scan Tool along with the PEP module the 500 psi pressure transducer and the transducer to test port adapter may also be used in place of the fuel pressure gauge 2 Start and warm engine and note pressu...

Page 1498: ...KEY IN OFF POSITION BEFORE ATTACHING TEST LEADS BE SURE ALL FUEL LINES AND FUEL SYSTEM COMPONENTS ARE CONNECTED CAUTION To prevent possible damage to the vehi cle electrical system and LCS adapter the...

Page 1499: ...d ule Rollover valve certain modules Fuel gauge sending unit fuel level sensor Fuel supply line connection at filter regulator A threaded locknut retaining pump module to fuel tank A gasket between ta...

Page 1500: ...the fuel pump module is ser viced the rubber gasket must be replaced 1 Using a new gasket position fuel pump module into opening in fuel tank Fig 17 Fuel Pump Module Gas Powered with 35 Gal Tank 1 FU...

Page 1501: ...20 Fuel Pump Module 35 Gallon Fuel Tank 1 FUEL FILTER PRESSURE REGULATOR 2 FUEL SUPPLY FITTING 3 ELECTRICAL CONNECTOR 4 LOCKNUT 5 FUEL PUMP MODULE 6 AUXILIARY CAPPED FITTING Fig 21 Locknut Removal Ins...

Page 1502: ...repairable CAUTION The left and right sections of the fuel rail are connected with a flexible connecting hose Do not attempt to separate the rail halves at this con necting hose Due to the design of...

Page 1503: ...ing hose 1 Remove negative battery cable at battery 2 Remove air cleaner 3 Perform fuel pressure release procedure 4 Remove throttle body from intake manifold Refer to Throttle Body removal in this gr...

Page 1504: ...S UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING FUEL RAIL FUEL SYSTEM PRESSURE MUST BE RELEASED 1 Remove negative battery cable at battery 2 Remove air cleaner housing and tube...

Page 1505: ...tor clip s to fuel rail 3 Position the fuel rail fuel injector assembly to the injector openings on the intake manifold 4 Guide each injector into the intake manifold Be careful not to tear the inject...

Page 1506: ...for rollover valve information An evaporation control system is connected to the rollover valve s to reduce emissions of fuel vapors into the atmosphere When fuel evaporates from the fuel tank vapors...

Page 1507: ...om rollover valves at top front and top rear of fuel tank Fig 38 d Disconnect fuel supply line at fuel filter fuel pressure regulator supply fitting Fig 36 or Fig 37 Refer to Quick Connect Fittings fo...

Page 1508: ...NUT Fig 37 Fuel Pump Module Gas Engine With 35 Gallon Tank 1 FUEL FILTER PRESSURE REGULATOR 2 FUEL SUPPLY FITTING 3 ELECTRICAL CONNECTOR 4 LOCKNUT 5 FUEL PUMP MODULE 6 AUXILIARY CAPPED FITTING Fig 38...

Page 1509: ...s Some may require the use of a spe cial tool for disconnection and removal Refer to Quick Connect Fittings Removal Installation for more information CAUTION The interior components o rings clips of q...

Page 1510: ...n on compo nent being serviced after fitting is disconnected The o rings and spacer will remain in quick con nect fitting connector body 6 Plastic Retainer Ring Type Fitting This type of fitting can b...

Page 1511: ...The latch clip may be used on certain fuel line fuel rail connection or to join fuel lines together a Type 1 Pry up on latch clip with a screw driver Fig 46 Fig 44 Typical Two Tab Type Quick Connect F...

Page 1512: ...ed Install latch clip snaps into position If latch clip will not fit this indi cates fuel line is not properly installed to fuel rail or other fuel line Recheck fuel line con nection 8 Connect negativ...

Page 1513: ...mov al Installation in Fuel System d The rollover valve is seated into a rubber grommet Remove valve by prying one side upward and then roll valve out of grommet e Discard old grommet Fig 50 Rollover...

Page 1514: ...er cap and drain fuel tank c Remove fuel tank Refer to Fuel Tank Remov al Installation in Fuel System d Disconnect tube line at valve e The rollover valve is seated into a rubber grommet Remove valve...

Page 1515: ...CRIPTION 53 OPERATION 53 DIAGNOSIS AND TESTING 53 FUEL INJECTOR TEST 53 REMOVAL 53 INSTALLATION 53 FUEL INJECTION GASOLINE VISUAL INSPECTION 3 9L 5 2L 5 9L ENGINES A visual inspection for loose discon...

Page 1516: ...oose or dirty connections Refer to 8 Wiring for ground loca tions 8 Verify positive crankcase ventilation PCV valve operation Refer to 25 Emission Control Sys tem for additional information Verify PCV...

Page 1517: ...firmly connected to injectors in the correct order Each harness connector is numerically tagged with the injector number INJ 1 INJ 2 etc of its corresponding fuel injector and cylinder number 18 Veri...

Page 1518: ...that fuel pump gauge sender unit wire connector is firmly connected to harness connector 28 Inspect fuel hoses at fuel pump gauge sender unit for cracks or leaks 29 Inspect transmission torque conver...

Page 1519: ...rk plugs are in their correct firing order Be sure that camshaft position sensor wire connector is firmly connected to harness connector Inspect spark plug condition Refer to 8 Ignition Connect vehicl...

Page 1520: ...ir control IAC motor and throttle position sensor TPS 19 Verify that wire harness connector is firmly connected to the engine coolant temperature sensor Fig 17 20 Raise and support the vehicle 21 Veri...

Page 1521: ...fuel pump gauge sender unit for cracks or leaks 29 Inspect transmission torque convertor housing automatic transmission or clutch housing manual transmission for damage to timing ring on drive plate...

Page 1522: ...Fuel Tank Mounting Nuts 41 30 Fuel Hose Clamps 1 10 IAC Motor To Throttle Body Bolts 7 60 Intake Manifold Air Temp Sensor All Engines 12 15 110 130 MAP Sensor Mounting Screws 3 9L 5 2L 5 9L Engines 3...

Page 1523: ...etering 6714 Adapters Fuel Pressure Test 6539 and or 6631 O2S Oxygen Sensor Remover Installer C 4907 Test Kit Fuel Pressure 5069 Test Kit Fuel Pressure C 4799 B Fuel Line Removal Tool 6782 14 36 FUEL...

Page 1524: ...o new pivots bushings Using large pliers press both bushings together until they bot tom on sides of pedal bracket assembly Bushing retaining ears will snap into position when properly installed 3 Fro...

Page 1525: ...ets of single notches Fig 24 The notches cause a pulse to be generated when they pass under the sensor The pulses are the input to the PCM The engine will not operate if the PCM does not receive a CKP...

Page 1526: ...determine fuel injector sequence Once crankshaft position has been determined the PCM begins energizing a ground circuit to each fuel injec tor to provide injector operation REMOVAL 3 9L 5 2L 5 9L Th...

Page 1527: ...of the cylinder block forward of the right engine mount just above the oil pan rail Fig 28 1 Apply a small amount of engine oil to sensor o ring Fig 30 2 Install sensor into cylinder block with a slig...

Page 1528: ...passage in the throttle body controlling air flow through the passage The IAC is controlled by the Powertrain Control Module PCM to maintain the target engine idle speed OPERATION At idle engine speed...

Page 1529: ...r operation for approx imately 0 5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell Using this program helps elim inate idle quality change...

Page 1530: ...ng the intake manifold based upon intake manifold temperature At key on a 5 volt power circuit is supplied to the sensor from the PCM The sensor is grounded at the PCM through a low noise sensor retur...

Page 1531: ...inuously every 12 milliseconds and com pares the current voltage to what it was at key on The difference between current voltage and what it was at key on is manifold vacuum During key on engine not r...

Page 1532: ...is part of the sensor and is not ser viced separately 1 Remove the electrical connector at the sensor 2 Clean the area around the sensor before removal 3 Remove the two sensor mounting bolts 4 Remove...

Page 1533: ...right side is referred to as 2 1 With this emission package a sensor is located in each of the exhaust downpipes before the main catalytic convertor OPERATION An O2 sensor is a galvanic battery that p...

Page 1534: ...The pre catalyst 1 2 and post catalyst 1 3 sensors will determine catalytic convertor efficiency efficiency of the main catalytic convertor This is also done through the PCM Heavy Duty 5 9L Engine Do...

Page 1535: ...e body Fuel is sprayed into the manifold by the fuel injectors OPERATION Filtered air from the air cleaner enters the intake manifold through the throttle body The throttle body contains an air contro...

Page 1536: ...attempt to adjust the engine idle speed using this screw All idle speed functions are controlled by the powertrain control module PCM 1 Clean the mating surfaces of the throttle body and the intake m...

Page 1537: ...at throttle lever ball Fig 45 snaps off 8 3 9L 5 2L 5 9L Engines Slip the cable end rearward from pin on throttle body Fig 44 9 Remove cable housing at throttle body mount ing bracket by pressing on r...

Page 1538: ...M 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...

Page 1539: ...end of the throttle body slides into a socket in the TPS Fig 50 The TPS must be installed so that it can be rotated a few degrees If the sensor will not rotate install the sensor with the throttle sh...

Page 1540: ...erical tag INJ 1 INJ 2 etc This is used to identify each fuel injector with its respective cylinder number The injectors are energized individually in a sequential order by the Powertrain Control Modu...

Page 1541: ...ESCRIPTION 73 OPERATION 74 DIAGNOSIS AND TESTING 74 HIGH PRESSURE FUEL LINE LEAK 74 REMOVAL 75 INSTALLATION 77 FUEL TANK DESCRIPTION 78 FUEL TANK MODULE DESCRIPTION 78 OPERATION 78 REMOVAL 78 INSTALLA...

Page 1542: ...FILTER WATER SEPARATOR 5 FUEL HEATER 18 DRAIN TUBE 6 FUEL PRESSURE TEST PORT 19 WATER IN FUEL WIF SENSOR 7 MAP BOOST SENSOR 20 ENGINE CONTROL MODULE ECM 8 FUEL INJECTORS 21 FUEL PRESSURE TEST PORT 9 F...

Page 1543: ...nections or defective seals Air can also enter the fuel system between the fuel tank and the transfer pump Inspect the fuel tank and fuel lines for damage that might allow air into the system For air...

Page 1544: ...pump is self priming When the key is first turned on without cranking engine the pump operates for approximately 2 seconds and then shuts off The pump will also operate for up to 25 seconds after the...

Page 1545: ...leeding injectors until engine runs smoothly It may take a few minutes for engine to run smooth 12 Tighten fuel line s at injector s to 38 N m 28 ft lbs torque SPECIFICATIONS FUEL SYSTEM PRESSURES DIE...

Page 1546: ...fuel filter replacement intervals For draining of water from canister refer to Fuel Filter Water Separator Removal Installation section A Water In Fuel WIF sensor is attached to side of canister Refe...

Page 1547: ...ixture in drain pan according to applicable regulations 4 After draining operation push valve handle downward to CLOSE position Fig 5 5 Fuel Filter Replacement The fuel filter is located inside of the...

Page 1548: ...o rings from filter housing INSTALLATION Refer to maintenance schedules in this manual for recommended fuel filter replacement intervals 1 Thoroughly clean inside of filter housing filter cap and all...

Page 1549: ...warming the fuel When the temper ature is above 75 68 degrees F the sensor stops cur rent flow to the heater element Battery voltage to operate the fuel heater element is supplied from the ignition sw...

Page 1550: ...n sor and key OFF check electrical mechanical opera tion of fuel temperature sensor Proceed to next step 3 Using an ohmmeter check for continuity across two terminals in electrical connector at side o...

Page 1551: ...ponent being operated Terminal number 86 is connected to a switched power source Terminal number 85 is grounded by the power train control module PCM TESTING 1 Remove relay before testing 2 Using an o...

Page 1552: ...for damage or corrosion Repair if necessary before installing relay 4 Check for pin height pin height should be the same for all terminals within the PDC connector Repair if necessary before installin...

Page 1553: ...connecting compo nents up to the pump will usually not require air bleeding from the fuel system However removal of the high pressure lines removal of the VP44 pump or allowing the vehicle to complete...

Page 1554: ...nformation Fig 17 Crankcase Vent Hose 1 HOSE CLAMP 2 CRANKCASE VENT HOSE 3 CRANKCASE BREATHER Fig 18 Injection Pump Gear Nut Washer 1 WASHER 2 PUMP NUT 3 ACCESS CAP Fig 19 Pump Keyway Keyway Arrow and...

Page 1555: ...CAUTION Refer to Cleaning Fuel System Parts 1 Disconnect both negative battery cables at both batteries Cover and isolate ends of cables 2 Thoroughly clean fuel lines at cylinder head and injection p...

Page 1556: ...ore engine is started Fig 23 Fuel Supply and Return Lines at Pump 1 FUEL SUPPLY LINE 2 FUEL RETURN LINE 3 BANJO BOLT TEST PORT FITTING 4 OVERFLOW VALVE 5 BANJO FITTING Fig 24 Crankcase Vent Hose 1 HOS...

Page 1557: ...plug covering this opening 11 Insert barring tool into flywheel housing open ing Fig 26 12 Rotate engine until keyway is at 12 o clock position Fig 27 Fig 27 Placing Keyway at 12 O clock Position 1 KE...

Page 1558: ...shaft drive gear Never attempt to crank or rotate the engine with the pump removed from the engine Serious damage will occur INSTALLATION 1 Inspect pump mounting surfaces at pump and mounting flange f...

Page 1559: ...inger tight only b Install 2 rear lower pump mounting bolts finger tight only c Do preliminary tightening of injection pump shaft nut to 30 N m 15 22 ft lbs torque This is not the final torque d Tight...

Page 1560: ...power source can only be veri fied with the circuit opened fuel tank module electrical connector unplugged With the con nectors plugged output voltages will vary from about 6 volts at FULL to about 7...

Page 1561: ...and installation is critical to smooth engine opera tion WARNING USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD HIGH F...

Page 1562: ...is attached with 2 Phillips screws 2 plastic retention clips and 2 push tabs Fig 39 Remove 2 Phillips screws and carefully pry out 2 retention clips After clip removal push rearward on front tab and u...

Page 1563: ...ine Fig 45 Discard old upper and lower gaskets 13 Remove 3 cable bracket housing mounting bolts Fig 44 Carefully position cable bracket and cable assembly to side of engine Leave cables con nected to...

Page 1564: ...hile removing While removing rear line bundle note line position INSTALLATION High pressure lines are used between the fuel injection pump and the fuel injectors only All high pressure fuel lines are...

Page 1565: ...rt mount ing bolt and tighten to 24 N m 18 ft lbs torque 17 Install engine oil dipstick to engine 18 Connect 2 electrical cables to cable mounting studs 19 Connect electrical connector to bottom of AP...

Page 1566: ...fuel transfer pump fuel lift pump is located on the left rear side of the engine cylinder block above the starter motor Fig 50 The 12 volt electric vane type pump is operated and controlled by the Eng...

Page 1567: ...ximately 97 kPa 14 psi and returns fuel to the fuel tank through the fuel return line DIAGNOSIS AND TESTING FUEL TRANSFER PUMP PRESSURE The following tests will include pressures tests of fuel transfe...

Page 1568: ...ove protective cap at inlet test port Fig 54 Clean area around cap fitting before cap removal 2 Remove protective cap at outlet test port Fig 55 Clean area around cap fitting before cap removal 3 Inst...

Page 1569: ...acuum reading is higher than 6 in hg 152 mm hg restriction exists in fuel supply line or in fuel tank module Check fuel supply line for damage dents or kinking If OK remove module and check module and...

Page 1570: ...ts to 12 N m 9 ft lbs torque 6 Tighten both banjo bolts to 24 N m 18 ft lbs torque 7 Tighten support bracket bolt 12 N m 9 ft lbs torque 8 Connect electrical connector to pump Fig 57 9 Connect fuel li...

Page 1571: ...injection pump before removal 2 Remove valve from pump and banjo fitting 3 Discard old sealing gaskets 4 Set regulated air pressure to approximately 97 kPa 14 16 psi 5 Using blow gun apply pressure t...

Page 1572: ...ECM when it senses water in the fuel filter water separator As the water level in the filter sep arator increases the resistance across the WIF sensor decreases This decrease in resistance is sent as...

Page 1573: ...1 Disconnect both negative battery cables at both batteries 2 Remove starter motor Refer to Group 8B for procedures 3 Disconnect fitting at T Fig 63 4 Remove banjo bolt at rear of cylinder head Disca...

Page 1574: ...AL 104 INSTALLATION 104 PTO SWITCH DESCRIPTION 104 THROTTLE CONTROL CABLE REMOVAL 104 INSTALLATION 105 FUEL INJECTION DIESEL DESCRIPTION DIESEL FUEL INJECTION SYSTEM The Engine Control Module ECM and...

Page 1575: ...ILTER WATER SEPARATOR 5 FUEL HEATER 18 DRAIN TUBE 6 FUEL PRESSURE TEST PORT 19 WATER IN FUEL WIF SENSOR 7 MAP BOOST SENSOR 20 ENGINE CONTROL MODULE ECM 8 FUEL INJECTORS 21 FUEL PRESSURE TEST PORT 9 FU...

Page 1576: ...er 4 Remove 1 8 brass fitting Fig 3 from turbo charger Temporarily replace this fitting with a 1 8 T fitting to adapt to pressure gauge 5 Reattach signal line to temporary T 6 Attach first pressure ga...

Page 1577: ...alve Mounting Screws 3 5 30 40 Fuel Heater Screws 2 3 15 20 Fuel Injector Clamp Bolts 10 89 Fuel Pump Module Locknut 24 44 18 32 Fuel Tank Mounting Nuts 41 30 Fuel Transfer Pump Mounting Nuts 12 9 Hig...

Page 1578: ...ntly positioned to its mount ing bracket CAUTION Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed sensor to bracket mounting screws are permanently...

Page 1579: ...S 2 4 OFF 5 THROTTLE CABLE 6 THROTTLE LEVER 7 THROTTLE LEVER PIN 8 OFF 9 CONNECTOR 10 SPEED CONTROL CABLE Fig 8 APPS Assembly 1 LEVER 2 MOUNTING BOLTS 6 3 WIRE HARNESS CLIP 4 CALIBRATION SCREWS NO ADJ...

Page 1580: ...placed as one assembly including the lever brackets and sensor The APPS is calibrated to its mounting bracket The APPS assem bly is located at left front of engine below plastic cable lever linkage co...

Page 1581: ...oth the fuel line to connector and the fuel connector to fuel injector The fitting torque is very critical If the fitting is under torqued the mating surfaces will not seal and a high pressure fuel le...

Page 1582: ...igh pressure fuel line can cause many of same symptoms as mal functioning injector Inspect for leaks in high pressure lines before checking for malfunctioning fuel injector WARNING THE INJECTION PUMP...

Page 1583: ...op pressure c Operate tester lever quickly several times to check injector spray pattern Verify fuel is spraying from each injector nozzle hole Injector should also spray evenly from each nozzle hole...

Page 1584: ...S REMOVAL 7 Thread Special Tool 8324 Fuel Injector Con nector Tube Remover onto end of injector connector tube Fig 20 8 Pull injector connector tube from cylinder head The injector connector tube mus...

Page 1585: ...end f Check nozzle color for signs of overheating Overheating will cause nozzle to turn a dark yel low tan or blue depending on overheating temper ature Fig 20 Fuel Injector Connector Tube Removal 1...

Page 1586: ...very critical If fitting is under torqued the mating surfaces will not seal and a high pressure fuel leak will result If fitting is over torqued the connector and injector will deform and also cause a...

Page 1587: ...element within the heater block assembly Refer to the Powertrain Diagnostic Procedures manual for an electrical operation and complete description of the intake heaters including pre heat and post he...

Page 1588: ...nnect rubber hose to air intake housing 7 Connect clamp to rubber hose at air intake housing 8 Connect both negative battery cables at both batteries INTAKE AIR HEATER RELAY DESCRIPTION The 2 intake m...

Page 1589: ...n mounting bolts to 4 5 N m 40 in lbs torque 2 Connect eight electrical connectors to relays 3 Connect battery cables to both batteries INTAKE AIR TEMPERATURE SENSOR DESCRIPTION DIESEL The intake mani...

Page 1590: ...P sensor is installed into the rear of the intake manifold Fig 31 OPERATION DIESEL The MAP sensor reacts to air pressure changes in the intake manifold It provides an input voltage to the Engine Contr...

Page 1591: ...AL 1 Disconnect both negative battery cables at both batteries 2 From inside vehicle hold up accelerator pedal Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm Fi...

Page 1592: ...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 21 Align inde...

Page 1593: ......

Page 1594: ...e power steering gear Fig 1 Vehicles equipped with trailer tow option have a power steering pump oil cooler OPERATION The gear acts as a rolling thread between the worm shaft and rack piston The worm...

Page 1595: ...n 2 Loose or damaged suspension components 2 Inspect and repair suspension 3 Loose or damaged steering linkage 3 Inspect and repair steering linkage 4 Internal gear noise 4 Repair steering gear 5 Pres...

Page 1596: ...and lubricate steering and suspension compnents 5 Low pump pressure 5 Pressure test and repair as necessary 6 Internal gear leak 6 Pressure and flow test and repair as necessary STEERING WHEEL DOES NO...

Page 1597: ...HYDRAULIC BOOSTER 1 Remove high pressure hose which goes to the steering gear from the tube coming out of the booster 2 Connect Adapter 6826 to the Power Steering Analyzer pressure gauge hose 3 Conne...

Page 1598: ...ition Compare the readings to the pump specifications chart If pressures readings are not within 50 psi of each other the gear is leak ing internally and must be repaired CAUTION Do not force the pump...

Page 1599: ...REMOVAL 13 INSTALLATION 13 COLUMN DESCRIPTION The tilt and standard column Fig 1 has been designed to be serviced as an assembly less wiring switches shrouds steering wheel etc Most steering column co...

Page 1600: ...19 STEERING COLUMN STEER ING WHEEL REMOVAL CAUTION Ensure the puller bolts are fully engaged into the steering wheel and not into the clock spring before attempting to remove the wheel Fail ure to do...

Page 1601: ...LOCKSPRING INSTALLATION NOTE Turn the Ignition Switch to the on position and verify the gear shifter moves If the shifter does not move ensure the Ignition Switch is installed properly 2 Column shift...

Page 1602: ...ll steering wheel and tighten nut to 61 N m 45 ft lbs Refer to 19 STEERING COL UMN STEERING WHEEL INSTALLATION 16 Install the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG INSTALLATION 17 Colu...

Page 1603: ...e defective This device is not serviceable If repair is necessary the steering column assembly must be replaced Refer to 19 STEERING COLUMN REMOVAL Vehicles equipped with a manual transmis sion and a...

Page 1604: ...is in the LOCKED or ACCESSORY position If it is difficult to rotate the key to or from the LOCK or ACCESSORY position the interlock device within the steering column may be defective This device is no...

Page 1605: ...electrical connectors at rear of ignition switch Fig 13 INSTALLATION The ignition key must be in the key cylinder for cylinder removal The key cylinder must be removed first before removing ignition s...

Page 1606: ...the steering column assembly CAUTION The pin must be installed in the original direction 3 Carefully Install the pin into the steering col umn assembly and through the shift lever If the pin binds che...

Page 1607: ...ON 29 GEAR DESCRIPTION The power steering gear is a recirculating ball type gear Fig 1 The gear ratio s used are 17 5 1 and 14 1 OPERATION The gear acts as a rolling thread between the worm shaft and...

Page 1608: ...2 O RING SEAL 3 INLET 4 OUTLET 5 SEAL 6 TORSION BAR 7 STUB SHAFT 8 ADJUSTER PLUG 9 THRUST BEARING 10 TEFLON SEALS 11 SPOOL VALVE 12 VALVE BODY 13 WORMSHAFT 14 PIN 15 PITMAN SHAFT 16 RACK PISTON 17 TE...

Page 1609: ...lt and tighten to 49 N m 36 ft lbs torque 3 Align and install the pitman arm 4 Install the washer and retaining nut on the pit man shaft Tighten the nut to 251 N m 185 ft lbs 5 Connect fluid hoses to...

Page 1610: ...hten lock nut to 108 N m 80 ft lbs Be sure adjustment cap does not turn while tightening the lock nut PITMAN SHAFT OVER CENTER PRELOAD NOTE Before performing this procedure the worm bearing preload ad...

Page 1611: ...shaft adjuster screw back COUNTERCLOCKWISE until fully extended then turn back in CLOCKWISE one full turn 7 Remeasure Over Center Rotating Torque If necessary turn the adjuster screw and repeat mea su...

Page 1612: ...Pitman Shaft Overcenter Drag New Gear under 400 miles 0 23 0 68 2 6 Wormshaft Preload TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Steering Gear Mounting Frame Bolts 176 130 Line...

Page 1613: ...ot clear the housing if it is not centered 6 Remove pitman shaft from the side cover 7 Remove dust seal from the housing with a seal pick Fig 12 CAUTION Use care not to score the housing bore when pry...

Page 1614: ...with Driver 8294 and Han dle C 4171 5 Install plastic backup washer NOTE The plastic backup washer has a lip on the inside diameter that faces down towards the oil seal 6 Install metal backup washer...

Page 1615: ...shaft from the side cover 7 Remove dust seal from the housing with a seal pick Fig 17 CAUTION Use care not to score the housing bore when prying out seals and washer 8 Remove retaining ring with snap...

Page 1616: ...OVAL 1 Clean exposed end of pitman shaft and housing with a wire brush 2 Remove preload adjuster nut Fig 19 3 Rotate the stub shaft with a 12 point socket from stop to stop and count the number of tur...

Page 1617: ...ide diameter that faces down towards the oil seal 6 Install metal backup washer 7 Install the retainer ring with snap ring pliers 8 Coat the dust seal with special grease sup plied with the new seal 9...

Page 1618: ...pulling and rotating the spool valve from the valve body Fig 28 7 Remove spool valve O ring and valve body teflon rings and O rings underneath the teflon rings Fig 29 Fig 24 Lock Nut and Adjuster Nut...

Page 1619: ...Install O rings and teflon rings over the O rings on valve body 5 Install O ring into the back of the stub shaft cap Fig 31 6 Install stub shaft and valve assembly in the housing Line up worm shaft to...

Page 1620: ...ousing 3 Install retaining ring so one end of the ring covers the housing access hole Fig 34 WORM SHAFT REMOVAL 1 Remove housing end plug Refer to 19 STEERING GEAR STEERING GEAR HOUSING PLUG REMOVAL 2...

Page 1621: ...ster lock nut and adjuster nut from the stub shaft 13 Pull the stub shaft with the spool valve and thrust support assembly out of the housing 14 Remove the worm shaft from the housing Fig 39 Fig 34 In...

Page 1622: ...de using grease to hold the balls in place Fig 41 6 Install the guide onto rack piston and install clamp and clamp bolts Tighten bolts to 4 8 N m 43 in lbs 7 Insert Arbor C 4175 into bore of rack pist...

Page 1623: ...side cover in the housing 14 Install rack piston plug and tighten to 150 N m 111 ft lbs 15 Install housing end plug Refer to 19 STEERING GEAR STEERING GEAR HOUSING PLUG INSTALLATION 16 Adjust worm sha...

Page 1624: ...ar The power steering pump is a constant flow rate and displacement vane type pump The pump is connected to the steering gear via the pressure hose and the return hose On vehi cles equipped with a hyd...

Page 1625: ...m can cause seal deterioration and affect steer ing gear booster spool valve operation 1 Raise the front end of the vehicle off the ground until the wheels are free to turn 2 Remove the return line fr...

Page 1626: ...sembly past the coolant tube 6 Remove the upper stud and remove upper bolt from cylinder head 7 Remove steering pump and mounting bracket from engine as an assembly 8 Remove the pump pulley with Pulle...

Page 1627: ...1 ENGINE BLOCK 2 LOWER PUMP ASSEMBLY BOLT 3 STEERING PUMP BRACKET ATTACHING NUT 4 BATTERY GROUND CABLE 5 OIL FEED LINE Fig 7 Pump Assembly Upper Bolt 1 PUMP UPPER BOLT 2 DRIVE COVER Fig 8 Bracket Moun...

Page 1628: ...to avoid damaging the oil seal in the vacuum pump during installation The steering pump housing and spacers must mate completely with the vacuum pump bracket 3 Install the vacuum pump bracket to stee...

Page 1629: ...entine Belts Run engine until warm 5 min and note any belt chirp If chirp exists move pulley outward approximately 0 5 mm 0 020 in If noise increases press on 1 0 mm 0 040 in Be careful that pulley do...

Page 1630: ...transfer high pressure power steering fluid from the power steering pump to the power steering gear HOSES RETURN DESCRIPTION Power steering return line is a hose which is clamped at the pump and the g...

Page 1631: ...puller to remove tie rod ends Fig 1 STANDARD PROCEDURE LUBRICATION Periodic lubrication of the idler arm is required Refer to Lubrication And Maintenance for the recom mended maintenance schedule REMO...

Page 1632: ...he vehicle to the surface Center steering wheel and adjust toe Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE NOTE Position the clamp on the sleeve so retain ing bolt is located on the botto...

Page 1633: ...equired Refer to Lubrication And Mainte nance for the recommended maintenance schedule The following components must be lubricated Tie rod Tie rod end Drag link REMOVAL 1 Remove steering damper mounti...

Page 1634: ...tall steering damper on the tie rod Tighten nut to 81 N m 60 ft lbs 8 Remove the supports and lower the vehicle to the surface Center steering wheel and adjust toe refer to Group 2 Suspension 9 After...

Page 1635: ...SPECIAL TOOLS STEERING LINKAGE Remover Ball Stud MB 991113 Puller Tie Rod C 3894 A Remover Pitman C 4150A 19 42 LINKAGE 4WD BR BE...

Page 1636: ...nsmission front housing A combination of roller and ball bearings are used to support the transmission shafts in the two hous ings The transmission gears all rotate on caged type needle bearings A rol...

Page 1637: ...Fig 1 NV3500 Manual Transmission 21 2 MANUAL NV3500 BR BE MANUAL NV3500 Continued...

Page 1638: ...ondition Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition HARD SHIFTING Hard shifting is usually caused by a low lubricant level improper or...

Page 1639: ...transmission jack 4 Remove nuts attaching transfer case to trans mission adapter housing 5 Remove transfer case with aid of helper 6 Support engine with a jack stand and a wood block 7 Remove nuts an...

Page 1640: ...Bolt is a shoulder bolt that secures the shift shaft bushing and lever 7 Remove bolts attaching input shaft bearing retainer to front housing and remove retainer NOTE Use pry tool to carefully lift r...

Page 1641: ...s at this time Leave at least one bolt in place until geartrain is ready to be removed from case 13 Separate front housing from rear housing Fig 10 Use plastic hammer to tap front housing off alignmen...

Page 1642: ...ift bushing and lever roll pint with a hammer and punch Fig 14 NOTE Use proper size punch to avoid bending the shift shaft 5 Pull shift shaft straight out of rear housing shift socket fifth reverse fo...

Page 1643: ...nput shaft counter shaft and idler gear Fig 20 d Stand geartrain and rear housing upright on fixture Fig 21 Have helper hold fixture tool in place while housing and geartrain is being rotated into upr...

Page 1644: ...open ing Fig 19 Reverse Idler Shaft Support 1 SUPPORT BOLT 2 SHAFT BOLT Fig 20 Fixture Assembly 1 FIXTURE 6747 2 ADAPTER 6747 1A 3 CUP 8115 4 REVERSE IDLER PEDESTAL 5 ADAPTER 6747 2B Fig 21 Geartrain...

Page 1645: ...g 25 5 Examine condition of bearing bore and idler shaft notch in rear housing Replace housing if any of these components are damaged Fig 23 Seperate Rear Housing From Output Shaft Bearing 2WD 1 REAR...

Page 1646: ...ng Fig 30 Use ham mer handle to push or tap bearing out of housing if needed 5 Examine condition of bearing bore counter shaft rear bearing race and idler shaft notch in rear housing Replace housing i...

Page 1647: ...ly to avoid intermix ing 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 Remove 3 4 sync...

Page 1648: ...first gear from output shaft with shop press and Bearing Splitter 1130 Fig 36 Position splitter between first and reverse gears Fig 33 Two Piece Thrust Washer 1 SECOND GEAR 2 THRUST WASHER 2 PIECE 3 W...

Page 1649: ...41 17 Remove fifth reverse synchro hub and sleeve with shop press Fig 42 18 Remove reverse gear and needle bearing Fig 43 Fig 37 First Gear Needle Bearing 1 FIRST GEAR NEEDLE BEARING Fig 38 Output Sh...

Page 1650: ...and not collapsed or distorted Minor scratches or nicks on the plunger can be smoothed with 320 400 grit emery soaked in oil Replace the plunger and spring if in doubt about condition Check condition...

Page 1651: ...e rear housing will have to be replaced if the countershaft rear bearing race is loose worn or damaged Fig 44 Reverse Idler Components 1 SNAP RING 2 FLAT WASHER 3 WAVE WASHER 4 THRUST WASHER 5 REVERSE...

Page 1652: ...lace the shaft if worn scored or the bolt threads are damaged beyond repair Replace the support seg ment if cracked or chipped and replace the idler attaching bolts if the threads are damaged Shift So...

Page 1653: ...a rubber band can be used to temporarily secure each strut and ball as they are installed 6 Verify the synchro three springs struts and detent balls are all in place Fig 47 OUTPUT SHAFT NOTE Lubricate...

Page 1654: ...8 to 0 086 in 7 Install fifth gear synchro ring in synchro hub and sleeve Fig 53 Fig 50 Reverse Gear Synchro 1 REVERSE GEAR 2 SYNCHRO RING Fig 51 Fifth Reverse Synchro Assembly 1 SPACER 2 PRESS RAM 3...

Page 1655: ...ear bearing on output shaft Fig 56 Verify bearing is seated on shaft shoulder and is properly joined 12 Install first gear on shaft and over bearing Fig 57 Verify bearing synchro cone is facing up as...

Page 1656: ...17 Install interm ring 18 Install thickest new 1 2 synchro hub snap ring Fig 61 that will fit in shaft groove Verify snap ring is seated in shaft groove NOTE Snap rings are available in thicknesses fr...

Page 1657: ...5 Verify i d grooves and markings noted during removal are facing the correct direction Fig 61 1 2 Synchro Hub Snap Ring 1 1 2 SYNCHRO 2 SPECIAL TOOL 6310 1 3 SYNCHRO SNAP RING Fig 62 Second Gear Sync...

Page 1658: ...lastic mallet Fig 67 Fig 65 Two Piece Thrust 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS 4 LUG BORE 5 LUG 6 WASHER HALF Fig 66 Retaining Ring 1 THRUST WASHER RETAINING RING 2 THRUST WASHE...

Page 1659: ...backwards if care is not exercised One side of the sleeve has grooves in it this side of sleeve faces the front of the shaft 30 Start 3 4 synchro hub on output shaft splines by hand Fig 71 Fig 68 Thir...

Page 1660: ...first gear Tapered side of fifth reverse sleeve must be facing forward REVERSE IDLER ASSEMBLY 1 Lubricate idler components with gear lube 2 Slide idler gear bearing on shaft Fig 76 Bearing fits either...

Page 1661: ...4 TAPER FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 76 Idler Gear And Bearing 1 IDLER GEAR 2 BEARING 3 LOCK BALL 4 REAR OF SHAFT Fig 77 Idler Gear...

Page 1662: ...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 5 If necessary th...

Page 1663: ...n be made after gear is positioned on pedestal Fig 79 Fixture For Geartrain Build up 1 ADAPTER 6747 2B 2 CUP 8115 3 ADAPTER 6747 1A 4 FIXTURE 6747 Fig 80 Pilot Bearing And Input Shaft 1 PILOT BEARING...

Page 1664: ...obably exist This difference will not interfere with assembly If difference is greater than this the countershaft adapter tool is probably upside down Remove countershaft reverse adapter tool reinstal...

Page 1665: ...in synchro sleeves and verify forks are seated in sleeves Fig 88 Fig 85 Reverse Idler Assembly On Assembly Fixture Tool 1 OUTPUT SHAFT AND GEARTRAIN 2 COUNTERSHAFT 3 REVERSE IDLER ASSEMBLY 4 TOOL PED...

Page 1666: ...en housing is installed 5 Apply light coat of petroleum jelly to shift shaft bushing bearing in rear housing Fig 91 6 Reach into countershaft rear bearing with fin ger and push each bearing roller out...

Page 1667: ...bolt heads Fig 93 10 Start first two bolts in retainer Fig 94 It may be necessary to move retainer rearward with pilot stud in order to start bolts in retainer 11 Remove Alignment Pin 8120 and install...

Page 1668: ...ng snap ring on output shaft Fig 96 10 Lubricate lip of new rear seal Fig 97 with Mopart Door Ease or transmission fluid 11 Install new rear seal in adapter housing bore with Installer C 3860 A Verify...

Page 1669: ...rough 1 2 and fifth reverse fork and into shift lever opening in rear housing Fig 102 7 Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing Fig 10...

Page 1670: ...e lever The lever bushing 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 106 13 Align roll pin holes in shift socket...

Page 1671: ...nto countershaft front bearing with fin ger and push each bearing roller outward against race Then apply extra petroleum jelly to hold rollers in place during housing installation 4 Apply small amount...

Page 1672: ...hand Fig 112 Then tighten bolts to 34 N m 25 ft lbs 12 Install shift shaft bushing lock bolt Fig 113 Apply Mopar Gasket Maker or equivalent to bolt threads shank and underside of bolt head before ins...

Page 1673: ...holes are aligned before seating retainer CAUTION Be sure sealer does not get into the oil feed hole in the transmission case or bearing retainer Fig 113 Shift Shaft Bushing Lock Bolt 1 SHIFT SHAFT LO...

Page 1674: ...ket and the offset in the tower is toward the passenger side of the vehicle before installing tower bolts 4 Install shift tower bolts Fig 122 and tighten bolts to 8 5 N m 75 2 in lbs Fig 118 Seal Bear...

Page 1675: ...lso install oil filter if removal was necessary 12 Install and connect exhaust system Align exhaust components before tightening clamp and bracket bolts and nuts Be sure exhaust components are clear o...

Page 1676: ...7 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...

Page 1677: ...Handle C 4171 Remover 8117 Remover Installer 6858 Fixture 6747 Adapter 6747 1A Adapter 6747 2B Cup 8115 Splitter 1130 Tube 6310 1 21 42 MANUAL NV3500 BR BE MANUAL NV3500 Continued...

Page 1678: ...Installer 8118 Remover Installer 8119 Stud Alignment 8120 Installer C 3860 A Installer 8123 Installer 6448 BR BE MANUAL NV3500 21 43 MANUAL NV3500 Continued...

Page 1679: ...used a standard duty for 5 9L applications and a heavy duty for V10 and Cummins diesel applications Main differences are the larger diameter input shaft output shaft and mainshaft fifth gear in the h...

Page 1680: ...Fig 1 NV4500 Manual Transmissions BR BE MANUAL NV4500 21 45 MANUAL NV4500 Continued...

Page 1681: ...cumference of the synchro nizer sleeve As the shift fork moves the synchronizer sleeve the synchronizer begins to speed up or slow down the selected gear depending on whether we are up shifting or dow...

Page 1682: ...me speeds Severe highly audible transmission noise is gener ally the initial indicator of a lubricant problem Insufficient improper or contaminated lubricant will promote rapid wear of gears synchros...

Page 1683: ...Move transmission rearward until input shaft clears clutch disc and release bearing 14 Lower transmission and remove it from under vehicle DISASSEMBLY EXTENSION ADAPTER HOUSING 1 Raise and support ve...

Page 1684: ...Remove snap ring that secures fifth gear clutch hub and gear on countershaft Fig 11 3 Remove countershaft fifth gear clutch gear and stop ring 4 Remove fifth gear shift fork and gear assembly Remove...

Page 1685: ...n place Fig 16 16 Install Puller and Bolt 6444 on puller rods Then secure puller to rods with retaining nuts Fig 17 17 Tighten puller bolt to remove gear from shaft splines Fig 17 Fig 10 Fifth Gear Sh...

Page 1686: ...Fig 15 Seating Puller Flange In First Puller 1 JAWS 2 PULLER FLANGE 6444 1 Fig 16 Retaining Collar Over Puller Jaws 1 JAWS 2 COLLAR 6444 8 Fig 17 Fifth Gear From Mainshaft Splines 1 COLLAR 6444 8 2 JA...

Page 1687: ...ut with pry tool 4 To remove front retainer bearing cup assemble Puller Flange 6444 1 and Puller Rods 6444 4 Fig 21 5 Insert Puller Jaws 6453 1 in puller flange Fig 21 Narrow lip of puller jaws will g...

Page 1688: ...and Puller Rods 6444 6 Fig 26 Then position first Puller Jaw 6447 on bearing 4 Slide assembled puller flange and rod tools onto input shaft Then seat flange in notch of puller jaw 5 Position second P...

Page 1689: ...lose on the mainshaft 6 Grasp mainshaft rear splines then turn spline end of mainshaft counterclockwise to rotate shaft and geartrain out of case Tilt mainshaft outward and removed from case Fig 25 Pi...

Page 1690: ...e idler gear away from countershaft and toward front of case Fig 33 5 Remove idler gear Fig 34 Fig 29 Mainshaft And Geartrain 1 MAINSHAFT AND CASE Fig 30 Countershaft Rear Bearing Plate 1 REAR BEARING...

Page 1691: ...l second Puller Jaw 6449 on bearing and in notch of puller flange 12 Slide Retaining Collar 6444 8 over puller jaws to hold them in place NOTE Retaining collar has small lip on one end and only fits o...

Page 1692: ...small lip on one end and only fits one way over jaws 21 Install puller bridge and bolt assembly 6444 on puller bolts and install retaining nuts 22 Tighten puller bolt to remove bearing from shaft If...

Page 1693: ...backwards Paint or scriber gear and synchro components for instal lation reference Then stack geartrain parts in order of removal to avoid incorrect assembly 1 Remove drive gear thrust bearing from en...

Page 1694: ...e thrust washer locating pin Fig 46 Use needle nose pliers to remove pin Fig 43 Third Gear Bearing 1 THIRD GEAR NEEDLE BEARING Fig 44 Snap Ring And Third Gear Bearing Spacer 1 SECOND GEAR THRUST WASHE...

Page 1695: ...synchro clutch ring and synchro stop ring Fig 50 Fig 47 Second Gear 1 SECOND GEAR Fig 48 Second Gear Bearing 1 SECOND GEAR NEEDLE BEARING Fig 49 Second Gear Clutch Cone Snap Ring 1 1 2 SLEEVE 2 SNAP...

Page 1696: ...ng and clutch ring Fig 53 15 Remove first gear clutch cone front snap ring from mainshaft hub Fig 54 Fig 51 1 2 Sleeve And Hub Snap Ring 1 1 2 HUB SNAP RING 2 1 2 SLEEVE AND HUB Fig 52 1 2 Synchro Sle...

Page 1697: ...of first puller jaw 21 Install the second Puller Jaw 6445 on the bearing cone and puller flange 22 Install Puller 6444 on the puller rods and secure with nuts 23 Hold hex portion of Puller 6444 a wre...

Page 1698: ...e clutch gear snap ring Fig 60 Tension of this snap ring is considerable Heavy duty snap ring pliers will be required to spread the ring far enough to remove it 30 Remove reverse clutch gear Fig 61 Fi...

Page 1699: ...led or rough Check the release bearing slide surface of the retainer carefully Minor corrosion nicks or pit ting can be smoothed with 400 grit emery and pol ished out with crocus cloth Wet the abrasiv...

Page 1700: ...ts pitting or other damage Replace the bearings if necessary Inspect the blocker ring and clutch gear replace either part if worn or damaged in any way Also be sure replacement parts fit properly befo...

Page 1701: ...dler gear and case boss Fig 67 10 Align idler gear bearings and thrust washers with a drift 11 Install reverse idler shaft with notched end of shaft facing countershaft Fig 68 Fig 65 Countershaft In G...

Page 1702: ...se and over rear bearing Fig 71 Tap cup into place with plastic mallet if necessary 17 Install countershaft rear bearing plate Fig 72 NOTE Verify plate is seated in notch in reverse idler shaft before...

Page 1703: ...plate bolts Then install and tighten bearing plate bolts to 23 N m 200 in lbs SHIFT LUG AND RAIL 1 Lubricate shift lug and rail with Castrolt Syn torq 2 Insert shift lug rail part way into case 3 Inst...

Page 1704: ...were disassem bled for service reassemble hub sleeve struts and springs as follows a Align and install sleeve on hub Rotate sleeve until it slides onto hub Sleeve only fits one way and will easily sl...

Page 1705: ...ring is seated and engaged in hub and sleeve 7 Install 1 2 synchro assembly and stop ring on mainshaft with the taper on the sleeve facing for ward Fig 83 8 Install snap ring that secures 1 2 synchro...

Page 1706: ...ap ring will not fit in groove clutch cone is slightly misaligned Fig 84 1 2 Synchro Snap Ring 1 SYNCHRO SNAP RING 2 1 2 SYNCHRO ASSEMBLY 3 MAINSHAFT HUB Fig 85 Second Gear Clutch Cone Clutch Ring And...

Page 1707: ...19 Install third gear over bearing and onto main shaft Fig 94 20 Install synchro stop ring on third gear Fig 95 Verify stop ring is seated on cone taper 21 If 3 4 synchro was disassembled for service...

Page 1708: ...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 co...

Page 1709: ...verse clutch gear snap ring Fig 100 32 Install reverse gear bearing on mainshaft Fig 100 33 If reverse gear sleeve and struts were disas sembled for service reassemble sleeve struts and springs as fol...

Page 1710: ...ruts 34 Install reverse gear and synchro assembly on mainshaft Fig 102 Rotate assembly until stop ring lugs engage in hub slots and gear drops into seated position 35 Install reverse gear thrust washe...

Page 1711: ...ll bearing on drive gear with Installer 6448 Fig 109 2 Lubricate pilot bearing with petroleum jelly and install it in drive gear bore 3 Install drive gear on mainshaft Work gear rearward until mainsha...

Page 1712: ...retainer into place with plastic mallet Install new retainer bolts and tighten to 30 N m 22 ft lbs Fig 113 NOTE Never reuse the old bolts Fig 109 Front Bearing On Drive Gear 1 INSTALLER 6448 2 BEARING...

Page 1713: ...lay then zero dial indicator 8 Move mainshaft upward and record dial indica tor reading Move mainshaft with pry tool positioned between drive gear and case 9 End play should be 0 051 0 15 mm 0 002 0 0...

Page 1714: ...th gear with tapered side of sleeve facing front and the flat side facing rear Fig 119 5 Install shift fork in synchro sleeve Fig 120 Fig 116 Fifth Gear Thrust Washer Pin 1 THRUST WASHER PIN 2 COUNTER...

Page 1715: ...hen install roll pins from top side of fork Fig 121 NOTE Roll pins only fit one way due to small shoulder at one end of each pin FIFTH GEAR NUT 1 Install belleville washer onto the mainshaft 2 Install...

Page 1716: ...gears by shifting all synchro sleeves out of the engaged position EXTENSION ADAPTER HOUSING 1 Clean mating surfaces of extension adapter housing and gear case with a wax and grease remover 2 Check al...

Page 1717: ...tor plate onto the shift cover metal side down 7 Install the shift tower onto the isolator plate No sealant is necessary between the shift tower and the isolator plate 8 Verify that the shift tower is...

Page 1718: ...ON N m Ft Lbs In Lbs Switch Back up Lamp 22 34 16 25 Countershaft Bearing Plate Bolts 19 26 14 19 170 230 Fifth Gear Nut 366 380 270 280 Fifth Gear Nut Clamp Bolt 13 5 10 Drain and Fill Plug 34 47 25...

Page 1719: ...er Bushing 8156 Handle C 4171 Installer Seal C 3972 A Installer Seal 8154 Installer Seal C 3860 A Wrench 6443 Wrench 6743 Socket 6441 Socket 6442 Socket 6993 21 84 MANUAL NV4500 BR BE MANUAL NV4500 Co...

Page 1720: ...Socket 6984 Puller 6444 Jaws 6459 Jaws 6820 Jaws and Insert 6453 Jaws 6447 Jaws 6449 Jaws 6451 Remover 6454 BR BE MANUAL NV4500 21 85 MANUAL NV4500 Continued...

Page 1721: ...Installer 6061 Installer C 4340 Installer C 4040 Installer 6448 Installer C 4308 Installer 6052 Rod Extension 8161 Installer 6446 Jaws 6445 21 86 MANUAL NV4500 BR BE MANUAL NV4500 Continued...

Page 1722: ...nsion housing seal Fig 129 using Remover C 3985 B 5 On heavy duty 4X2 vehicles remove extension housing seal with a pry tool or a slide hammer mounted screw 6 On light duty transmissions remove the ex...

Page 1723: ...ork pads are held in place by a combination of tension and a small locating tang Three pads are used on the fork Fig 135 The pads can be removed either by hand or with a narrow blade screwdriver To re...

Page 1724: ...n time 3 Lubricate synchro sleeves with Castrol Syntorq gear lubricant Then apply light coat of petroleum jelly to shift fork contact surfaces 4 Verify that the shift fork pads Fig 137 are properly an...

Page 1725: ...er with suitable wax and grease remover 2 Apply Mopart Gasket Maker or equivalent to the sealing surface of the shift cover Do not over apply sealant 3 Install the isolator plate onto the shift cover...

Page 1726: ...132 INSTALLATION 133 MANUAL NV5600 DESCRIPTION The NV5600 is a six speed constant mesh manual transmission Fig 1 All gear ranges including reverse are synchronized First and second gears uti lize dual...

Page 1727: ...Fig 1 NV5600 Manual Transmission 21 92 MANUAL NV5600 BR BE MANUAL NV5600 Continued...

Page 1728: ...positioned in a groove in the outer circumference of the synchro nizer sleeve As the shift fork moves the synchronizer sleeve the synchronizer begins to speed up or slow down the selected gear depend...

Page 1729: ...enerate a mild whine that is audible but generally only at extreme speeds Severe highly audible transmission noise is gener ally the initial indicator of a lubricant problem Insufficient improper or c...

Page 1730: ...under vehicle DISASSEMBLY NOTE The use of Fixture 8241 for moving and han dling the NV5600 is required The fixture supports the transmission at the center of gravity in order to ease mounting the tra...

Page 1731: ...ON Fig 8 PRIMARY SHIFT RAIL DETENT 1 PRIMARY SHFT RAIL DETENT PLUG Fig 9 PRIMARY SHIFT RAIL DETENT 1 PRIMARY SHFT RAIL DETENT SPRING Fig 10 PRIMARY SHIFT RAIL DETENT 1 PRIMARY SHFT RAIL DETENT PLUNGER...

Page 1732: ...g and plunger from the extension adapter housing Fig 14 4 Remove bolt and washer holding the crossover cam to the extension adapter housing Fig 15 5 Remove crossover cam from the extension adapter hou...

Page 1733: ...r a slide hammer mounted screw 10 On 4X4 vehicles remove adapter housing seal with a pry tool or a slide hammer mounted screw Fig 14 Crossover Cam Detent Plug 1 DETENT PLUG 2 EXTENSION HOUSING Fig 15...

Page 1734: ...bearing from the countershaft reverse gear assembly with Puller C 293 PA and Adapters C 293 52 Fig 20 6 With a bearing splitter and shop press separate the countershaft reverse gear and sleeve Fig 21...

Page 1735: ...bearing sleeve from the output shaft Fig 25 NOTE If necessary heat the sleeve slightly 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...

Page 1736: ...re 8232 to the output shaft and countershaft Fig 29 3 Attach an engine crane or equivalent to Fixture 8232 and raise the geartrain approximately 1 4 in from the clutch housing 4 Remove 5 6 crossover b...

Page 1737: ...he geartrain Fig 31 9 Raise the geartrain until the input shaft is clear of the clutch housing Fig 28 5 6 CROSSOVER 1 5 6 CROSSOVER BRACKET Fig 29 ATTACH FIXTURE 8232 1 FIXTURE 8232 Fig 30 HOLDING TOO...

Page 1738: ...b COUNTERSHAFT BEARINGS 1 Remove snap ring holding the front counter shaft bearing onto the countershaft 2 Remove front countershaft bearing with Sleeve 6444 8 Adapters 6451 Puller Rods 6444 4 and Pul...

Page 1739: ...ler 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 SH...

Page 1740: ...m the output shaft 2 Remove first gear bearing from the output shaft Fig 40 3 Remove first gear blocker rings 2 and cones from the 1 2 synchro assembly Fig 41 4 Install the remainder of the output sha...

Page 1741: ...xture 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 45 6 Remove countershaft...

Page 1742: ...Fix ture 8227 11 Remove third countershaft gear bearing from the countershaft Fig 48 12 The 2 3 thrust washer should not normally need to be removed from the countershaft If neces sary slid 2 3 thrus...

Page 1743: ...over 6061 1 and Handle C 4171 Fig 51 4 Remove input shaft bearing race with Remover Installer 8237 and Handle C 4171 5 Remove input shaft oil guide and retainer seal Fig 52 Fig 47 THIRD COUNTERSHAFT G...

Page 1744: ...eeth are chipped cracked or worn thin Inspect the drive gear and bearings Minor scratches and burrs on the gear surfaces can be reduced with an oil stone and 400 grit paper wetted with oil Replace eit...

Page 1745: ...rted Replace worn distorted synchro parts to avoid shift problems after assembly and installation The shift fork should be inspected for evidence of wear and distortion Check fit of the sleeve in the...

Page 1746: ...NER BLOCKER RING 2 GEAR Fig 54 Friction Cone 1 LOW AREA 2 GEAR 3 HIGH AREA Fig 55 Outer Blocker Ring 1 OUTER BLOCKER RING 2 LUG 3 GEAR Fig 56 3 4 Synchro Assembly 1 SYNCHRO 2 GEAR BR BE MANUAL NV5600...

Page 1747: ...the first gear synchro friction cone Align one of the lugs on the outer ring with a lug on the inner ring Fig 55 15 Reverse the output shaft in the press 16 Install first gear bearing sleeve onto the...

Page 1748: ...Install the sixth gear friction cone onto sixth gear 27 Install sixth gear blocker ring over the sixth gear friction cone Fig 64 28 Install Guide 8235 onto the end of the output shaft Fig 65 29 Insta...

Page 1749: ...EARING Fig 64 Sixth Gear Blocker Ring 1 6TH GEAR BLOCKER RING 2 6TH GEAR FRICTION CONE Fig 65 Output Shaft Guide 1 GUIDE 8235 2 OUTPUT SHAFT Fig 66 5 6 Synchro 1 INSTALLER 8156 2 5 6 SYNCHRO 21 114 MA...

Page 1750: ...o the 3 4 synchro assembly Fig 71 11 Install fourth countershaft gear bearing sleeve onto the output shaft 12 Press fourth countershaft bearing sleeve onto the countershaft with Installer 8228 and a s...

Page 1751: ...tershaft into 3 4 Synchro 1 COUNTERSHAFT 2 2 3 THRUST WASHER 3 THIRD COUNTERSHAFT GEAR Fig 72 Fourth Countershaft onto Sixth Countershaft Gear 1 4TH BEARING 2 4TH COUNTERSHAFT GEAR 3 6TH COUNTERSHAFT...

Page 1752: ...ng onto the coun tershaft INPUT SHAFT 1 Place the input shaft bearing onto the input shaft 2 Install input shaft bearing with Installer MD998805 Fig 75 3 Position the input shaft bearing oil guide on...

Page 1753: ...sealer from the input shaft retainer and the clutch housing but DO NOT apply new sealer at this time New sealer will be applied after all the preload measurements are made and end play shims are insta...

Page 1754: ...re 8232 and move the geartrain from the Support Stand 8246 to the clutch housing Fig 81 9 Install shift forks and rails onto the geartrain Fig 82 NOTE The closest shift arm to the geartrain is for Rev...

Page 1755: ...ay into the clutch housing 14 Install the 5 6 crossover bracket bolts Fig 84 15 Remove engine crane and Fixture 8232 from the output shaft and the countershaft Fig 81 Lift Geartrain with Engine Crane...

Page 1756: ...MAINSHAFT AND COUNTERSHAFT ENDPLAY 1 With transmission in vertical position use Socket 6993 to rotate the shafts and seat the bear ings 2 Measure mainshaft endplay with Dial Indicator Set C 3339 and E...

Page 1757: ...leeve onto the output shaft with Installer 6446 if necessary Fig 89 4 Install reverse gear reverse gear synchronizer cone reverse gear outer blocker ring and reverse gear bearing Fig 90 5 Install outp...

Page 1758: ...aft 12 Install idler and reverse countershaft gears together Fig 92 13 Install reverse idler thrust washer from the reverse idler 14 Install crossover cam rollers and pin Fig 93 Fig 90 Reverse Gear Co...

Page 1759: ...from the extension adapter housing 10 Place Gauge Bar 6311 across the housing face Measure the distance from the top of the bar to the bottom of the reverse countershaft bearing race bore Fig 95 11 Su...

Page 1760: ...f front retainer release bearing bore release fork release fork ball stud propeller shaft slip yoke 1 Apply sealer to threads of bottom PTO cover bolt and install bolt in case 2 Mount transmission on...

Page 1761: ...ubri cant if necessary 8 Install transfer case skid plate if equipped and crossmember Tighten attaching bolts nuts to 41 N m 30 ft lbs 9 Install exhaust system components 10 Remove support and lower v...

Page 1762: ...8155 Installer Bushing 8156 Handle Universal C 4171 Installer Seal C 3972 A Installer Seal 8154 Wrench Output Shaft 8226 Wrench Splined Socket 6984 Wrench Splined Socket 6984 Puller Bearing and Gear...

Page 1763: ...444 6447 Jaws Bearing Cone For Puller 6444 6451 Installer 6061 Installer Bearing Cone 6448 Installer Bearing Cup C 4308 Rod Extension 8161 Fixture 8227 Installer 8228 Fixture 8230 21 128 MANUAL NV5600...

Page 1764: ...Adapter 8232 Remover 8233 Remover 8234 Guide 8235 Installer 8236 Installer Remover 8237 Installer Remover 8238 Installer 8239 BR BE MANUAL NV5600 21 129 MANUAL NV5600 Continued...

Page 1765: ...Remover 8240 Transport Fixture 8241 Holding Tool 8242 Remover 8243 Puller 8244 Remover 8245 Support Stand 8246 Remover 8262 21 130 MANUAL NV5600 BR BE MANUAL NV5600 Continued...

Page 1766: ...8271 Dial Indicator Set C 3339 Installer Bearing C 4965 Remover L 4518 Puller Bearing C 293 PA Adapter Bearing Puller C 293 52 Installer MD998805 Installer BR BE MANUAL NV5600 21 131 MANUAL NV5600 Co...

Page 1767: ...extension housing bushing with Installer 8156 Fig 99 and Handle C 4171 2 Install adapter housing seal with Installer 8154 and Handle C 4171 Fig 100 3 Install transfer case and propeller shaft s 4 Che...

Page 1768: ...o the isolator plate No sealant is necessary between the shift tower and top of the isolator plate 6 Verify that the shift tower isolator plate and the shift tower bushings are properly aligned 7 Inst...

Page 1769: ...INSTALLATION 198 FLUID AND FILTER DIAGNOSIS AND TESTING 199 EFFECTS OF INCORRECT FLUID LEVEL 199 CAUSES OF BURNT FLUID 199 FLUID CONTAMINATION 199 STANDARD PROCEDURE 199 FLUID LEVEL CHECK 199 FLUID AN...

Page 1770: ...ENTS 304 AUTOMATIC TRANSMISSION 42RE DESCRIPTION The 42RE is a four speed fully automatic transmis sion Fig 1 with an electronic governor The 42RE is equipped with a lock up clutch in the torque con v...

Page 1771: ...Fig 1 42RE Transmission 21 136 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1772: ...itch is OFF when the vehicle is cruising on a level surface after the vehicle has warmed up The torque converter clutch will disengage momen tarily when an increase in engine load is sensed by the PCM...

Page 1773: ...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 sp...

Page 1774: ...ansferred 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...

Page 1775: ...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 carr...

Page 1776: ...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 to...

Page 1777: ...e results Therefore when two members are rotating at the same speed and in the same direction it is the same as being locked up The rear planetary set is also locked up given the sun gear is still the...

Page 1778: ...D TESTING PRELIMINARY Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVE...

Page 1779: ...h is slipping If the transmission does not slip in Reverse the rear clutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive clutch is slipping Simi larly if the...

Page 1780: ...should be same as line pres sure within 3 psi 20 68 kPa Test Two Transmission In 2 Range NOTE This test checks pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this...

Page 1781: ...firmly apply service brakes so wheels will not rotate 4 Note governor pressure Governor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing If pressure exceeds 2...

Page 1782: ...ne pressure high Output shaft plugged sticky regulator valve Line pressure low Sticky regulator valve clogged filter worn pump DIAGNOSIS AND TESTING AIR CHECKING TRANSMISSION CLUTCH AND BAND OPERATION...

Page 1783: ...rter itself Fig 11 Pump o ring or gasket leaks usually travel down the inside of the converter housing Front band lever pin plug leaks are generally deposited on the housing and not on the converter T...

Page 1784: ...VE OR REVERSE 1 Fluid Level Low 1 Add Fluid 2 Throttle Linkage Mis adjusted 2 Adjust linkage setting may be too long 3 Mount and Driveline Bolts Loose 3 Check engine mount transmission mount propeller...

Page 1785: ...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 R...

Page 1786: ...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 SH...

Page 1787: ...ect Look for stuck 1 2 valve or governor plug NO LOW GEAR MOVES IN 2ND OR 3RD GEAR ONLY 1 Governor Circuit Electrical Fault 1 Test with DRBT scan tool and repair as required 2 Valve Body Malfunction 2...

Page 1788: ...to determine cause and repair as required BUZZING NOISE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Shift Cable Mis assembled 2 Route cable away from engine and bell housing 3 Valve Body Mis a...

Page 1789: ...ressure check clutch servo operation and repair as required 8 Overrunning Clutch Worn Not Holding Slips in 1 Only 8 Replace Clutch SLIPS IN LOW GEAR 9D9 ONLY BUT NOT IN MANUAL 1 POSITION Overrunning C...

Page 1790: ...equired 2 PCM Malfunction 2 Check PCM operation with DRBT scan tool Replace PCM only if faulty 3 TPS Malfunction 3 Check TPS with DRBT scan tool at PCM 4 Lockup Solenoid Not Venting 4 Remove valve bod...

Page 1791: ...ions with 12V test lamp and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor Malfunction 4 Check with DRBT scan tool and repair or replace as necessary 5 TPS...

Page 1792: ...aft 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 Thr...

Page 1793: ...ttings Loose Leaks Damaged 1 Tighten fittings If leaks persist replace fittings and lines if necessary 2 Fill Tube where tube enters case Leaks Damaged 2 Replace tube seal Inspect tube for cracks in f...

Page 1794: ...erviced separately It is not necessary to remove the entire transmission assembly to perform overdrive unit repairs 1 Disconnect battery negative cable 2 Disconnect and lower or remove necessary exhau...

Page 1795: ...nsmission and remove assembly from under the vehicle 24 To remove torque converter remove C clamp from edge of bell housing and carefully slide torque converter out of the transmission DISASSEMBLY 1 C...

Page 1796: ...Remove valve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 19 11 Remove accumulator piston and inner and outer springs Fig 20 12 Remove...

Page 1797: ...ort assembly from case Fig 21 17 Loosen front band adjusting screw until band is completely loose 18 Squeeze front band together and remove band strut Fig 22 19 Remove front band lever Fig 23 20 Remov...

Page 1798: ...shaft hub Fig 27 26 Slide front band off driving shell Fig 28 and remove band from case Fig 24 Removing Front Rear Clutch Assemblies 1 INPUT SHAFT 2 FRONT CLUTCH 3 REAR CLUTCH Fig 25 Separating Front...

Page 1799: ...ove low reverse drum snap ring Fig 30 31 Remove low reverse drum and reverse band 32 Remove overrunning clutch roller and spring assembly as a unit Fig 31 Fig 29 Removing Planetary Geartrain And Inter...

Page 1800: ...A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation Lubricate transmission parts with Mopart ATF 4 type 9602 transmission fluid during overhaul and assembly...

Page 1801: ...lation Petroleum jelly can also be used to hold thrust washers thrust plates and gaskets in position during assembly However do not use chassis grease bear ing grease white grease or similar lubricant...

Page 1802: ...m hub into overrunning clutch rollers d Press drum rearward and turn it in clock wise direction until drum seats in overrunning clutch Fig 38 e Turn drum back and forth Drum should rotate freely in cl...

Page 1803: ...hold thrust plate in place Fig 42 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT HUB 2 INTERMEDIATE SHAFT THRUST PLATE Fig 39 Installing Low Reverse Drum Retaining Snap Ring 1 LOW RE...

Page 1804: ...ld washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Note thickness of this washer It is a select fit par...

Page 1805: ...19 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Also be sure front clutch drive lugs are fully engaged in slots of driving shell after i...

Page 1806: ...ust washer is incorrect The intermediate shaft thrust washer is selective a Attach Adapter 8266 6 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the...

Page 1807: ...n filter screws to 4 N m 35 in lbs 34 Adjust front and rear bands 35 Install seal on park neutral position switch Then install and tighten switch to 34 N m 25 ft lbs 36 Install magnet in oil pan Magne...

Page 1808: ...rans mission mount to crossmember 15 Remove engine support fixture 16 Install crankshaft position sensor Refer to 14 FUEL SYSTEM FUEL INJECTION CRANKSHAFT POSITION SENSOR INSTALLATION 17 Install new p...

Page 1809: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK 21 174 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1810: ...HYDRAULIC FLOW IN NEUTRAL BR BE AUTOMATIC TRANSMISSION 42RE 21 175 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1811: ...HYDRAULIC FLOW IN REVERSE 21 176 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1812: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR BR BE AUTOMATIC TRANSMISSION 42RE 21 177 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1813: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 178 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1814: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED BR BE AUTOMATIC TRANSMISSION 42RE 21 179 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1815: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED 21 180 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1816: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED BR BE AUTOMATIC TRANSMISSION 42RE 21 181 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1817: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED 21 182 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1818: ...HYDRAULIC FLOW IN MANUAL LOW 1 BR BE AUTOMATIC TRANSMISSION 42RE 21 183 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1819: ...HYDRAULIC FLOW IN MANUAL SECOND 2 21 184 AUTOMATIC TRANSMISSION 42RE BR BE AUTOMATIC TRANSMISSION 42RE Continued...

Page 1820: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING BR BE AUTOMATIC TRANSMISSION 42RE 21 185 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1821: ...21 1 THRUST WASHER SPACER SNAP RING DIMENSIONS Component Metric Inch Front clutch thrust washer reaction shaft support hub 1 55 mm 0 061 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in I...

Page 1822: ...5 psi at stand still will prevent transmission from downshifting TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fitting cooler line at trans 18 13 Bolt torque convertor 31 270 Bolt clevis bracket...

Page 1823: ...ot Extension Housing C 3288 B Gauge Oil Pressure C 3292 Gauge Oil Pressure C 3293SP Dial Indicator C 3339 Compressor Spring C 3422 C Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer...

Page 1824: ...aller Seal C 4193 A Dial Caliper C 4962 Kit Bushing Remover Installer C 3887 J Nut Bushing Remover SP 1191 From kit C 3887 J Cup Bushing Remover SP 3633 From kit C 3887 J Remover Bushing SP 3551 BR BE...

Page 1825: ...Compressor Spring C 3575 A Gauge 6312 Adapter Band Adjuster C 3705 Flusher Oil Cooler 6906 B Installer Piston 8114 Remover Bushing 6957 Installer Bushing 6951 Retainer Detent Ball and Spring 6583 21...

Page 1826: ...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 balanc...

Page 1827: ...imilar in 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...

Page 1828: ...ly 5 N m 47 50 in lbs torque 4 Back off front band adjusting screw 3 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 o...

Page 1829: ...for varying conditions One curve is used for operation when fluid temperature is at or below 1 C 30 F A second curve is used when fluid temperature is at or above 10 C 50 F during nor mal city or high...

Page 1830: ...ure is needed NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not...

Page 1831: ...essure sensor from governor body 8 Remove bolts holding governor body to valve body 9 Separate governor body from valve body Fig 71 10 Remove governor body gasket Fig 68 Governor Solenoid And Pressure...

Page 1832: ...re solenoid to bore in governor body Fig 73 9 Push solenoid into governor body 10 Place solenoid retainer in position on governor Fig 74 11 Install screws to hold pressure solenoid retainer to governo...

Page 1833: ...l with Seal Remover C 3985 B Fig 78 from overdrive housing INSTALLATION 1 Place seal in position on overdrive housing 2 Drive seal into overdrive housing with Seal Installer C 3995 A Fig 79 3 Carefull...

Page 1834: ...not removed beforehand Take the time to wipe the cap and tube clean before withdrawing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remed...

Page 1835: ...9602 to restore correct level Do not over fill PROCEDURE TWO 1 Start engine and apply parking brake 2 Shift the transmission into DRIVE for approxi mately 2 seconds 3 Shift the transmission into REVER...

Page 1836: ...ere 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 pints 6 quarts of ATF 4...

Page 1837: ...s 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...

Page 1838: ...Components 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLUTCH PLATE 10 SNAP RING 5 SEAL 11 SPRING RETAINER 6 CLUTCH RETAINER BR BE AUTOMATIC TRANSMISSION 42RE 21 203 FRO...

Page 1839: ...ch Components 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLUTCH PLATE 10 SNAP RING 5 SEAL 11 SPRING RETAINER 6 CLUTCH RETAINER 21 204 AUTOMATIC TRANSMISSION 42RE BR BE...

Page 1840: ...r Fig 87 The ball must move freely and not stick NOTE Inspect the clutch retainer bushings care fully Fig 88 The retainer bushings are NOT ser viceable It will be necessary to replace the retainer if...

Page 1841: ...g and retainer with Com pressor Tool C 3575 A Fig 86 Then install new snap ring to secure spring retainer and spring 8 Install clutch plates and discs Fig 85 Install steel plate then disc until all pl...

Page 1842: ...overlap between them DISASSEMBLY 1 Remove seal ring from rod guide Fig 92 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discard ser...

Page 1843: ...rance between the gear 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 betwee...

Page 1844: ...selector in neutral 3 If one quart of transmission fluid is collected in the container in 20 seconds or less oil pump flow vol ume is within acceptable limits If fluid flow is inter mittent or it take...

Page 1845: ...17 Fig 103 Bushing should be flush with pump housing bore 3 Stake new pump bushing in two places with blunt punch Fig 104 Remove burrs from stake points with knife blade afterward Fig 101 Pump Gear Re...

Page 1846: ...cored pitted or dam aged Replace the pump gears if pitted worn chipped or damaged Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn sco...

Page 1847: ...ntil ring ends are securely hooked together CAUTION The reaction shaft support seal rings will break if overspread or twisted If new rings are being installed spread them only enough for instal lation...

Page 1848: ...ng in position on geartrain with 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 Instal...

Page 1849: ...e 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 i...

Page 1850: ...ERDRIVE ELECTRICAL CONTROLS The overdrive off switch valve body solenoid case connectors and related wiring can all be tested with a 12 volt test lamp or a volt ohmmeter Check conti nuity of each comp...

Page 1851: ...iate shaft Do not allow the shaft to support the entire weight of the over drive unit 10 Carefully work overdrive unit off intermediate shaft Do not tilt unit during removal Keep it as level as possib...

Page 1852: ...etain spacer It is a select fit part and may possibly be reused Fig 119 Transmission Speed Sensor Removal 1 SOCKET AND WRENCH 2 SPEED SENSOR 3 O RING Fig 120 Overdrive Piston Thrust Bearing Removal 1...

Page 1853: ...s for assembly reference Fig 126 Fig 123 Overdrive Piston Removal 1 PISTON RETAINER 2 OVERDRIVE PISTON Fig 124 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig...

Page 1854: ...ding type snap ring pliers Then push output shaft forward to release shaft bearing from locating ring Fig 131 Fig 127 Overdrive Clutch Wave 1 WAVE SPRING Fig 128 Overdrive Clutch Reaction Snap Ring Re...

Page 1855: ...PRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 1 Mount geartrain assembly in shop press Fig 134 2 Position Compressor Tool 6227 1 on clutch hub Fig 134 Support output shaft flange with s...

Page 1856: ...5 Direct Clutch Pack Snap Ring Removal 1 CLUTCH HUB 2 SPECIAL TOOL 6227 1 3 DIRECT CLUTCH PACK SNAP RING 4 PRESS PLATES 5 CLUTCH DRUM Fig 136 Direct Clutch Hub Retaining Ring Removal 1 SPECIAL TOOL 62...

Page 1857: ...Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 141 Use small center punch or scriber to make alignment marks Fig 138 Direct Clutch Hub And Spring Removal 1...

Page 1858: ...ng out of groove as shown 11 Remove annulus gear from output shaft Fig 146 Use rawhide or plastic mallet to tap gear off shaft Fig 142 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2...

Page 1859: ...eck condition of the annulus gear direct clutch hub clutch drum and clutch spring Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or cracked Be sure the spli...

Page 1860: ...s 5 Install clutch drum outer retaining ring Fig 149 6 Slide clutch drum forward and install inner retaining ring Fig 150 7 Install rear bearing and snap ring on output shaft Fig 151 Be sure locating...

Page 1861: ...ll planetary gear in annulus gear Fig 154 Be sure planetary pinions are fully seated in annulus gear before proceeding 12 Coat planetary thrust bearing and bearing contact surface of spring plate with...

Page 1862: ...in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 157 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proceeding...

Page 1863: ...ised splines Plate should be flush with this end of hub Fig 160 c Install first clutch disc followed by a steel plate until all discs and plates have been installed d Install pressure plate This is la...

Page 1864: ...place 22 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 23 Realign clutch pack on hub and se...

Page 1865: ...se On 4 x 2 gear case use same Han dle C 4171 and Installer C 3995 A to seat seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 167 7 Support ge...

Page 1866: ...fset from each other NOTE The 42RE transmission has 3 overdrive clutch discs and 2 plates 3 Assemble overdrive clutch pack Fig 173 4 Install overdrive clutch reaction plate first NOTE The reaction pla...

Page 1867: ...ushing in output shaft Be sure tool bottoms against planetary shoulder b Position Gauge Tool 6311 across face of over drive case Fig 175 Then position Dial Caliper C 4962 over gauge tool c Extend slid...

Page 1868: ...r not be installed until after overdrive unit is secured to transmission OVERDRIVE PISTON 1 Install new seals on over drive piston 2 Stand transmission case upright on bellhous ing 3 Position Guide Ri...

Page 1869: ...Be sure the shoulder on the inside diam eter of the bearing is facing forward 8 Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Align ment Tool 6227 2 Overd...

Page 1870: ...he rollers try to move 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 uni...

Page 1871: ...k for assembly reference 2 Mark location of non threaded hole in clutch cam and blank area in bolt circle with grease pencil 3 Align and install overrunning clutch and cam in case Fig 186 Be sure cam...

Page 1872: ...he remaining transmission compo nents and the overdrive unit PARK NEUTRAL POSITION SWITCH DIAGNOSIS AND TESTING PARK NEUTRAL POSITION SWITCH The center terminal of the park neutral position switch is...

Page 1873: ...Fig 190 is nothing more than force lbs divided by area in or ft or force per unit area Given a 100 lb block and an area of 100 sq in on the floor the pressure exerted by the block is 100 lbs 100 in or...

Page 1874: ...simple algebra the output force may be found This concept is extremely important as it is also used in the design and operation of all shift valves and limiting valves in the valve body as well as th...

Page 1875: ...be able to flow One member must be held Another member must be driven or used as an input The third member may be used as an output for power flow For direct drive to occur two gear members in the fro...

Page 1876: ...tion to the machined bushing bearing surfaces on the shaft and the governor valve shaft bore at the shaft rear Replace the output shaft if the machined surfaces are scored pitted or damaged in any way...

Page 1877: ...plate on sun gear and at front rear of shell Fig 199 Assembling Rear Annulus And Planetary Gear 1 REAR ANNULUS GEAR 2 TABBED THRUST WASHER 3 REAR PLANETARY Fig 200 Installing Rear Annulus And Planeta...

Page 1878: ...ed in sun gear ring groove Fig 206 12 Install assembled driving shell and sun gear on output shaft Fig 207 Fig 204 Installing Driving Shell Rear Thrust Plate 1 DRIVING SHELL 2 SUN GEAR 3 REAR THRUST P...

Page 1879: ...support Fig 210 Note that plate has two tabs on it These tabs fit in notches of annulus hub 19 Install thrust washer in front annulus Fig 211 Align flat on washer with flat on planetary hub Also be s...

Page 1880: ...geartrain end play with feeler gauge Fig 214 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartrain end play should be 0 12 to 1 22 mm 0 005 to 0 048 in If end play i...

Page 1881: ...tion shaft support With pressure applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the clutch pack This action applies the clutch pack allowi...

Page 1882: ...ston seals 7 Remove input shaft snap ring Fig 217 It may be necessary to press the input shaft in slightly to relieve tension on the snap ring 8 Press input shaft out of retainer with shop press and s...

Page 1883: ...219 a Be sure clutch hub seal ring is fully seated in groove and is not twisted 3 Lubricate splined end of input shaft and clutch retainer with transmission fluid Then press input shaft into retainer...

Page 1884: ...REAR SEAL RING 2 TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT Fig 220 Pressing Input Shaft Into Rear Clutch Retainer 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3...

Page 1885: ...reverse servo consists of a single stage or diameter piston and a spring loaded plug The spring is used to cushion the application of the rear low reverse band OPERATION While in the de energized stat...

Page 1886: ...SECOND 2 Manual LOW 1 OPERATION Manual LOW 1 range provides first gear only Overrun braking is also provided in this range Man ual SECOND 2 range provides first and second gear only DRIVE range provi...

Page 1887: ...uses a magnetic force to perform work It consists of a coil of wire wrapped around a magnetic core made from steel or iron and a spring loaded movable plunger which performs the work or straight line...

Page 1888: ...ry to allow free movement of the plunger the magnetic field is maximized SPEED SENSOR DESCRIPTION The speed sensor Fig 228 is located in the over drive gear case The sensor is positioned over the park...

Page 1889: ...and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction Fig 233 If cable end and attachment stud are misaligned off center cable will have to be a...

Page 1890: ...T V cable in the set position push the T V cable lock A into the down position Fig 233 This will lock the present T V cable adjustment NOTE Be sure that as the cable is pulled forward and centered on...

Page 1891: ...also provides reduced transmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is servic...

Page 1892: ...e 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 235 Impeller 1 ENGINE FLEXPLATE 4 ENGI...

Page 1893: ...hrough 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 236 Turbin...

Page 1894: ...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 mechan...

Page 1895: ...ocks and holds the stator 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...

Page 1896: ...seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmissio...

Page 1897: ...se an overheating condition and possible transmission failure CAUTION The drainback valve is a one way flow device It must be properly oriented in terms of flow direction for the cooler to function pr...

Page 1898: ...shift valve 3 4 timing valve 3 4 quick fill valve 3 4 accumulator Throttle valve Throttle pressure plug Switch valve Manual valve Converter clutch lock up valve Converter clutch lock up timing Valve...

Page 1899: ...ER 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 1...

Page 1900: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 1901: ...4 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 CAS...

Page 1902: ...rects line pressure to the spring end of the 2 3 shift valve in either Manual Low or Manual 2nd forcing the downshift to 2nd gear regardless of governor pressure 6 Provides a by pass around the front...

Page 1903: ...r and manual valves back to the sump Meanwhile the torque converter is filled slowly In all other gear positions Fig 249 fluid flows between two right side lands to the switch valve and torque convert...

Page 1904: ...g the supply of line pressure to the reaction area left of land 4 With this pressure blocked there is less area for pressure to act on to balance the force of the spring on the right This allows line...

Page 1905: ...Fig 250 Regulator Valve in DRIVE Position Fig 251 Regulator Valve in REVERSE Position 21 270 AUTOMATIC TRANSMISSION 42RE BR BE VALVE BODY Continued...

Page 1906: ...ht 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 va...

Page 1907: ...ttom 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 o...

Page 1908: ...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...

Page 1909: ...he vehicle is in motion and under acceleration there is throttle pressure being applied to the spring side of the valve and between lands 3 and 4 As vehicle speed increases governor pressure increases...

Page 1910: ...Fig 258 2 3 Shift Valve Before Shift Fig 259 2 3 Shift Valve After Shift BR BE AUTOMATIC TRANSMISSION 42RE 21 275 VALVE BODY Continued...

Page 1911: ...hift valve in an upshift position The purpose is to prevent the 2 3 valve from downshifting before the 3 4 valve Fig 260 3 4 QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of the...

Page 1912: ...ressure plug on the pressure valve The larger spring at the right closes the regulator valve passage and maintains or increases line pressure The increased line pressure works against the reac tion ar...

Page 1913: ...nsmission Once the TCC control valve has moved to the right Fig 264 line pressure is directed to the tip of the switch valve forcing the valve to the right The switch valve now vents oil from the fron...

Page 1914: ...Fig 264 Switch Valve Torque Converter Locked BR BE AUTOMATIC TRANSMISSION 42RE 21 279 VALVE BODY Continued...

Page 1915: ...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 posit...

Page 1916: ...utch 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...

Page 1917: ...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...

Page 1918: ...ws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 273 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLENOID 3 SOLENOID SCREWS 4 GOVERNOR SENSOR WIRES 5 OVERDRIVE SOLENO...

Page 1919: ...lift manual lever off valve body and throttle lever shaft Then slide throttle lever out of valve body Fig 276 Detent Ball And Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 277 Park Rod...

Page 1920: ...spring and manual valve Fig 283 20 Remove kickdown detent kickdown valve and throttle valve and spring Fig 283 21 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remov...

Page 1921: ...RNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 284 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW 2 REMOVE THESE SCREWS 3 3 4 ACCUMULATOR HOUSING...

Page 1922: ...all out when lower housing and separator plate are removed 27 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 289 Note position of boost valve tube brace for a...

Page 1923: ...separator plate for assembly reference 33 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 293 Fig 290 ECE Check Ball 1 ECE CHECK B...

Page 1924: ...housing around and remove limit valve and shift valve covers Fig 297 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 297 9 Remo...

Page 1925: ...ER 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 1...

Page 1926: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 1927: ...ings 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 1...

Page 1928: ...nt 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 c...

Page 1929: ...istortion or burrs the valve body components should all slide into place easily In addition do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort th...

Page 1930: ...tion assembled transfer plate and upper housing separator plate on upper housing Fig 304 Be sure filter screen is seated in proper housing recess Fig 303 Check Ball Locations In Upper Housing 1 SMALL...

Page 1931: ...t control valve and spring 5 Install retainer spring limit valve and 2 3 throttle plug from limit valve housing 6 Install limit valve housing and cover plate Tighten screws to 4 N m 35 in lbs 7 Instal...

Page 1932: ...ER 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 1...

Page 1933: ...OR 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 T...

Page 1934: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 1935: ...finger tighten three screws that secure tube brace to valve body housings Fig 311 7 Bend tube brace tabs up and against tube to hold it in position Fig 312 8 Tighten all valve body housing screws to 4...

Page 1936: ...n on manual lever until fully seated Remove detent ball retainer tool after lever is seated 6 Then install manual lever seal washer and E clip 7 Verify that throttle lever is aligned with end of kickd...

Page 1937: ...down 2 Install new O rings on governor pressure sole noid and sensor 3 Lubricate solenoid and sensor O rings with clean transmission fluid 4 Install governor pressure sensor in governor body 5 Install...

Page 1938: ...g 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 ca...

Page 1939: ...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 To...

Page 1940: ...9 INSTALLATION 369 FLUID AND FILTER DIAGNOSIS AND TESTING 370 EFFECTS OF INCORRECT FLUID LEVEL 370 CAUSES OF BURNT FLUID 370 FLUID CONTAMINATION 370 STANDARD PROCEDURE 370 FLUID LEVEL CHECK 370 FLUID...

Page 1941: ...ENTS 476 AUTOMATIC TRANSMISSION 44RE DESCRIPTION The 44RE is a four speed fully automatic transmis sion Fig 1 with an electronic governor The 44RE is equipped with a lock up clutch in the torque con v...

Page 1942: ...Fig 1 44RE Transmission BR BE AUTOMATIC TRANSMISSION 44RE 21 307 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1943: ...itch is OFF when the vehicle is cruising on a level surface after the vehicle has warmed up The torque converter clutch will disengage momen tarily when an increase in engine load is sensed by the PCM...

Page 1944: ...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 sp...

Page 1945: ...ansferred 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...

Page 1946: ...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 carr...

Page 1947: ...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 to...

Page 1948: ...e results Therefore when two members are rotating at the same speed and in the same direction it is the same as being locked up The rear planetary set is also locked up given the sun gear is still the...

Page 1949: ...D TESTING PRELIMINARY Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVE...

Page 1950: ...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 tra...

Page 1951: ...in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward from full forward positi...

Page 1952: ...rnor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing If pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes s...

Page 1953: ...ne pressure high Output shaft plugged sticky regulator valve Line pressure low Sticky regulator valve clogged filter worn pump DIAGNOSIS AND TESTING AIR CHECKING TRANSMISSION CLUTCH AND BAND OPERATION...

Page 1954: ...rter itself Fig 11 Pump o ring or gasket leaks usually travel down the inside of the converter housing Front band lever pin plug leaks are generally deposited on the housing and not on the converter T...

Page 1955: ...VE OR REVERSE 1 Fluid Level Low 1 Add Fluid 2 Throttle Linkage Mis adjusted 2 Adjust linkage setting may be too long 3 Mount and Driveline Bolts Loose 3 Check engine mount transmission mount propeller...

Page 1956: ...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 R...

Page 1957: ...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 SH...

Page 1958: ...ect Look for stuck 1 2 valve or governor plug NO LOW GEAR MOVES IN 2ND OR 3RD GEAR ONLY 1 Governor Circuit Electrical Fault 1 Test with DRBT scan tool and repair as required 2 Valve Body Malfunction 2...

Page 1959: ...to determine cause and repair as required BUZZING NOISE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Shift Cable Mis assembled 2 Route cable away from engine and bell housing 3 Valve Body Mis a...

Page 1960: ...SITION Overrunning Clutch Faulty Replace overrunning clutch GROWLING GRATING OR SCRAPING NOISES 1 Drive Plate Broken 1 Replace 2 Torque Converter Bolts Hitting Dust Shield 2 Dust shield bent Replace o...

Page 1961: ...Connector Shorted 2 Test solenoids and replace if seized or shorted 3 PCM Malfunction 3 Test with DRBT scan tool Replace PCM if faulty 4 Valve Body Stuck Valves 4 Repair stuck 3 4 lockup or lockup ti...

Page 1962: ...rive and repair as needed 11 Hydraulic Pressure Low 11 Pressure test transmission to determine cause 12 Valve Body Valve Stuck 12 Repair stuck 3 4 shift valve 3 4 timing valve 13 O D Piston Incorrect...

Page 1963: ...lace solenoid if faulty and repair wiring if necessary 7 Overdrive Excess Clearance 7 Remove unit Measure end play and select proper spacer 8 O D Check Valve Missing or Stuck 8 Check for presence of c...

Page 1964: ...bolts or gasket or tighten both 8 Adapter Extension Gasket Damaged Leaks Damaged 8 Replace gasket 9 Park Neutral Switch or Transmission Range Sensor Leaks Damaged 9 Replace switch and gasket 10 Conve...

Page 1965: ...transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 9 Remove fill tube bracket bolts and pull tube out of transmission Retain fill tube seal Fig 13 On...

Page 1966: ...ion 3 Measure input shaft end play as follows Fig 16 a Attach Adapter 8266 6 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 t...

Page 1967: ...Fig 19 11 Remove accumulator piston and inner and outer springs Fig 20 12 Remove pump oil seal with suitable pry tool or slide hammer mounted screw Fig 18 Valve Body Bolt Locations 1 VALVE BODY BOLTS...

Page 1968: ...ort assembly from case Fig 21 17 Loosen front band adjusting screw until band is completely loose 18 Squeeze front band together and remove band strut Fig 22 19 Remove front band lever Fig 23 20 Remov...

Page 1969: ...aft thrust plate from inter mediate shaft hub Fig 27 Fig 26 Removing Intermediate Shaft Thrust Washer 1 INTERMEDIATE SHAFT THRUST WASHER 2 INPUT SHAFT 3 REAR CLUTCH RETAINER HUB Fig 27 Removing Interm...

Page 1970: ...unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 29 Loosen rear band adjusting screw 4 5 turns 30 Remove low reverse drum snap ring Fig 30 Fig 28...

Page 1971: ...a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid...

Page 1972: ...nsmission components during assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for assembly operations are equally clean Shop towels used for wi...

Page 1973: ...earward and turn it in clock wise direction until drum seats in overrunning clutch Fig 38 e Turn drum back and forth Drum should rotate freely in clockwise direction and lock in counterclockwise direc...

Page 1974: ...hold thrust plate in place Fig 42 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT HUB 2 INTERMEDIATE SHAFT THRUST PLATE Fig 39 Installing Low Reverse Drum Retaining Snap Ring 1 LOW RE...

Page 1975: ...ld washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Note thickness of this washer It is a select fit par...

Page 1976: ...19 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Also be sure front clutch drive lugs are fully engaged in slots of driving shell after i...

Page 1977: ...ust washer is incorrect The intermediate shaft thrust washer is selective a Attach Adapter 8266 6 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the...

Page 1978: ...n filter screws to 4 N m 35 in lbs 34 Adjust front and rear bands 35 Install seal on park neutral position switch Then install and tighten switch to 34 N m 25 ft lbs 36 Install magnet in oil pan Magne...

Page 1979: ...rans mission mount to crossmember 15 Remove engine support fixture 16 Install crankshaft position sensor Refer to 14 FUEL SYSTEM FUEL INJECTION CRANKSHAFT POSITION SENSOR INSTALLATION 17 Install new p...

Page 1980: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK BR BE AUTOMATIC TRANSMISSION 44RE 21 345 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1981: ...HYDRAULIC FLOW IN NEUTRAL 21 346 AUTOMATIC TRANSMISSION 44RE BR BE AUTOMATIC TRANSMISSION 44RE Continued...

Page 1982: ...HYDRAULIC FLOW IN REVERSE BR BE AUTOMATIC TRANSMISSION 44RE 21 347 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1983: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 348 AUTOMATIC TRANSMISSION 44RE BR BE AUTOMATIC TRANSMISSION 44RE Continued...

Page 1984: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR BR BE AUTOMATIC TRANSMISSION 44RE 21 349 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1985: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED 21 350 AUTOMATIC TRANSMISSION 44RE BR BE AUTOMATIC TRANSMISSION 44RE Continued...

Page 1986: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED BR BE AUTOMATIC TRANSMISSION 44RE 21 351 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1987: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 352 AUTOMATIC TRANSMISSION 44RE BR BE AUTOMATIC TRANSMISSION 44RE Continued...

Page 1988: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED BR BE AUTOMATIC TRANSMISSION 44RE 21 353 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1989: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 354 AUTOMATIC TRANSMISSION 44RE BR BE AUTOMATIC TRANSMISSION 44RE Continued...

Page 1990: ...HYDRAULIC FLOW IN MANUAL SECOND 2 BR BE AUTOMATIC TRANSMISSION 44RE 21 355 AUTOMATIC TRANSMISSION 44RE Continued...

Page 1991: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING 21 356 AUTOMATIC TRANSMISSION 44RE BR BE AUTOMATIC TRANSMISSION 44RE Continued...

Page 1992: ...VERSE 2 21 1 THRUST WASHER SPACER SNAP RING DIMENSIONS Component Metric Inch Front clutch thrust washer reaction shaft support hub 1 55 mm 0 061 in Rear clutch thrust washer clutch retainer 1 55 mm 0...

Page 1993: ...ansmission from downshifting TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fitting cooler line at trans 18 13 Bolt torque convertor 31 270 Bolt clevis bracket to crossmember 47 35 Bolt clevis br...

Page 1994: ...ot Extension Housing C 3288 B Gauge Oil Pressure C 3292 Gauge Oil Pressure C 3293SP Dial Indicator C 3339 Compressor Spring C 3422 C Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer...

Page 1995: ...aller Seal C 4193 A Dial Caliper C 4962 Kit Bushing Remover Installer C 3887 J Nut Bushing Remover SP 1191 From kit C 3887 J Cup Bushing Remover SP 3633 From kit C 3887 J Remover Bushing SP 3551 21 36...

Page 1996: ...Compressor Spring C 3575 A Gauge 6312 Adapter Band Adjuster C 3705 Flusher Oil Cooler 6906 B Installer Piston 8114 Remover Bushing 6957 Installer Bushing 6951 Retainer Detent Ball and Spring 6583 BR...

Page 1997: ...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 balanc...

Page 1998: ...n band is made of steel and faced on its inner circumference with a friction type lining One end of the band is anchored to the transmission case and the other is acted on with a pushing force by a se...

Page 1999: ...rew locknut Fig 64 Then back locknut off 3 5 turns Be sure adjusting screw turns freely in case Apply lubricant to screw threads if necessary 3 Tighten band adjusting screw to 8 N m 72 in lbs torque w...

Page 2000: ...he governor pressure solenoid valve is mounted in the governor body The body is bolted to the lower side of the transfer plate Fig 67 GOVERNOR PRESSURE CURVES There are four governor pressure curves p...

Page 2001: ...alve that develops the necessary governor pressure GOVERNOR PRESSURE CURVES LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conven tional governor can delay shifts resulting...

Page 2002: ...ody 8 Remove bolts holding governor body to valve body 9 Separate governor body from valve body Fig 71 10 Remove governor body gasket INSTALLATION Before installing the pressure sensor and solenoid in...

Page 2003: ...Fig 74 11 Install screws to hold pressure solenoid retainer to governor body 12 Engage wire connectors into pressure sensor and solenoid Fig 75 13 Install transmission fluid pan and new filter 14 Low...

Page 2004: ...l with Seal Remover C 3985 B Fig 78 from overdrive housing INSTALLATION 1 Place seal in position on overdrive housing 2 Drive seal into overdrive housing with Seal Installer C 3995 A Fig 79 3 Carefull...

Page 2005: ...ot removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remed...

Page 2006: ...9602 to restore correct level Do not overfill PROCEDURE TWO 1 Start engine and apply parking brake 2 Shift the transmission into DRIVE for approxi mately 2 seconds 3 Shift the transmission into REVER...

Page 2007: ...ere 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 pints 6 quarts of ATF 4...

Page 2008: ...he clutch retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the input shaft into the driving discs and into the clutch plates and pressure pla...

Page 2009: ...Components 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLUTCH PLATE 10 SNAP RING 5 SEAL 11 SPRING RETAINER 6 CLUTCH RETAINER 21 374 AUTOMATIC TRANSMISSION 44RE BR BE FRO...

Page 2010: ...onents Typical 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLUTCH PLATE 10 SNAP RING 5 SEAL 11 SPRING RETAINER 6 CLUTCH RETAINER BR BE AUTOMATIC TRANSMISSION 44RE 21 375...

Page 2011: ...grooves in the clutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Check action of the check ball in the retainer Fig 87 The ball...

Page 2012: ...ansmission 9 Install pressure plate and waved snap ring Clearance should be 1 70 to 3 40 mm 0 067 to 0 134 in If clearance is incorrect clutch discs plates pressure plates and snap ring may have to be...

Page 2013: ...NG Clean the servo piston components Fig 93 with solvent and dry them with compressed air INSPECTION Inspect the servo components Fig 94 Replace the springs if collapsed distorted or broken Replace th...

Page 2014: ...m 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 STANDARD PROCEDURE OIL PUMP VOLUME CHECK Mea...

Page 2015: ...l the transmission to proper level DISASSEMBLY 1 Remove seal ring from housing and reaction shaft support Fig 98 2 Mark pump housing and support assembly for alignment reference 3 Remove bolts attachi...

Page 2016: ...emover tool hex nut down against remover cup to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of...

Page 2017: ...ump housing 4 Separate the reaction shaft housing from the pump housing and measure the Plastigage follow ing the instructions supplied with it Clearance between inner gear tooth and outer gear should...

Page 2018: ...pump housing are all aligned holes are offset for one way fit 10 Install all bolts that attach support to pump housing Then tighten bolts finger tight 11 Tighten support to pump bolts to required tor...

Page 2019: ...1 TRANSMISSION TRANSAXLE AUTOMATIC OVERDRIVE REMOVAL 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear bearing into overdrive housing Fig 112 4 Using a suitable dr...

Page 2020: ...late are lugged to the overdrive housing This allows the intermediate shaft to transfer the engine torque to the planetary gear and overrunning clutch This drives the planetary gear inside the annulus...

Page 2021: ...from the lever 1 Pull the connector out of the lever just enough to grasp it CAUTION Be careful not to bend the pins on the overdrive off switch Use care when installing the switch as it is not indexe...

Page 2022: ...ate 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 overrunni...

Page 2023: ...ton from retainer Fig 123 Fig 120 Overdrive Piston Thrust Bearing Removal 1 THRUST BEARING 2 OVERDRIVE PISTON 3 THRUST PLATE Fig 121 Overdrive Piston Thrust Plate Removal 1 OVERDRIVE PISTON 2 OVERDRIV...

Page 2024: ...27 Note that snap ring is located in same groove as wave spring 3 Remove Torx head screws that attach access cover and gasket to overdrive case Fig 128 Fig 124 Removing Overdrive Clutch Pack Retaining...

Page 2025: ...etains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 132 Fig 129 Access Cover And Gasket Removal 1 ACCESS COVER AND GASKET Fig 130 Releasing Bearing From Locating Ring 1 EXP...

Page 2026: ...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 p...

Page 2027: ...G RING 3 PRESS BED 4 PRESS PLATES Fig 136 Direct Clutch Pack Removal 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH HUB 3 DIRECT CLUTCH PACK Fig 137 Direct Clutch Hub And Spring Removal 1 DIRECT CLUTCH SPRING...

Page 2028: ...small center punch or scriber to make alignment marks 7 Remove direct clutch drum rear retaining ring Fig 141 8 Remove direct clutch drum outer retaining ring Fig 142 Fig 141 Clutch Drum Inner Retain...

Page 2029: ...ansmission filter and fluid 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 da...

Page 2030: ...ch assembly or the 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...

Page 2031: ...9 Install thrust bearing on overrunning clutch hub Use generous amount of petroleum jelly to hold bearing in place for installation Bearing fits one way only Be sure bearing is seated squarely agains...

Page 2032: ...tallation 13 Install planetary thrust bearing on sun gear Fig 154 Slide bearing onto gear and seat it against spring plate as shown Bearing fits one way only If it does not seat squarely against sprin...

Page 2033: ...ct clutch reaction plate on clutch hub first Note that one side of reaction plate is counterbored Be sure this side faces rearward Splines at rear of hub are raised slightly Counter bore in plate fits...

Page 2034: ...Direct Clutch Reaction Plate 1 REACTION PLATE COUNTERBORE 2 DIRECT CLUTCH REACTION PLATE FLUSH WITH END OF HUB 3 CLUTCH HUB Fig 160 Correct Position Of Direct Clutch Pressure Plate 1 DIRECT CLUTCH PR...

Page 2035: ...spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 23 Realign clutch pack on hub and seat clutch discs and plates in clutch dru...

Page 2036: ...t seal in case On 4 x 2 gear case use same Han dle C 4171 and Installer C 3995 A to seat seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 166...

Page 2037: ...g clutch discs and plates in same order 6 Install clutch pack pressure plate 7 Install clutch pack wire type retaining ring Fig 172 INTERMEDIATE SHAFT SPACER SELECTION 1 Place overdrive unit in vertic...

Page 2038: ...ed thrust plate from information in thrust plate chart Fig 176 3 Leave Alignment Tool 6227 2 in place Tool will keep planetary and clutch hub splines in alignment until overdrive unit is ready for ins...

Page 2039: ...reusable prepare new gasket by trimming it 3 Cut out old case gasket around piston retainer with razor knife Fig 177 4 Use old gasket as template and trim new gas ket to fit 5 Position new gasket over...

Page 2040: ...ler shaft if nec essary Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER DESCRIPTION The overrunning clutch Fig 179 consi...

Page 2041: ...carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damaged ASSEMBLY 1 Examine bolt holes in overrunning clutc...

Page 2042: ...ng 8114 1 on outer edge of overdrive piston retainer 11 Position Seal Guide 8114 2 on inner edge of overdrive piston retainer 12 Install overdrive piston in overdrive piston retainer by aligning locat...

Page 2043: ...wires 3 Remove switch from case INSTALLATION 1 Move shift lever to PARK and NEUTRAL posi tions Verify that switch operating lever fingers are centered in switch opening in case Fig 187 2 Install new s...

Page 2044: ...same no matter which direction is taken The pressure created in the fluid is equal to the force applied divided by the piston area If the force is 100 lbs and the piston area is 10 sq in then the pres...

Page 2045: ...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 ar...

Page 2046: ...INSPECTION Check sun gear and driving shell condition Replace the gear if damaged or if the bushings are scored or worn The bushings are not serviceable Replace the driving shell if worn cracked or da...

Page 2047: ...he output shaft to be sure ASSEMBLY 1 Lubricate output shaft and planetary compo nents with transmission fluid Use petroleum jelly to lubricate and hold thrust washers and plates in posi tion 2 Assemb...

Page 2048: ...un gear ring groove Fig 204 12 Install assembled driving shell and sun gear on output shaft Fig 205 13 Install rear thrust washer on front planetary gear Fig 206 Use enough petroleum jelly to hold was...

Page 2049: ...R 2 DRIVING SHELL 3 WOOD BLOCK Fig 204 Installing Sun Gear Lock Ring 1 LOCK RING GROOVE 2 SUN GEAR LOCK RING 3 DRIVING SHELL 4 REAR THRUST PLATE Fig 205 Installing Assembled Sun Gear And Driving Shell...

Page 2050: ...ers Fig 211 Be sure ring is fully seated 22 Turn planetary geartrain assembly over so driving shell is facing workbench Then support geartrain on wood block positioned under forward end of output shaf...

Page 2051: ...Installing Front Annulus Snap Ring 1 SNAP RING PLIERS 2 FRONT ANNULUS SNAP RING Fig 211 Installing Planetary Selective Snap Ring 1 SELECTIVE SNAP RING 2 SNAP RING PLIERS Fig 212 Checking Planetary Ge...

Page 2052: ...ys and enters the clutch through the hub of the reaction shaft support With pressure applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the cl...

Page 2053: ...iston seals 7 Remove input shaft snap ring Fig 215 It may be necessary to press the input shaft in slightly to relieve tension on the snap ring 8 Press input shaft out of retainer with shop press and...

Page 2054: ...in groove and is not twisted 3 Lubricate splined end of input shaft and clutch retainer with transmission fluid Then press input shaft into retainer Fig 218 Use a suitably sized press tool to support...

Page 2055: ...REAR SEAL RING 2 TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT Fig 218 Pressing Input Shaft Into Rear Clutch Retainer 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3...

Page 2056: ...pring loaded plug The spring is used to cushion the application of the rear low reverse band OPERATION While in the de energized state no pressure applied the piston is held up in its bore by the pis...

Page 2057: ...first second third and over drive fourth gear ranges The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range No further movement o...

Page 2058: ...enoid valve is defined as a valve which allows hydraulic flow when no current or voltage is applied to the solenoid The normally closed sole noid valve is defined as a valve which does not allow hydra...

Page 2059: ...triggered by the park gear lugs as they rotate past the sensor pickup face Input signals from the sensor are sent to the trans mission control module for processing Signals from this sensor are share...

Page 2060: ...thin 1 mm 0 039 in in either direction Fig 231 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 6 Re...

Page 2061: ...T V cable in the set position push the T V cable lock A into the down position Fig 231 This will lock the present T V cable adjustment NOTE Be sure that as the cable is pulled forward and centered on...

Page 2062: ...also provides reduced transmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is servic...

Page 2063: ...tput or driven member of the converter The turbine is mounted within the housing opposite the impeller but is not attached to the housing The input shaft is inserted through the center of the impeller...

Page 2064: ...tor to rotate only in a clockwise direc tion When the stator is locked against the over run ning clutch the torque multiplication feature of the torque converter is operational Fig 234 Turbine 1 TURBI...

Page 2065: ...fluid pressure generated by the impeller rotates and turns the transmission input shaft TURBINE As the fluid that was put into motion by the impel ler blades strikes the blades of the turbine some of...

Page 2066: ...ator 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 way as to cause it...

Page 2067: ...ary The hub must be smooth to avoid damaging the pump seal at installation 1 Lubricate oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not da...

Page 2068: ...assembly and is immersed in transmission fluid at all times OPERATION The PCM prevents engagement of the converter clutch and overdrive clutch when fluid temperature is below approximately 10 C 50 F I...

Page 2069: ...OR 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 T...

Page 2070: ...ER 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 1...

Page 2071: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2072: ...4 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 CAS...

Page 2073: ...tting line pressure from the 3 4 Timing Valve on the interlock area of the 2 3 shift valve thereby preventing a 3rd gear Lock up to 2nd gear kickdown REGULATOR VALVE The pressure regulator valve is ne...

Page 2074: ...nce of the fluid pres sure pushing the valve to the right and the spring pressure pushing to the left determines the size of the metering passage at land 2 land 1 being at the far right of the valve i...

Page 2075: ...gear posi tions 145 280 psi The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there is...

Page 2076: ...Fig 248 Regulator Valve in DRIVE Position Fig 249 Regulator Valve in REVERSE Position BR BE AUTOMATIC TRANSMISSION 44RE 21 441 VALVE BODY Continued...

Page 2077: ...rive breakaway KICKDOWN LIMIT VALVE The purpose of the limit valve is to prevent a 3 2 downshift at higher speeds when a part throttle downshift is not desirable At these higher speeds only a full thr...

Page 2078: ...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...

Page 2079: ...e The result of this increased modulated throttle pressure is a firmer WOT upshift 2 3 SHIFT VALVE The 2 3 shift valve mechanism Fig 256 consists of the 2 3 shift valve governor plug and spring and a...

Page 2080: ...ressure to the 2 3 shift valve With out throttle pressure present in the circuit now the governor plug will push the valve over far enough to bottom the valve in its bore This allows land 2 to direct...

Page 2081: ...upshift into direct drive The theory for the blocking of the valve is the same as that of the 1 2 shift valve 3 4 SHIFT VALVE The PCM energizes the overdrive solenoid during the 3 4 upshift Fig 258 T...

Page 2082: ...ide 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 with...

Page 2083: ...of the transmis sion Once the TCC control valve has moved to the right Fig 262 line pressure is directed to the tip of the switch valve forcing the valve to the right The switch valve now vents oil f...

Page 2084: ...Fig 261 Switch Valve Torque Converter Unlocked BR BE AUTOMATIC TRANSMISSION 44RE 21 449 VALVE BODY Continued...

Page 2085: ...chanism The valve is held in each of its positions by a spring loaded roller or ball that engages the roostercomb of the manual valve lever CONVERTER CLUTCH LOCK UP VALVE The torque converter clutch T...

Page 2086: ...ttle valve controls the qual ity of the kickdown shift by restricting the rate of fluid discharge from the front clutch and servo release circuits During a 3 2 kickdown fluid dis charges through the s...

Page 2087: ...hift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 266 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and g...

Page 2088: ...ht 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 268 R...

Page 2089: ...3 SOLENOID SCREWS 4 GOVERNOR SENSOR WIRES 5 OVERDRIVE SOLENOID 6 HARNESS 7 CASE CONNECTOR Fig 272 Boost Valve 1 BOOST VALVE HOUSING AND COVER 2 BOOST VALVE TUBE Fig 273 Boost Valve Components 1 SPRING...

Page 2090: ...gnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 278 17 Remove screws attaching pressure adjusting screw brack...

Page 2091: ...lve regulator valve and spring and manual valve Fig 281 20 Remove kickdown detent kickdown valve and throttle valve and spring Fig 281 Fig 277 Manual And Throttle Lever 1 PARK ROD 2 MANUAL LEVER ASSEM...

Page 2092: ...n boost valve tube brace Fig 285 Fig 281 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 REGULATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VA...

Page 2093: ...ACCUMULATOR HOUSING 2 CONVERTER CLUTCH VALVE SPRING 3 CLUTCH VALVE PLUG 4 3 4 SHIFT VALVE SPRING Fig 284 Accumulator Housing Valve Springs And Plug 1 3 4 SHIFT VALVE SPRING 2 CONVERTER CLUTCH VALVE SP...

Page 2094: ...g and overdrive separa tor plate from transfer plate Fig 287 29 Remove the ECE check ball from the transfer plate Fig 288 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 30 Remove trans...

Page 2095: ...mit valve and shift valve covers Fig 295 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 295 9 Remove 1 2 shift control valve an...

Page 2096: ...sing 1 SMALL DIAMETER CHECK BALLS 6 2 LARGE DIAMETER CHECK BALL 1 Fig 293 Shuttle Valve E Clip And Secondary Spring Location 1 E CLIP 2 SECONDARY SPRING AND GUIDES 3 SHUTTLE VALVE BR BE AUTOMATIC TRAN...

Page 2097: ...ER 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 1...

Page 2098: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2099: ...ard piston seals Fig 297 Fig 296 Lower Housing Shift Valves and Springs 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 SPR...

Page 2100: ...rn 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 w...

Page 2101: ...during reassembly If the valve body bores valves and plugs are free of distortion or burrs the valve body components should all slide into place easily In addition do not overtighten the transfer pla...

Page 2102: ...The ECE check ball is approximately 4 8 mm 3 16 in in diameter 4 Position lower housing separator plate on transfer plate Fig 303 5 Install lower housing on assembled transfer plate and upper housing...

Page 2103: ...uttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E clip in groove at end of shuttle valve e Verify that spring and E clip are properly seated before proce...

Page 2104: ...ER 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 1...

Page 2105: ...OR 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 T...

Page 2106: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2107: ...clutch valve and 3 4 shift valve springs in housing Fig 311 2 Loosely attach accumulator housing with right side screw Fig 311 Install only one screw at this time as accumulator must be free to pivot...

Page 2108: ...itch valve 16 Position adjusting screw bracket on valve body Align valve springs and press bracket into place Install short upper bracket screws first and long bottom screw last Verify that valve spri...

Page 2109: ...in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 in lbs torque 9 Connect harness wires to governor pressure solenoid and governor pressure sensor 10 Inst...

Page 2110: ...ing installation Make sure the rod is actually engaged in the pawl and has not displaced into this cavity 8 Install accumulator springs and piston into case Then swing valve body over piston and outer...

Page 2111: ...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 To...

Page 2112: ...INSTALLATION 544 FLUID AND FILTER DIAGNOSIS AND TESTING 545 EFFECTS OF INCORRECT FLUID LEVEL 545 CAUSES OF BURNT FLUID 545 FLUID CONTAMINATION 545 STANDARD PROCEDURE 545 FLUID LEVEL CHECK 545 FLUID A...

Page 2113: ...ENTS 646 AUTOMATIC TRANSMISSION 46RE DESCRIPTION The 46RE Fig 1 is a four speed fully automatic transmissions with an electronic governor The 46RE is equipped with a lock up clutch in the torque con v...

Page 2114: ...Fig 1 46RE Transmission BR BE AUTOMATIC TRANSMISSION 46RE 21 479 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2115: ...torque converter clutch engages in fourth gear and in third gear 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 warme...

Page 2116: ...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 sp...

Page 2117: ...ansferred 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...

Page 2118: ...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 carr...

Page 2119: ...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 to...

Page 2120: ...e results Therefore when two members are rotating at the same speed and in the same direction it is the same as being locked up The rear planetary set is also locked up given the sun gear is still the...

Page 2121: ...D TESTING PRELIMINARY Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVE...

Page 2122: ...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 tra...

Page 2123: ...in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward from full forward positi...

Page 2124: ...rnor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing If pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes s...

Page 2125: ...t rear clutch and band operation The test can be conducted with the transmission either in the vehicle or on the work bench as a final check after overhaul Air pressure testing requires that the oil p...

Page 2126: ...HOUSING AREA LEAK CORRECTION 1 Remove converter 2 Tighten front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is...

Page 2127: ...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 P...

Page 2128: ...ves or bores are damaged 5 Transmission Overrunning Clutch Broken 5 Remove and disassemble transmission Replace overrunning clutch 6 Input Shaft Seal Rings Worn Damaged 6 Remove and disassemble transm...

Page 2129: ...5 Adjust linkage cable as described in service section 6 Clutch or Servo Failure 6 Remove valve body and air test clutch and band servo operation Disassemble and repair transmission as needed 7 Govern...

Page 2130: ...in linkage NO KICKDOWN OR NORMAL DOWNSHIFT 1 Throttle Linkage Mis adjusted 1 Adjust linkage 2 Accelerator Pedal Travel Restricted 2 Verify floor mat is not under pedal repair worn accelerator cable or...

Page 2131: ...mbled 2 Route cable away from engine and bell housing 3 Valve Body Mis assembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are dam...

Page 2132: ...ressure check clutch servo operation and repair as required 8 Overrunning Clutch Worn Not Holding Slips in 1 Only 8 Replace Clutch SLIPS IN LOW GEAR 9D9 ONLY BUT NOT IN MANUAL 1 POSITION Overrunning C...

Page 2133: ...equired 2 PCM Malfunction 2 Check PCM operation with DRBT scan tool Replace PCM only if faulty 3 TPS Malfunction 3 Check TPS with DRBT scan tool at PCM 4 Lockup Solenoid Not Venting 4 Remove valve bod...

Page 2134: ...ions with 12V test lamp and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor Malfunction 4 Check with DRBT scan tool and repair or replace as necessary 5 TPS...

Page 2135: ...aft 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 Thr...

Page 2136: ...ttings Loose Leaks Damaged 1 Tighten fittings If leaks persist replace fittings and lines if necessary 2 Fill Tube where tube enters case Leaks Damaged 2 Replace tube seal Inspect tube for cracks in f...

Page 2137: ...is not necessary to remove the entire trans mission assembly to perform overdrive unit repairs 1 Disconnect battery negative cable 2 Disconnect and lower or remove necessary exhaust components 3 Remov...

Page 2138: ...emove assembly from under the vehicle 24 To remove torque converter remove C clamp from edge of bell housing and carefully slide torque converter out of the transmission DISASSEMBLY 1 Clean exterior o...

Page 2139: ...ut of case Then work park rod and valve body out of case Fig 19 10 Remove accumulator outer spring piston and inner spring Fig 20 Note position of piston and springs for assembly reference Remove and...

Page 2140: ...ools C 3752 into threaded holes in flange of oil pump housing Fig 23 d Remove oil pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case Fig 24 Fig 22 Tigh...

Page 2141: ...ide band over front clutch retainer and out of case Fig 27 18 Remove front and rear clutch assemblies as a unit Fig 28 Fig 28 Removing Front Rear Clutch Assemblies 1 FRONT AND REAR CLUTCH ASSEMBLIES F...

Page 2142: ...install Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 24 Loosen rear band locknut and loosen adjust...

Page 2143: ...position of rollers and springs for assembly reference 29 Remove rear band adjusting lever reaction lever and pin Fig 37 30 Remove strut from rear band Keep strut with levers and pin for cleaning ins...

Page 2144: ...e scratched or nicked if care is not exercised 37 Remove tools and remove rear servo retainer spring and piston assembly CLEANING Clean the case in a solvent tank Flush the case bores and fluid passag...

Page 2145: ...nents during assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for reassembly operations are equally clean Shop towels used for wiping off tool...

Page 2146: ...ing to press it back into groove and ease installation Fig 44 Rotate piston into bore at same time Rock piston slightly to ease piston ring past snap ring groove and into bore Fig 41 Rear Servo Piston...

Page 2147: ...Install overrunning clutch components if not yet installed 2 Position rear band and link in case Fig 46 3 Install low reverse drum Fig 47 Slide drum through rear band onto piston retainer hub and int...

Page 2148: ...ment Shaft 6227 2 if installed previously 2 Install assembled intermediate shaft and plane tary geartrain Fig 51 Support shaft carefully dur ing installation Do not allow shaft bearing bushing surface...

Page 2149: ...d rear clutches Fig 54 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...

Page 2150: ...ront 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 11 Slide front band over...

Page 2151: ...part ATF 4 type 9602 6 Mount oil pump on pilot studs and slide pump into case opening Fig 61 Work pump into case by hand Do not use a mallet or similar tools to seat pump 7 Remove pilot studs and inst...

Page 2152: ...position 3 Install new valve body manual shaft seal in case Fig 64 Lubricate seal lip and manual shaft with petroleum jelly Start seal over shaft and into case Seat seal with 15 16 inch deep well soc...

Page 2153: ...ease to ter minal pins of solenoid case connector and neutral switch 6 Fill transmission with recommended fluid Refer to Service Procedures section of this group INSTALLATION 1 Check torque converter...

Page 2154: ...ay old grom met Use pliers to snap new grommet into lever and to snap rod into grommet at assembly 18 Connect gearshift and throttle cable to trans mission 19 Connect wires to park neutral position sw...

Page 2155: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK 21 520 AUTOMATIC TRANSMISSION 46RE BR BE AUTOMATIC TRANSMISSION 46RE Continued...

Page 2156: ...HYDRAULIC FLOW IN NEUTRAL BR BE AUTOMATIC TRANSMISSION 46RE 21 521 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2157: ...HYDRAULIC FLOW IN REVERSE 21 522 AUTOMATIC TRANSMISSION 46RE BR BE AUTOMATIC TRANSMISSION 46RE Continued...

Page 2158: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR BR BE AUTOMATIC TRANSMISSION 46RE 21 523 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2159: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 524 AUTOMATIC TRANSMISSION 46RE BR BE AUTOMATIC TRANSMISSION 46RE Continued...

Page 2160: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED BR BE AUTOMATIC TRANSMISSION 46RE 21 525 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2161: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED 21 526 AUTOMATIC TRANSMISSION 46RE BR BE AUTOMATIC TRANSMISSION 46RE Continued...

Page 2162: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED BR BE AUTOMATIC TRANSMISSION 46RE 21 527 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2163: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED 21 528 AUTOMATIC TRANSMISSION 46RE BR BE AUTOMATIC TRANSMISSION 46RE Continued...

Page 2164: ...HYDRAULIC FLOW IN MANUAL LOW 1 BR BE AUTOMATIC TRANSMISSION 46RE 21 529 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2165: ...HYDRAULIC FLOW IN MANUAL SECOND 2 21 530 AUTOMATIC TRANSMISSION 46RE BR BE AUTOMATIC TRANSMISSION 46RE Continued...

Page 2166: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING BR BE AUTOMATIC TRANSMISSION 46RE 21 531 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2167: ...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...

Page 2168: ...5 psi at stand still will prevent transmission from downshifting TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fitting cooler line at trans 18 13 Bolt torque convertor 31 23 Bolt clevis bracket...

Page 2169: ...Detent Ball and Spring 6583 Gauge Block 6312 Fixture Engine Support C 3487 A Stand Transmission Repair C 3750 B Compressor Spring C 3863 A Spring Compressor and Alignment Shaft 6227 Bar Gauge 6311 St...

Page 2170: ...Compressor Spring C 3422 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer Seal C 3860 A Remover Seal C 3985 B Installer Overdrive Piston Seal 8114 Installer Seal C 3995 A BR BE AU...

Page 2171: ...3887 J Remover Front Clutch Bushing SP 3629 From kit C 3887 J Cup Bushing Remover SP 3633 From kit C 3887 J Installer Oil Pump Bushing SP 5118 From kit C 3887 J Remover Reaction Shaft Bushing SP 5301...

Page 2172: ...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...

Page 2173: ...to the transmission case and the other is acted on with a pushing force by a servo piston The front band is a single wrap design the band does not completely encompass wrap the drum that it holds LOW...

Page 2174: ...evers 1 Raise vehicle 2 Loosen band adjusting screw locknut Fig 73 Then back locknut off 3 5 turns Be sure adjusting screw turns freely in case Apply lubricant to screw threads if necessary 3 Tighten...

Page 2175: ...ifts It is an electro hydraulic device located in the governor body on the valve body trans fer plate Fig 75 GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the gover...

Page 2176: ...ontrol cir cuit GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM This feedback is needed to ade quately control governor pressure GOVERNOR BODY AND TRANSFER...

Page 2177: ...nsfer case is in low range REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove transmission fluid pan and filter 3 Disengage wire connectors from pressure sen sor and solenoid Fig 77 4 Remov...

Page 2178: ...re solenoid to bore in governor body Fig 82 9 Push solenoid into governor body 10 Place solenoid retainer in position on governor Fig 83 11 Install screws to hold pressure solenoid retainer to governo...

Page 2179: ...l with Seal Remover C 3985 B Fig 87 from overdrive housing INSTALLATION 1 Place seal in position on overdrive housing 2 Drive seal into overdrive housing with Seal Installer C 3995 A Fig 88 3 Carefull...

Page 2180: ...ot removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remed...

Page 2181: ...pe 9602 to restore correct level Do not overfill PROCEDURE TWO 1 Start engine and apply parking brake 2 Shift the transmission into DRIVE for approxi mately 2 seconds 3 Shift the transmission into REV...

Page 2182: ...ere 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 pints 6 quarts of ATF 4...

Page 2183: ...allowing torque to flow through the input shaft into the driving discs and into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the...

Page 2184: ...lutch piston inner and outer seals 7 Assemble Tool Handle C 4171 and Bushing Remover SP 3629 Fig 96 8 Insert remover tool in bushing and drive bush ing straight out of clutch retainer Fig 94 Removing...

Page 2185: ...the ball is missing or seized in place ASSEMBLY NOTE The 46RE transmission uses three plates and discs for the front clutch 1 Mount Bushing Installer SP 5511 on tool han dle Fig 97 2 Slide new bushin...

Page 2186: ...aved snap ring 16 Check clutch pack clearance with feeler gauge Fig 99 Clearance between waved spring and pres sure plate should 1 78 3 28 mm 0 070 0 129 in If clearance is incorrect clutch plates clu...

Page 2187: ...e front clutch application is taking place Otherwise engine runaway or a shift hesitation will occur To accomplish this the band retains its holding capacity until the front clutch is applied giving a...

Page 2188: ...an 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 2 Install rod in piston Install spring and washer on rod Comp...

Page 2189: ...Measuring the oil pump output volume will deter mine if sufficient oil flow to the transmission oil cooler exists and whether or not an internal trans mission failure is present Verify that the trans...

Page 2190: ...smission to proper level DISASSEMBLY 1 Mark position of support in oil pump body for assembly alignment reference Use scriber or paint to make alignment marks 2 Place pump body on two wood blocks 3 Re...

Page 2191: ...y 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 21 556 AUTOMATIC TRANSMISSION 46RE...

Page 2192: ...n scored pitted or dam aged Replace the pump gears if pitted worn chipped or damaged Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn...

Page 2193: ...llow bushing to become cocked during installation 4 Stake pump bushing in two places with blunt punch Remove burrs from stake points with knife blade Fig 113 REACTION SHAFT SUPPORT BUSHING 1 Place rea...

Page 2194: ...tall bolts attaching reaction shaft support to pump Tighten bolts to 20 N m 175 in lbs torque 6 Install new pump seal with Installer Tool C 3860 A Fig 115 Use hammer or mallet to tap seal into place 7...

Page 2195: ...with each engine and vehicle combination OPERATION To apply the clutch pressure is applied between the piston retainer and piston The fluid pressure is provided by the oil pump transferred through th...

Page 2196: ...ire 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 h...

Page 2197: ...cer It is a select fit part and may possibly be reused Fig 120 Transmission Speed Sensor 1 SOCKET AND WRENCH 2 SPEED SENSOR 3 O RING Fig 121 Overdrive Piston Thrust Bearing Removal Installation 1 THRU...

Page 2198: ...ave spring Fig 128 Fig 124 Overdrive Piston Removal 1 PISTON RETAINER 2 OVERDRIVE PISTON Fig 125 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig 126 Overdrive...

Page 2199: ...shaft bearing from locating ring Fig 132 6 Lift gear case up and off geartrain assembly Fig 133 Fig 129 Overdrive Clutch Reaction Snap Ring Removal 1 REACTION RING 2 CLUTCH HUB Fig 130 Access Cover S...

Page 2200: ...p press Fig 135 2 Position Compressor Tool 6227 1 on clutch hub Fig 135 Support output shaft flange with steel press plates as shown and center assembly under press ram 3 Apply press pressure slowly C...

Page 2201: ...DIRECT CLUTCH PACK SNAP RING 4 PRESS PLATES 5 CLUTCH DRUM Fig 137 Direct Clutch Hub Retaining Ring Removal 1 SPECIAL TOOL 6227 1 2 CLUTCH HUB RETAINING RING 3 PRESS BED 4 PRESS PLATES Fig 138 Direct...

Page 2202: ...irect clutch drum outer retaining ring Fig 144 9 Mark annulus gear and output shaft for assem bly alignment reference Fig 145 Use punch or scriber to mark gear and shaft Fig 141 Overrunning Clutch Ass...

Page 2203: ...ow bearings to air dry Do not use shop towels for wiping parts dry unless the towels are made from a lint free material A suf ficient quantity of lint from shop towels cloths rags etc could plug the t...

Page 2204: ...iced separately The planetary carrier and pinions must be in good condition Also be sure the pinion pins are secure and in good condition Replace the carrier if worn or dam aged Inspect the overrunnin...

Page 2205: ...eat squarely 10 Install overrunning clutch in output shaft Fig 154 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion 11 Insta...

Page 2206: ...r to install with assem bly mounted in press 16 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 158 Insert tool through sun gear and into splines of Fig 1...

Page 2207: ...tion plate is counterbored Be sure this side faces rearward Splines at rear of hub are raised slightly Counter bore in plate fits over raised splines Plate should be flush with this end of hub Fig 161...

Page 2208: ...MUM RAM TRAVEL OF 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 20 Position Compresso...

Page 2209: ...p ring 4 Install reaction plug snap ring Fig 167 Com press snap ring only enough for installation do not distort it 5 Install new seal in gear case Use Handle C 4171 and Installer C 3995 A to seat sea...

Page 2210: ...securely in groove Also ensure that the ends of the two rings are offset from each other 3 Assemble overdrive clutch pack Fig 174 Fig 168 Correct Rear Bearing Locating Ring Position 1 CASE ACCESS HOLE...

Page 2211: ...ear planetary 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 176 Then position Dial Caliper C...

Page 2212: ...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...

Page 2213: ...lignment Tool 6227 2 out of over drive planetary gear and overrunning clutch splines 10 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reac...

Page 2214: ...nent 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 rem...

Page 2215: ...he clutch is locked and acts as one unit DISASSEMBLY 1 Remove the overdrive piston Fig 187 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Tap ol...

Page 2216: ...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 189 4 Insert Adapter Tool SP 5124 into piston retainer Fi...

Page 2217: ...gasket with feed passages in case Fig 194 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 14 Position overdri...

Page 2218: ...l and the transmission case Continuity should exist only when the transmission is in PARK or NEUTRAL Shift the transmission into REVERSE and test continuity at the switch outer terminals Continuity sh...

Page 2219: ...te pressure Piston sealing is extremely important in hydraulic operation Several kinds of seals are used to accomplish this within a transmission These include but are not limited to O rings D rings l...

Page 2220: ...he input piston at the jack handle must move 20 inches downward PLANETARY GEARTRAIN OUTPUT SHAFT DESCRIPTION The planetary gearsets Fig 201 are designated as the front rear and overdrive planetary gea...

Page 2221: ...position for assembly reference 4 Remove tabbed thrust washer from driving shell Fig 205 Note washer position for assembly reference 5 Remove sun gear and driving shell as assembly Fig 206 Fig 202 Rem...

Page 2222: ...r 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 r...

Page 2223: ...ate in driving shell 3 Install rear annulus gear on intermediate shaft Fig 211 4 Install thrust plate in annulus gear Fig 212 Be sure plate is seated on shaft splines and against gear 5 Install rear p...

Page 2224: ...riving shell Use extra petroleum jelly to hold washer in place if desired 10 Install tabbed thrust washer on front plane tary gear Fig 217 Seat washer tabs in matching slots in face of gear carrier Us...

Page 2225: ...nts are assembled correctly 14 Install new planetary snap ring in groove at end of intermediate shaft Fig 220 15 Turn planetary geartrain over Position wood block under front end of intermediate shaft...

Page 2226: ...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 numbe...

Page 2227: ...The check valve is needed to eliminate the pos sibility of plate drag caused by centrifugal force acting on the residual fluid trapped in the clutch pis ton retainer DISASSEMBLY 1 Remove fiber thrust...

Page 2228: ...d or damaged in any way ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install new seal rings on clutch retainer hub and input shaft if necessary a Be sure cl...

Page 2229: ...rvo consists of a single stage or diameter piston and a spring loaded plug The spring is used to cushion the application of the rear low reverse band OPERATION While in the de energized state no press...

Page 2230: ...rth gear range occurs only after the transmission has completed the shift into D third gear range No further movement of the shift mechanism is required to complete the 3 4 shift The fourth gear upshi...

Page 2231: ...enoid valve is defined as a valve which allows hydraulic flow when no current or voltage is applied to the solenoid The normally closed sole noid valve is defined as a valve which does not allow hydra...

Page 2232: ...N The speed sensor Fig 231 is located in the over drive gear case The sensor is positioned over the park gear and monitors transmission output shaft rotating speed OPERATION Speed sensor signals are t...

Page 2233: ...off attachment stud on throttle body lever 5 Compare position of cable end to attachment stud on throttle body lever Cable end and attachment stud should be aligned or centered on one another to with...

Page 2234: ...T V cable in the set position push the T V cable lock A into the down position Fig 236 This will lock the present T V cable adjustment NOTE Be sure that as the cable is pulled forward and centered on...

Page 2235: ...also provides reduced transmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is servic...

Page 2236: ...e 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 238 Impeller 1 ENGINE FLEXPLATE 4 ENGI...

Page 2237: ...hrough 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 239 Turbin...

Page 2238: ...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 mechan...

Page 2239: ...tating 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 st...

Page 2240: ...orque converter hub into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge...

Page 2241: ...ine Other wise flow will be blocked and would cause an over heating condition and eventual transmission failure TRANSMISSION TEMPERATURE SENSOR DESCRIPTION Transmission fluid temperature readings are...

Page 2242: ...shift valve 3 4 timing valve 3 4 quick fill valve 3 4 accumulator Throttle valve Throttle pressure plug Switch valve Manual valve Converter clutch lock up valve Converter clutch lock up timing Valve...

Page 2243: ...ER 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 1...

Page 2244: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2245: ...4 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 CAS...

Page 2246: ...rects line pressure to the spring end of the 2 3 shift valve in either Manual Low or Manual 2nd forcing the downshift to 2nd gear regardless of governor pressure 6 Provides a by pass around the front...

Page 2247: ...ncrease 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 th...

Page 2248: ...ring 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...

Page 2249: ...Fig 253 Regulator Valve in DRIVE Position Fig 254 Regulator Valve in REVERSE Position 21 614 AUTOMATIC TRANSMISSION 46RE BR BE VALVE BODY Continued...

Page 2250: ...ht 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 va...

Page 2251: ...ttom 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 o...

Page 2252: ...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...

Page 2253: ...e pressure will then dead end at land 2 until the 2 3 valve is ready to make its shift Now that the vehicle is in motion and under acceleration there is throttle pressure being applied to the spring s...

Page 2254: ...ion preventing an upshift into direct drive The theory for the blocking of the valve is the same as that of the 1 2 shift valve Fig 261 2 3 Shift Valve Before Shift Fig 262 2 3 Shift Valve After Shift...

Page 2255: ...hift valve in an upshift position The purpose is to prevent the 2 3 valve from downshifting before the 3 4 valve Fig 263 3 4 QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of the...

Page 2256: ...ressure plug on the pressure valve The larger spring at the right closes the regulator valve passage and maintains or increases line pressure The increased line pressure works against the reac tion ar...

Page 2257: ...smission 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 direct...

Page 2258: ...y 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 sh...

Page 2259: ...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 posit...

Page 2260: ...utch 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...

Page 2261: ...vernor 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 smal...

Page 2262: ...ERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 276 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLENOID 3 SOLENOID SCREWS 4 GOVERNOR SENSOR WIRES 5 OVERDRIVE SOLENOID 6 HA...

Page 2263: ...nd lift manual lever off valve body and throttle lever shaft Then slide throttle lever out of valve body Fig 279 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 280 Park Rod 1...

Page 2264: ...spring and switch valve spring Fig 285 Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal Fig 285 Adjusting Screw Bracket...

Page 2265: ...rock opposite end of tube back and forth to work it out of lower housing CAUTION Do not use tools to loosen or pry the connecting tube out of the valve body housings Loosen and remove the tube by hand...

Page 2266: ...ST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4 UPPER HOUSING Fig 292 Lower Housing 1 LOWER HOUSING 2 OVERDRIVE SEPARATOR PLATE 3 TRANSFER PLATE AND UPPER HOUSING Fig 288 3 4 Shift...

Page 2267: ...ator plate for assembly reference 33 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 296 Fig 293 ECE Check Ball 1 ECE CHECK BALL 3...

Page 2268: ...pper housing around and remove limit valve and shift valve covers Fig 300 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 300 9...

Page 2269: ...R 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...

Page 2270: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2271: ...ings 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 1...

Page 2272: ...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...

Page 2273: ...ld all slide into place easily In addition do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve sticking cross leak...

Page 2274: ...lower housing separator plate on transfer plate Fig 308 5 Install lower housing on assembled transfer plate and upper housing Fig 309 6 Install and start all valve body screws by hand except for the s...

Page 2275: ...ng and cover plate Tighten screws to 4 N m 35 in lbs 7 Install shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Install shuttle...

Page 2276: ...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 311 Upper Housing Control Valve Locations 1 UPPER HOUSING 8...

Page 2277: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2278: ...in lbs torque after tube and brace are installed Tighten screws in diagonal pattern starting at center and working outward 3 4 ACCUMULATOR 1 Position converter clutch valve and 3 4 shift valve springs...

Page 2279: ...ove detent ball retainer tool after lever is seated 6 Then install manual lever seal washer and E clip 7 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm...

Page 2280: ...Align screw holes in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 in lbs torque 9 Connect harness wires to governor pressure solenoid and governor pressu...

Page 2281: ...eck and adjust gearshift and throttle valve cables if necessary ADJUSTMENTS VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body Line Pressure Throttle...

Page 2282: ...and bottom the throt tle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge...

Page 2283: ...INSTALLATION 715 FLUID AND FILTER DIAGNOSIS AND TESTING 715 EFFECTS OF INCORRECT FLUID LEVEL 715 CAUSES OF BURNT FLUID 715 FLUID CONTAMINATION 715 STANDARD PROCEDURE 715 FLUID LEVEL CHECK 715 FLUID A...

Page 2284: ...ENTS 818 AUTOMATIC TRANSMISSION 47RE DESCRIPTION The 47RE Fig 1 is a four speed fully automatic transmissions with an electronic governor The 47RE is equipped with a lock up clutch in the torque con v...

Page 2285: ...Fig 1 47RE Transmission 21 650 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2286: ...e converter clutch engages in fourth gear and in third gear 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...

Page 2287: ...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 sp...

Page 2288: ...ansferred 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...

Page 2289: ...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 carr...

Page 2290: ...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 to...

Page 2291: ...e results Therefore when two members are rotating at the same speed and in the same direction it is the same as being locked up The rear planetary set is also locked up given the sun gear is still the...

Page 2292: ...D TESTING PRELIMINARY Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVE...

Page 2293: ...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 tra...

Page 2294: ...in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward from full forward positi...

Page 2295: ...rnor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing If pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes s...

Page 2296: ...t rear clutch and band operation The test can be conducted with the transmission either in the vehicle or on the work bench as a final check after overhaul Air pressure testing requires that the oil p...

Page 2297: ...HOUSING AREA LEAK CORRECTION 1 Remove converter 2 Tighten front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is...

Page 2298: ...eded 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 pro...

Page 2299: ...h Broken 5 Remove and disassemble transmission Replace overrunning clutch 6 Input Shaft Seal Rings Worn Damaged 6 Remove and disassemble transmission Replace seal rings and any other worn or damaged p...

Page 2300: ...e body and air test clutch and band servo operation Disassemble and repair transmission as needed 7 Governor Circuit Electrical Fault 7 Test using DRBT scan tool and repair as required 8 Front Band Mi...

Page 2301: ...in linkage NO KICKDOWN OR NORMAL DOWNSHIFT 1 Throttle Linkage Mis adjusted 1 Adjust linkage 2 Accelerator Pedal Travel Restricted 2 Verify floor mat is not under pedal repair worn accelerator cable or...

Page 2302: ...mbled 2 Route cable away from engine and bell housing 3 Valve Body Mis assembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are dam...

Page 2303: ...ressure check clutch servo operation and repair as required 8 Overrunning Clutch Worn Not Holding Slips in 1 Only 8 Replace Clutch SLIPS IN LOW GEAR 9D9 ONLY BUT NOT IN MANUAL 1 POSITION Overrunning C...

Page 2304: ...equired 2 PCM Malfunction 2 Check PCM operation with DRBT scan tool Replace PCM only if faulty 3 TPS Malfunction 3 Check TPS with DRBT scan tool at PCM 4 Lockup Solenoid Not Venting 4 Remove valve bod...

Page 2305: ...ions with 12V test lamp and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor Malfunction 4 Check with DRBT scan tool and repair or replace as necessary 5 TPS...

Page 2306: ...aft 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 Thr...

Page 2307: ...ttings Loose Leaks Damaged 1 Tighten fittings If leaks persist replace fittings and lines if necessary 2 Fill Tube where tube enters case Leaks Damaged 2 Replace tube seal Inspect tube for cracks in f...

Page 2308: ...s not necessary to remove the entire transmission assembly to perform overdrive unit repairs 1 Disconnect battery negative cable 2 Disconnect and lower or remove necessary exhaust components 3 Remove...

Page 2309: ...move assembly from under the vehicle 24 To remove torque converter remove C clamp from edge of bell housing and carefully slide torque converter out of the transmission DISASSEMBLY 1 Clean exterior of...

Page 2310: ...ut of case Fig 19 10 Remove accumulator outer spring piston and inner spring Fig 20 Note position of piston and springs for assembly reference Remove and discard piston seals if worn or cut 11 Remove...

Page 2311: ...oil pump housing Fig 23 Fig 22 Tightening Front Band To Hold Front Clutch In Place 1 LOCK NUT 2 FRONT BAND ADJUSTER Fig 23 Oil Pump Removal Tools 1 PUMP HOUSING 2 SLIDE HAMMER TOOLS THREAD INTO PUMP...

Page 2312: ...y loose 16 Remove front band strut and anchor Fig 26 17 Squeeze front band together slightly and slide band over front clutch retainer and out of case Fig 27 Fig 24 Oil Pump Removal 1 OIL PUMP AND REA...

Page 2313: ...stall Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 24 Loosen rear band locknut and loosen adjust ing...

Page 2314: ...he race Fig 35 Overrunning Clutch Race Position On Low Reverse Drum 1 OVERRUNNING CLUTCH RACE 2 LOW REVERSE DRUM Fig 32 Intermediate Shaft And Planetary Geartrain 1 INTERMEDIATE SHAFT AND PLANETARY GE...

Page 2315: ...rk removal tool around back of snap ring until free of ring groove Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 36 Remove tools and remove re...

Page 2316: ...o make sure the tools and workbench area used for reassembly operations are equally clean Shop towels used for wiping off tools and your hands must be made from lint free materials Lint will stick to...

Page 2317: ...r size tool on guide and position C clamp on tool and case Fig 43 b Slowly compress rod guide while simulta neously easing seal ring into bore with suitable tool 9 Install rod guide snap ring Fig 43 F...

Page 2318: ...sure lever and the single lug on the band are aligned and engaged before seating band pivot pin in case PLANETARY GEARTRAIN FRONT REAR CLUTCH AND FRONT BAND 1 Remove Alignment Shaft 6227 2 if installe...

Page 2319: ...Use petroleum jelly to hold washer in place Position washer so grooves are facing outward Washer only fits one way in clutch retainer hub 7 Place transmission case in upright position or place blocks...

Page 2320: ...ighten front band adjusting screw until band is tight on clutch retainer This will hold clutches in place while oil pump is being installed Verify that front rear clutch assembly is still properly sea...

Page 2321: ...into case by hand Do not use a mallet or similar tools to seat pump 7 Remove pilot studs and install oil pump bolts Tighten pump bolts alternately and evenly to fully seat pump in case Then final tigh...

Page 2322: ...as follows a Start park rod into park pawl If rod will not slide past park pawl pawl is engaged in park gear Rotate overdrive output shaft with suitable size 12 point socket this will free pawl and a...

Page 2323: ...converter lugs should be 19mm 0 75 in to the rear of straightedge when the converter is fully seated 7 Temporarily secure converter with C clamp 8 Position transmission on jack and secure it with cha...

Page 2324: ...s 21 Install converter housing access cover 22 Install starter motor and cooler line bracket Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 23 Connect cooler lines to transmission 24 Instal...

Page 2325: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK 21 690 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2326: ...HYDRAULIC FLOW IN NEUTRAL BR BE AUTOMATIC TRANSMISSION 47RE 21 691 AUTOMATIC TRANSMISSION 47RE Continued...

Page 2327: ...HYDRAULIC FLOW IN REVERSE 21 692 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2328: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR BR BE AUTOMATIC TRANSMISSION 47RE 21 693 AUTOMATIC TRANSMISSION 47RE Continued...

Page 2329: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 694 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2330: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED BR BE AUTOMATIC TRANSMISSION 47RE 21 695 AUTOMATIC TRANSMISSION 47RE Continued...

Page 2331: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED 21 696 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2332: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED BR BE AUTOMATIC TRANSMISSION 47RE 21 697 AUTOMATIC TRANSMISSION 47RE Continued...

Page 2333: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED 21 698 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2334: ...HYDRAULIC FLOW IN MANUAL LOW 1 BR BE AUTOMATIC TRANSMISSION 47RE 21 699 AUTOMATIC TRANSMISSION 47RE Continued...

Page 2335: ...HYDRAULIC FLOW IN MANUAL SECOND 2 21 700 AUTOMATIC TRANSMISSION 47RE BR BE AUTOMATIC TRANSMISSION 47RE Continued...

Page 2336: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING BR BE AUTOMATIC TRANSMISSION 47RE 21 701 AUTOMATIC TRANSMISSION 47RE Continued...

Page 2337: ...IMENSIONS 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 Inte...

Page 2338: ...kPa 1 5 psi at stand still will prevent transmission 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 br...

Page 2339: ...g 6951 Retainer Detent Ball and Spring 6583 Gauge Block 6312 Fixture Engine Support C 3487 A Stand Transmission Repair C 3750 B Compressor Spring C 3863 A Spring Compressor and Alignment Shaft 6227 Ba...

Page 2340: ...P Set Dial Indicator C 3339 Compressor Spring C 3422 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer Seal C 3860 A Remover Seal C 3985 B Installer Overdrive Piston Seal 8114 BR BE...

Page 2341: ...ing Remover Installer C 3887 J Nut Bushing Remover SP 1191 From kit C 3887 J Remover Front Clutch Bushing SP 3629 From kit C 3887 J Cup Bushing Remover SP 3633 From kit C 3887 J Installer Oil Pump Bus...

Page 2342: ...ody Fig 61 Remover Reaction Shaft Bushing SP 5301 From Kit C 3887 J Installer Reaction Shaft Bushing SP 5302 From kit C 3887 J Installer Front Clutch Bushing SP 5511 From kit C 3887 J Remover Bushing...

Page 2343: ...ine pressure will fin ish pushing the accumulator up into its bore When the large end of the accumulator piston is seated in its bore the band or clutch is fully applied NOTE The accumulator is shown...

Page 2344: ...o the sun gear driving shell and in turn splined directly to the sun gear The application of the band by the servo is typ ically done by an apply lever and link bar LOW REVERSE REAR BAND The rear band...

Page 2345: ...which regulates the governor pressure needed for upshifts and downshifts It is an electro hydraulic device located in the governor body on the valve body trans fer plate Fig 69 GOVERNOR PRESSURE SENS...

Page 2346: ...s sets the maximum governor pressure The powertrain control module PCM turns on the trans control relay which supplies electrical power to the solenoid valve Operating voltage is 12 volts DC The PCM c...

Page 2347: ...celerate to its peak more rapidly than in Normal range resulting in delayed shifts and undesirable engine 9flare 9 The low range governor pressure curve is also higher than normal to initiate upshifts...

Page 2348: ...re 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 76 9 Push solenoid...

Page 2349: ...l seal in housing using Seal Installer C 3995 A Fig 80 EXTENSION HOUSING SEAL REMOVAL 1 Raise vehicle 2 Mark propeller shaft and axle yoke for align ment reference 3 Disconnect and remove propeller sh...

Page 2350: ...n is generally a result of adding incorrect fluid failure to clean dipstick and fill tube when checking level engine coolant entering the fluid internal failure that generates debris overheat that gen...

Page 2351: ...must be at normal operat ing temperature for accurate fluid level check Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 C 180 F 2 Position vehicle on...

Page 2352: ...ding rear of pan to transmis sion 5 Slowly separate front of pan away from trans mission allowing the fluid to drain into drain pan 6 Hold up pan and remove remaining bolt hold ing pan to transmission...

Page 2353: ...T CLUTCH DESCRIPTION The front clutch assembly Fig 87 is composed of the front clutch retainer pressure plate clutch plates driving discs piston piston return spring return spring retainer and snap ri...

Page 2354: ...with a twisting motion 6 Remove and discard clutch piston inner and outer seals 7 Assemble Tool Handle C 4171 and Bushing Remover SP 3629 Fig 90 8 Insert remover tool in bushing and drive bush ing str...

Page 2355: ...omponents 1 INNER PISTON SEAL 7 CLUTCH DISCS 2 CLUTCH PISTON 8 RETAINER SNAP RING 3 CLUTCH PISTON SPRING RETAINER 9 CLUTCH PISTON SPRINGS 9 4 CLUTCH PLATES 10 OUTER PISTON SEAL 5 CLUTCH PACK SNAP RING...

Page 2356: ...f the ball is missing or seized in place ASSEMBLY NOTE The 47RE transmission uses four plates and discs for the front clutch 1 Mount Bushing Installer SP 5511 on tool han dle Fig 91 2 Slide new bushin...

Page 2357: ...aved snap ring 16 Check clutch pack clearance with feeler gauge Fig 93 Clearance between waved spring and pres sure plate should 1 78 3 28 mm 0 070 0 129 in If clearance is incorrect clutch plates clu...

Page 2358: ...rod Then remove piston rod spring and washer from pis ton 3 Remove and discard servo component O ring and seal rings CLEANING Clean the servo piston components Fig 96 with solvent and dry them with c...

Page 2359: ...mission to the proper level with Mopart ATF 4 type 9602 Auto matic Transmission Fluid 1 Disconnect the To cooler line at the cooler inlet and place a collecting container under the dis connected line...

Page 2360: ...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 BR BE AUTOMATIC TRANSMISSION 47RE 21...

Page 2361: ...te support from pump body Fig 100 4 Remove pump inner and outer gears Fig 101 5 Remove o ring seal from pump body Fig 102 Discard seal after removal 6 Remove oil pump seal with Remover Tool C 3981 Dis...

Page 2362: ...y 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 BR BE AUTOMATIC TRANSMISSION 47RE 2...

Page 2363: ...n scored pitted or dam aged Replace the pump gears if pitted worn chipped or damaged Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn...

Page 2364: ...g 106 2 Place bushing on installer tool and start bush ing into shaft 3 Tap bushing into place until Installer Tool SP 5118 bottoms in pump cavity Keep tool and bush ing square with bore Do not allow...

Page 2365: ...rwise the rings will either prevent pump installation or break during installation 4 Align and install reaction shaft support on pump body 5 Install bolts attaching reaction shaft support to pump Tigh...

Page 2366: ...ansmission case NOTE The number of discs and plates may vary with each engine and vehicle combination OPERATION To apply the clutch pressure is applied between the piston retainer and piston The fluid...

Page 2367: ...gnition switch is cycled OFF and ON The normal position for the con trol switch is the ON position The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control swit...

Page 2368: ...nsfer case if equipped 4 Mark propeller shaft universal joint s and axle pinion yoke or the companion flange and flange yoke for alignment reference at installation if necc esary 5 Disconnect and remo...

Page 2369: ...g Bearing may remain on piston or in clutch hub during removal 13 Position drain pan on workbench 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 15 Examine fluid fo...

Page 2370: ...ig 123 2 Remove overdrive clutch pack Fig 124 3 Note position of clutch pack components for assembly reference Fig 125 Fig 120 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PISTON 2 O...

Page 2371: ...rive Clutch Pack Removal 1 OVERDRIVE CLUTCH PACK Fig 125 Overdrive Clutch Component Position Typical 1 REACTION PLATE 3 PRESSURE PLATE 2 CLUTCH PLATES 3 4 CLUTCH DISCS 4 Fig 126 Overdrive Clutch Wave...

Page 2372: ...AVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 1 Mount geartrain assembly in...

Page 2373: ...op Press 1 PRESS RAM 2 SPECIAL TOOL C 3995 A OR SIMILAR TOOL 3 CLUTCH HUB 4 PLATES 5 PRESS BED 6 SPECIAL TOOL 6227 1 Fig 134 Direct Clutch Pack Snap Ring Removal 1 CLUTCH HUB 2 SPECIAL TOOL 6227 1 3 D...

Page 2374: ...osition of annulus gear and direct clutch drum for assembly alignment reference Fig 140 Use small center punch or scriber to make alignment marks Fig 136 Direct Clutch Pack Removal 1 SPECIAL TOOL 6227...

Page 2375: ...king Direct Clutch Drum And Annulus Gear For Assembly Alignment 1 DIRECT CLUTCH DRUM 2 HAMMER 3 PUNCH Fig 141 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2 DIRECT CLUTCH DRUM 3 ANN...

Page 2376: ...Check condition of the park lock components and the overdrive case Check the bushings in the overdrive case Replace the bushings if severely scored or worn Also replace the case seal if loose distorte...

Page 2377: ...verrunning clutch hub bushing Replace either bushing if scored pitted cracked or worn ASSEMBLY GEARTRAIN AND DIRECT CLUTCH 1 Soak direct clutch and overdrive clutch discs in Mopart ATF 4 type 9602 tra...

Page 2378: ...tary gear in annulus gear Fig 153 Be sure planetary pinions are fully seated in annulus gear before proceeding 12 Coat planetary thrust bearing and bearing contact surface of spring plate with generou...

Page 2379: ...g 157 Be sure spring is properly seated on spring plate NOTE The direct clutch in a 47RE transmission uses 10 clutch discs Fig 152 Overrunning Clutch Installation 1 CLUTCH DRUM 2 OVERRUNNING CLUTCH AS...

Page 2380: ...plate This is last clutch pack item to be installed Be sure plate is installed with shoulder side facing upward Fig 159 19 Install clutch hub and clutch pack on direct clutch spring Fig 160 Be sure hu...

Page 2381: ...ly enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 23 Realign clutch pack on hub and seat clutch discs and plates in clutch drum 24 Install direct clutch pack sna...

Page 2382: ...aller C 3995 A to seat seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 165 7 Support geartrain on Tool 6227 1 Fig 166 Be sure tool is securel...

Page 2383: ...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 reac...

Page 2384: ...d Fig 172 d Select proper thickness end play spacer from spacer chart based on distance measured Fig 173 e Remove Gauge Alignment Tool 6312 OD THRUST PLATE SELECTION 1 Place overdrive unit in vertical...

Page 2385: ...ton 8 Install overdrive piston thrust bearing on over drive piston 9 Install transmission speed sensor and o ring seal in overdrive case INSTALLATION 1 Be sure overdrive unit Alignment Tool 6227 2 is...

Page 2386: ...15 Align and install rear propeller shaft if nec essary Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER DESCRIPTION The...

Page 2387: ...nt is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damage...

Page 2388: ...ughly Be sure any chips shavings generated during 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...

Page 2389: ...ve piston to the two mating holes in retainer b Lubricate overdrive piston seals with Mopart Door Ease or equivalent c Install piston over Seal Guide 8114 3 and inside Guide Ring 8114 1 d Push overdri...

Page 2390: ...UTRAL posi tions Verify that switch operating lever fingers are centered in switch opening in case Fig 188 2 Install new seal on switch and install switch in case Tighten switch to 34 N m 25 ft lbs to...

Page 2391: ...ontainer FORCE MULTIPLICATION Using the 10 PSI example used in the illustration Fig 191 a force of 1000 lbs can be moved with a force of only 100 lbs The secret of force multiplica tion in hydraulic s...

Page 2392: ...iven or used as an input The third member may be used as an output for power flow For direct drive to occur two gear members in the front planetary gearset must be driven NOTE Gear ratios are dependen...

Page 2393: ...NNULUS GEAR 3 FRONT PLANETARY GEAR Fig 196 Disassembling Front Planetary And Annulus Gears 1 FRONT PLANETARY GEAR 2 TABBED THRUST WASHER 3 FRONT ANNULUS GEAR Fig 197 Driving Shell Thrust Washer Remova...

Page 2394: ...8 Sun Gear And Driving Shell Removal 1 INTERMEDIATE SHAFT 2 DRIVING SHELL 3 SUN GEAR Fig 199 Rear Planetary Thrust Washer Removal 1 SUN GEAR 2 REAR PLANETARY THRUST WASHER 3 DRIVING SHELL Fig 200 Rear...

Page 2395: ...s are not serviceable Replace the thrust plate if worn or severely scored Replace the driving shell if distorted cracked or damaged in any way Replace all snap rings during geartrain assembly Reusing...

Page 2396: ...was not displaced during installation 9 Install tabbed thrust washer in driving shell Fig 208 be sure washer tabs are seated in tab slots of driving shell Use extra petroleum jelly to hold washer in p...

Page 2397: ...d 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 1...

Page 2398: ...lus Gear Assembly 1 DRIVING SHELL 2 ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS Fig 212 Installing Planetary Snap Ring 1 SNAP RING PLIERS 2 PLANETARY SNAP RING Fig 213 Checking Planetary Geartrain End...

Page 2399: ...pack allowing torque to flow through the input shaft into the driving discs and into the clutch plates and pressure plate that are lugged to the clutch retainer The waved spring is used to cushion the...

Page 2400: ...d worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs on the pressure and...

Page 2401: ...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 s...

Page 2402: ...up in its bore by the pis ton spring The plug is held down in its bore in the piston by the plug spring When pressure is applied to the top of the piston the plug is forced down in its bore taking up...

Page 2403: ...SECOND 2 Manual LOW 1 OPERATION Manual LOW 1 range provides first gear only Overrun braking is also provided in this range Man ual SECOND 2 range provides first and second gear only DRIVE range provi...

Page 2404: ...uses a magnetic force to perform work It consists of a coil of wire wrapped around a magnetic core made from steel or iron and a spring loaded movable plunger which performs the work or straight line...

Page 2405: ...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...

Page 2406: ...IFICATION 1 Turn ignition key to OFF position 2 Remove air cleaner 3 Verify that lever on throttle body is at curb idle position Fig 226 Then verify that the transmission throttle lever Fig 227 is als...

Page 2407: ...will result in an incorrect T V cable adjustment Slide the sheath of the T V cable D back and forth until the centerlines of the T V cable end B and the throttle bell crank lever C are aligned within...

Page 2408: ...also provides reduced transmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is servic...

Page 2409: ...e 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 230 Impeller 1 ENGINE FLEXPLATE 4 ENGI...

Page 2410: ...hrough 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 231 Turbin...

Page 2411: ...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 mechan...

Page 2412: ...achieved by locking the stator s over running clutch to its shaft Fig 236 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and...

Page 2413: ...e oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the...

Page 2414: ...ENSOR DESCRIPTION Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor Fig 238 The temperature readings are used to control engagement of the fou...

Page 2415: ...shift valve 3 4 timing valve 3 4 quick fill valve 3 4 accumulator Throttle valve Throttle pressure plug Switch valve Manual valve Converter clutch lock up valve Converter clutch lock up timing Valve...

Page 2416: ...ER 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 1...

Page 2417: ...NG 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTT...

Page 2418: ...G 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 PI...

Page 2419: ...valve to the left This closes a dump vent that is used to lower pressure The clos ing of the dump will cause the oil pressure to increase Oil pressure on the opposite end of the valve pushes the valve...

Page 2420: ...Fig 243 Regulator Valve in PARK Position Fig 244 Regulator Valve in NEUTRAL Position BR BE AUTOMATIC TRANSMISSION 47RE 21 785 VALVE BODY Continued...

Page 2421: ...gear posi tions 145 280 psi The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there i...

Page 2422: ...ive breakaway KICKDOWN LIMIT VALVE The purpose of the limit valve is to prevent a 3 2 downshift at higher speeds when a part throttle downshift is not desirable At these higher speeds only a full thro...

Page 2423: ...Fig 247 Kickdown Valve Wide Open Throttle Fig 248 Kickdown Limit Valve Low Speeds 21 788 AUTOMATIC TRANSMISSION 47RE BR BE VALVE BODY Continued...

Page 2424: ...ild speed governor pressure is created and is applied to the left of the valve at the governor plug When governor pressure builds to a point where it can overcome the combined force of the spring and...

Page 2425: ...2 shift control valve This additional pressure is directed to the 1 2 shift control s spring cavity add ing to the spring load on the valve The result of this increased modulated throttle pressure is...

Page 2426: ...Fig 252 1 2 Shift Control Valve Fig 253 2 3 Shift Valve Before Shift BR BE AUTOMATIC TRANSMISSION 47RE 21 791 VALVE BODY Continued...

Page 2427: ...tion preventing an upshift into direct drive The theory for the blocking of the valve is the same as that of the 1 2 shift valve 3 4 SHIFT VALVE The PCM energizes the overdrive solenoid during the 3 4...

Page 2428: ...e temporarily bypasses the clutch piston feed orifice at the start of a 3 4 upshift Fig 255 This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequ...

Page 2429: ...st the reac tion area of the line pressure plug and the reaction area left of land 3 simultaneously moves the regu lator valve train to the right and controls the meter ing passage The kickdown valve...

Page 2430: ...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 shut...

Page 2431: ...lock up valve controls the back ON side of the torque converter clutch When the PCM energizes the TCC solenoid to engage the converter clutch piston pressure is applied to the TCC lock up valve which...

Page 2432: ...from the front clutch and servo release circuits During a 3 2 kickdown fluid dis charges through the shuttle by pass circuit When the shuttle valve closes the by pass circuit fluid dis charge is rest...

Page 2433: ...hift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 263 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and g...

Page 2434: ...ulling 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 ho...

Page 2435: ...ll and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 275 Fig 267 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 268 Solen...

Page 2436: ...g 271 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 272 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD Fig 273 Throttle Lever E Clip And Washer 1 THROTTLE LEVER SHAFT 2 E CLIP A...

Page 2437: ...g attaching screws Fig 279 22 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 280 23 Remove left side screw and remove...

Page 2438: ...RNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 279 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW 2 REMOVE THESE SCREWS 3 3 4 ACCUMULATOR HOUSING...

Page 2439: ...all from the transfer plate Fig 285 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 30 Remove transfer plate from upper housing Fig 286 31 Turn transfer plate over so upper housing sep...

Page 2440: ...ATE Fig 287 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PLATE 3 FILTER SCREEN 4 BRACE Fig 288 Rear Clutch and Rear Servo Check Ball Locations 1 REAR CLUTCH CHECK BALL 2 RE...

Page 2441: ...pper housing around and remove limit valve and shift valve covers Fig 292 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 292 9...

Page 2442: ...R 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...

Page 2443: ...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 interfe...

Page 2444: ...ved with crocus cloth using only very light pressure Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth Position the crocus cloth on...

Page 2445: ...correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve body assembly unless it is damaged in han dling The only serviceabl...

Page 2446: ...and position upper housing separator plate on transfer plate Fig 297 4 Install brace plate Fig 297 Tighten brace attaching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attachin...

Page 2447: ...and start all valve body screws by hand except for the screws to hold the boost valve tube brace Save those screws for later installation Then tighten screws evenly to 4 N m 35 in lbs torque Start at...

Page 2448: ...e valve e Verify that spring and E clip are properly 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 gover...

Page 2449: ...with valve body screw holes Fig 306 6 Install and finger tighten three screws that secure tube brace to valve body housings Fig 306 7 Bend tube brace tabs up and against tube to hold it in position Fi...

Page 2450: ...ER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTTLE PRESSURE SPRING AND PLUG 7 LIMIT VALVE AND SPRING Fig 305 Boost Valve Tube 1 BOOST VAL...

Page 2451: ...old detent ball and spring in detent housing with Retainer Tool 6583 Fig 310 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing...

Page 2452: ...re harness is properly routed Fig 313 Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover GOVERNOR BODY SENSOR AND SOLENOID 1 Turn valv...

Page 2453: ...8 Install accumulator springs and piston into case Then swing valve body over piston and outer spring to hold it in place 9 Align accumulator piston and outer spring manual lever shaft and electrical...

Page 2454: ...en the throttle lever cam and the kickdown valve stem Fig 318 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve Maintain pressure against kic...

Page 2455: ...ronizer mechanism consists of a brass stop ring synchro hub and the sliding clutch The synchronizer components allow the transfer case to be shifted between the 2H and 4H operating ranges while the ve...

Page 2456: ...a suspected transfer case malfunction check all other driveline compo nents beforehand The actual cause of a problem may be related to such items as front hubs axles propeller shafts wheels and tires...

Page 2457: ...aces 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 SKI...

Page 2458: ...earing as assembly Fig 7 COMPANION FLANGE AND SHIFT LEVER 1 Shift transfer case into NEUTRAL 2 Remove companion flange nut Fig 8 Discard nut after removal It is not reusable Fig 2 Rear Extension Bolt...

Page 2459: ...t shaft bearing 3 Note position of bolts that attach rear case to front case Fig 11 Some bolts studs at ends of case require flat washers Mark position of these bolts with paint or scriber 4 Remove re...

Page 2460: ...ig 14 9 Remove front sprocket retaining ring Fig 15 Fig 12 Loosening Rear Case Breaking Sealer Bead 1 SLOT 2 REAR CASE 3 PRY TOOL Fig 13 Removing Rear Case From Alignment Dowels 1 CASE DOWELS 2 2 REAR...

Page 2461: ...that screw has O ring seal Remove and discard seal this seal 4 Remove poppet plunger with magnet Fig 20 Fig 16 Removing Drive Chain And Front Sprocket 1 CHAIN 2 DRIVE SPROCKET 3 FRONT SPROCKET Fig 17...

Page 2462: ...9 Remove range fork and hub as an assembly Fig 24 Note fork position for installation reference 10 Remove shift sector Fig 25 Fig 21 Front Output Shaft Removal 1 BALL BEARING 2 FRONT OUTPUT SHAFT Fig...

Page 2463: ...ers to remove this retaining ring 2 Remove synchronizer hub Fig 28 Fig 25 Shift Sector Removal 1 SHIFT SECTOR Fig 26 Removing Sector Shaft O Ring And Retainer 1 SHAFT BORE 2 NYLON RETAINING RING 3 SEC...

Page 2464: ...ainer attaching bolts Fig 32 2 Remove front bearing retainer Pry retainer loose with pry tool positioned in slots at each end of retainer Fig 33 Fig 29 Synchronizer Strut And Spring Removal 1 SYNCHRON...

Page 2465: ...ow range gear Fig 36 2 Remove retainer Fig 37 3 Remove front tabbed thrust washer Fig 38 4 Remove input gear Fig 39 5 Remove rear tabbed thrust washer from low range gear Fig 40 Fig 33 Front Bearing R...

Page 2466: ...rom oil feed passages in the case halves retainers gears and shafts Fig 37 Input Gear Retainer Removal 1 INPUT GEAR 2 LOW RANGE GEAR 3 RETAINER Fig 38 Front Tabbed Thrust Washer Removal 1 FRONT TABBED...

Page 2467: ...n 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 pinio...

Page 2468: ...Fig 42 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 43 Shift Forks 1 RANGE FORK...

Page 2469: ...plete assembly The pickup screen hose and tube are the only serviceable parts and are available separately ASSEMBLY BEARINGS AND SEALS 1 Using Remover C 4210 and Handle C 4171 drive input shaft bearin...

Page 2470: ...Bearing Installation 1 HANDLE C 4171 2 REMOVER INSTALLER 6953 Fig 49 Front Output Seal Installation 1 INSTALLER 8143 A 2 TRANSFER CASE Fig 50 Install Front Bearing Retainer Seal 1 FRONT BEARING RETAIN...

Page 2471: ...ed transmission fluid 2 Install first thrust washer in low range gear Fig 56 Be sure washer tabs are properly aligned in gear notches 3 Install input gear in low range gear Be sure input gear is fully...

Page 2472: ...LLER 5066 Fig 55 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER Fig 56 Input Low Range Gear Components 1 SNAP RING 2 RETAINER PLATE 3 INPUT GEAR 4 LOW...

Page 2473: ...T FORKS AND MAINSHAFT 1 Lubricate mainshaft splines with recommended transmission fluid 2 Install drive sprocket on mainshaft Fig 60 3 Install brass stop ring on drive sprocket Fig 61 4 Install 3 sync...

Page 2474: ...Hub has shoulder on one side which goes toward sprocket rear of shaft Flat side of hub faces front of shaft Fig 62 Installing First Synchro Strut And Spring 1 FIRST STRUT 2 SYNCHRONIZER HUB 3 SPRING F...

Page 2475: ...tion 9 Lubricate mainshaft components with trans mission fluid 10 Lubricate sector shaft with transmission fluid and install shift sector in case Fig 69 Position slot in sector so it will be aligned w...

Page 2476: ...into case bore Fig 69 Shift Sector Installation 1 SHIFT SECTOR Fig 70 Install Range Fork And Hub Assembly 1 RANGE HUB 2 RANGE FORK Fig 71 Assembling Mode Fork And Mainshaft 1 SLIDING CLUTCH 2 MODE FOR...

Page 2477: ...ore installation Then tighten nut to 27 34 N m 20 25 ft lbs torque 19 Install poppet plunger and spring Fig 76 20 Install new O ring on poppet screw and install screw in front case Fig 77 Tighten scre...

Page 2478: ...uring chain installation align and reseat mainshaft in input gear and hub 6 Install front sprocket retaining ring Fig 80 7 Install spring and cup on shift rail Fig 81 Fig 78 Front Output Shaft Install...

Page 2479: ...ositioned 3 Insert oil pickup tube in oil pump and position pump in rear case Fig 85 4 Apply bead of Mopart Gasket Maker or equiv alent to mating surface of front case Keep sealer bead width to maximu...

Page 2480: ...lves Fig 88 If stud was loosened or came out during disassembly apply Loctite 242 to stud threads and reseat stud in case 9 Apply Loctite 242 to remainder of rear case to front case bolt threads and i...

Page 2481: ...r case housing or rear retainer 3 Align and install rear retainer on rear case Fig 92 4 Apply Mopart Silicone Sealer to threads of rear retainer bolts Then install retainer bolts finger tight 5 Instal...

Page 2482: ...Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission 2 Install and tighten transfer case attaching nuts Tighten nuts to 30 41 N m 20 30...

Page 2483: ...40 Bolt Extension Housing 35 46 26 34 Bolt Front Brg Retainer 16 27 12 24 Bolt Case Half 35 46 26 34 Nut Front Yoke 122 176 90 130 Screw Oil Pump 1 2 1 8 12 15 Nut Range Lever 27 34 20 25 Bolt Rear Re...

Page 2484: ...l C 4171 Installer Seal 8143 A Installer Bearing 6953 Installer Seal C 4210 Remover Bushing 6957 Installer Bushing 8157 Installer Seal D 163 Installer Seal 7884 Installer Bushing 5066 BR BE TRANSFER C...

Page 2485: ...extension housing with fluid port in bushing aligned with slot in housing 3 Using Installer 8157 drive bushing into hous ing until installer seats against case 4 Using Installer D 163 install seal in...

Page 2486: ...1 Shift transfer case into NEUTRAL 2 Raise vehicle 3 Remove front propeller shaft Refer to 3 DIF FERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT REMOVAL 4 Remove companion flange nut Fig 98 5 Remo...

Page 2487: ...shifter knob cap 3 Remove nut holding shifter knob to shift lever 4 Remove shifter knob 5 Remove the shift boot from the shifter bezel 6 Remove the bolts securing the shifter mecha nism to the floor...

Page 2488: ...e 8 Lower vehicle 9 Install the bolts to hold the shifter mechanism to the floor pan 10 Install the transfer case shifter bezel 11 Install the shifter boot and the shifter knob onto the shifter lever...

Page 2489: ...he shifter bracket assembly Fig 107 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 ro...

Page 2490: ...f aluminum 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 bal...

Page 2491: ...s while the vehicle is in motion The vehicle must have the transmission placed in NEUTRAL or the clutch depressed in the case of a manual trans mission and be moving less than 2 3 MPH when shifting in...

Page 2492: ...arT ATF 4 type 9602 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 clu...

Page 2493: ...e with suitable jack Secure transfer case to jack with safety chains 12 Remove nuts attaching transfer case to trans mission 13 Move transfer case assembly rearward until free of transmission output s...

Page 2494: ...seal from front output shaft Fig 9 5 Remove nut and washer that retain shift lever to sector shaft Then remove shift lever from shaft Fig 10 FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Remove output bearing...

Page 2495: ...ment dowels Fig 13 7 Remove rear case and oil pump assembly from front case 8 Remove shift rail cup and spring Fig 14 Fig 10 Shift Lever Removal 1 SHIFT LEVER 2 NUT WASHER Fig 11 Removing Case Attachi...

Page 2496: ...nd spring Fig 19 Note that screw has O ring seal Remove and discard seal this seal Fig 15 Removing Front Sprocket Retaining Ring 1 FRONT SPROCKET 2 RETAINING RING 3 FRONT OUTPUT SHAFT Fig 16 Removing...

Page 2497: ...utch fits in fork long side of clutch goes to front 8 Remove range fork retaining ring Fig 20 Poppet Plunger Removal 1 MAGNET 2 POPPET PLUNGER Fig 21 Front Output Shaft Removal 1 BALL BEARING 2 FRONT...

Page 2498: ...nizer hub onto mainshaft Fig 27 Use standard instead of parallel jaw snap ring pliers to remove this retaining ring Fig 24 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 25 Shift Sector Remov...

Page 2499: ...ring if worn cracked or any teeth are missing 5 Remove drive sprocket Fig 31 Fig 28 Synchronizer Hub Removal 1 SYNCHRONIZER HUB 2 MAINSHAFT Fig 29 Synchronizer Strut And Spring Removal 1 SYNCHRONIZER...

Page 2500: ...al position Then remove input gear and low range gear as an assem bly Fig 35 Tap gear out of bearing with plastic mallet if necessary Fig 32 Front Bearing Retainer Bolts 1 FRONT CASE 2 FRONT BEARING R...

Page 2501: ...all traces of sealer from the cases and retainers with a scraper and 3M all purpose cleaner Use compressed air to remove solvent residue from oil feed passages in the case halves retainers gears and s...

Page 2502: ...n Check a replacement synchronizer ring for proper fit on the cone with a minimum of wobble Also check the synchronizer struts for wear or damage INPUT GEAR AND PLANETARY CARRIER Check the teeth on th...

Page 2503: ...s 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 Fig 42 Input Gear And Carrier Components 1 PLANETAR...

Page 2504: ...ar 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...

Page 2505: ...ase bore as shown The seal could loosen or become cocked if not seated to recommended depth 9 Remove seal from front bearing retainer with suitable pry tool Fig 47 Seating Input Shaft Bearing 1 SNAP R...

Page 2506: ...l new pilot bearing with Plug C 293 3 15 Remove the front output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 54 Fig 54 Front Output Shaft Rear Bearing Removal 1 REA...

Page 2507: ...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 retai...

Page 2508: ...ION Do not block fluid return cavity on seal ing surface of retainer when applying MoparT Gas ket Maker or equivalent silicone adhesive sealer Seal failure and fluid leak can result 11 Install bolts t...

Page 2509: ...ing is positioned under struts to properly secure them Fig 65 d Turn hub over and install remaining spring in hub Position hooked end of second spring oppo site the first spring s hooked end Fig 63 In...

Page 2510: ...clutch is installed so a gap between splines is aligned with one or more struts gear clash will result 8 Support front case on wood blocks so case inte rior is facing up Place blocks between mounting...

Page 2511: ...ign and insert range fork pin in shift sector slot 13 Install mode fork and shift rail in sliding clutch Fig 72 Fig 69 Correct Alignment Of Struts And Sliding Clutch 1 SLEEVE TOOTH ALIGNED WITH STRUT...

Page 2512: ...17 Install shift lever on sector shaft Fig 76 18 Install washer and nut on sector shaft to secure shift lever Apply 1 2 drops Mopart Lock N Seal or equivalent to nut threads before installation Then t...

Page 2513: ...mainshaft about 2 54 cm one inch and seat front sprocket on front output shaft 5 If mainshaft and mode sleeve were unseated during chain installation align and reseat mainshaft in input gear and hub F...

Page 2514: ...case Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches Fig 85 Be sure hose that connects tube to filter is securely positioned Fig 81 Front Sprocket Retai...

Page 2515: ...ed torque at this time CAUTION Verify that shift rail Fig 88 and case alignment dowels are seated before installing any bolts Case could be cracked if shaft rail or dowels are misaligned 7 Verify that...

Page 2516: ...aft Fig 92 Then install and tighten flange nut to 176 271 N m 130 200 ft lbs torque REAR RETAINER AND EXTENSION 1 Clean mating surfaces of transfer case housing and the rear retainer of any original g...

Page 2517: ...lign splines by rotating transfer case rear output shaft yoke if nec essary Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission 2 Inst...

Page 2518: ...40 Bolt Extension Housing 35 46 26 34 Bolt Front Brg Retainer 16 27 12 24 Bolt Case Half 35 46 26 34 Nut Front Yoke 122 176 90 130 Screw Oil Pump 1 2 1 8 12 15 Nut Range Lever 27 34 20 25 Bolt Rear Re...

Page 2519: ...al 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 21 884 TRANSFER C...

Page 2520: ...eller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 6 Verify proper transfer case fluid level 7 Lower vehicle FLUID STANDARD PROCEDURE FLUID DRAIN AND REFILL T...

Page 2521: ...oes toward interior of case b Start seal in bore Once seal is started con tinue tapping seal into bore until installer tool bot toms against case c Remove installer and verify that seal is recessed th...

Page 2522: ...he floor pan along the driver s side of the transmission tunnel Fig 105 7 Raise and support the vehicle 8 Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion If rod lacks enough tr...

Page 2523: ...Tighten the shift rod lock bolt to 10 N m 90 in lbs 7 Remove the shifter adjustment locating pin from the adjustment channel and the locating hole 8 Lower vehicle 9 Install the bolts to hold the shift...

Page 2524: ...he shifter bracket assembly Fig 108 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 ro...

Page 2525: ...ow range gear system The transfer case 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 capabil i...

Page 2526: ...0 SEAL 6 REAR CASE 21 COMPANION FLANGE 7 OIL PUMP 22 SECTOR SHAFT 8 REAR RETAINER 23 SLIDING CLUTCH 9 OUTPUT BEARING 24 SLIDING HUB 10 REAR EXTENSION 25 PTO GEAR 11 SEAL 26 ANNULUS GEAR 12 BUSHING 27...

Page 2527: ...ransfer case The switch is operated by the transfer case range rod SHIFT MECHANISM The transfer case is operated by an adjustable floor mounted shift linkage The transfer case shift lever is directly...

Page 2528: ...arT ATF 4 type 9602 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 clu...

Page 2529: ...aft 14 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 EXTENSION H...

Page 2530: ...to break sealer bead Insert tool in slot at each end of case Fig 7 6 Unseat rear case from alignment dowels Fig 8 7 Remove rear case and oil pump assembly from front case 8 Remove shift rail cup and...

Page 2531: ...spring Fig 14 Note that screw has o ring seal Remove and dis card seal this seal Fig 10 Removing Front Drive Sprocket Retaining Ring 1 FRONT SPROCKET 2 RETAINING RING 3 FRONT OUTPUT SHAFT Fig 11 Remov...

Page 2532: ...Note which way clutch fits in fork long side of clutch goes to front Fig 15 Poppet Plunger Removal 1 MAGNET 2 POPPET PLUNGER Fig 16 Front Output Shaft Removal 1 BALL BEARING 2 FRONT OUTPUT SHAFT Fig...

Page 2533: ...ront case Fig 22 Fig 19 Sliding Hub Retaining Ring Removal 1 RETAINING RING 2 RANGE FORK 3 SLIDING HUB Fig 20 Range Fork And Sliding Hub Removal 1 SUPPORT SLEEVE 2 RANGE FORK Fig 21 Shift Sector Remov...

Page 2534: ...Remove brass stop ring Fig 26 Discard stop ring if worn cracked or any teeth are missing 5 Remove drive sprocket Fig 27 Fig 23 Synchronizer Hub Retaining Ring Removal 1 SYNCHRONIZER HUB 2 RETAINING RI...

Page 2535: ...ning planetary components are fixed parts and are serviced as an assembly 1 Position planetary assembly so PTO gear is on bench Fig 33 2 Remove retaining ring that secures input gear and lock ring in...

Page 2536: ...ear Retaining Ring 1 INPUT GEAR 2 PLANETARY ASSEMBLY 3 PTO GEAR 4 RETAINING RING Fig 34 Planetary Lock Ring And Front Thrust Washer Removal 1 THRUST WASHER 2 PLANETARY 3 LOCK RING Fig 35 Removing Inpu...

Page 2537: ...38 If evidence of chipping or excessive wear is appar ent replace the hub The hooked end of each synchro nizer spring should be inserted in one of the struts In addition the springs should not interf...

Page 2538: ...he annulus gear Be sure the gear teeth are in good condition Replace the front case and annulus as an assembly if the gear is damaged Check condition of the shift fork pads Fig 39 The pads should be r...

Page 2539: ...ear opening Fig 42 2 Install locating ring on new bearing 3 Position case so that the forward end is facing upward 4 Using Remover C 4210 and Handle C 4171 drive input shaft bearing into case The bear...

Page 2540: ...s recessed the proper amount Seal should be 2 03 to 2 5 mm 0 080 to 0 100 in below top edge of seal bore in front case This is correct final seal posi tion CAUTION Be sure the front output seal is sea...

Page 2541: ...ring 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 51 16 Install new pilot bearing with Plug C 293 3 17 Remove...

Page 2542: ...ot Bearing 1 DRIFT 2 INPUT GEAR Fig 52 Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 53 Output Shaft Rear Bearing Installation 1 HANDLE C 4...

Page 2543: ...n planetary carrier Fig 57 6 Install second thrust washer in planetary car rier Be sure washer tabs are seated in carrier slots 7 Install lock ring Fig 58 Fig 55 Thrust Washer Installation 1 THRUST WA...

Page 2544: ...6 inch Do not use excessive amount of sealer as excess could be dis placed into oil channel and feed hole in case 6 Align oil channel in retainer with oil feed hole in front case Fig 62 7 Install reta...

Page 2545: ...as follows a Insert first strut in hub Fig 66 Strut shoulders rest and slide on sides hub slot as shown Fig 65 Synchronizer Stop Ring Installation 1 BRASS STOP RING 2 DRIVE SPROCKET Fig 66 Installing...

Page 2546: ...as shoulder on one side which goes toward sprocket rear of shaft Flat side of hub faces front of shaft 5 Install synchronizer hub retaining ring Fig 70 Be sure ring is fully seated before proceeding F...

Page 2547: ...on forward surface of case Be sure blocks will not interfere with input gear installation 2 Lubricate mainshaft components with trans mission fluid 3 Lubricate sector shaft with transmission fluid and...

Page 2548: ...mode fork and shift rail in sliding clutch Fig 77 Fig 74 Assembling Range Fork And Sliding Hub 1 RANGE FORK 2 SLIDING HUB Fig 75 Seating Range Fork And Hub 1 RANGE FORK 2 RANGE FORK PIN 3 SECTOR SLOT...

Page 2549: ...Install shift lever on sector shaft Fig 81 11 Install washer and nut on sector shaft to secure shift lever Apply 1 2 drops Mopart Lock N Seal or equivalent to nut threads before installation Then tig...

Page 2550: ...on front output shaft 5 If mainshaft and sliding clutch were unseated during chain installation align and reseat mainshaft in input gear and hub Then reseat synchronizer hub in sliding clutch Press s...

Page 2551: ...osition oil pickup tube and filter in rear case Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches Fig 90 Be sure hose that connects tube to filter is secur...

Page 2552: ...t case bolts to hold rear case in position Tighten bolts snug but not to specified torque at this time CAUTION Verify that shift rail Fig 93 and case alignment dowels are seated before installing any...

Page 2553: ...part Gasket Maker or equiv alent to mating surface of extension housing Keep sealer bead width to maximum of 3 16 inch Do not use excessive amount of sealer as excess could be dis placed into oil pump...

Page 2554: ...ER SHAFT PROPELLER SHAFT INSTALLATION 6 Connect vacuum harness and vent hose 7 Connect shift rod to transfer case lever or floor shift arm Use channel lock style pliers to press rod back into lever gr...

Page 2555: ...sal C 4171 Installer Seal 6888 Installer Bushing 8156 Remover Bushing 8155 Installer Seal 8154 Installer Bearing 6953 Installer Seal 7884 Plug Extension C 293 3 Installer Seal C 4210 21 920 TRANSFER C...

Page 2556: ...sion housing with fluid port in bushing aligned with slot in housing 3 Using Installer 8156 drive bushing into hous ing until installer seats against case Fig 99 4 Using Installer 8154 install seal in...

Page 2557: ...nut after removal It is not reusable 5 Remove companion flange from output shaft Use a suitable puller if flange can not be removed by hand 6 Remove companion flange rubber seal from front output shaf...

Page 2558: ...front shaft Fig 105 3 Install companion flange on front shaft Fig 106 Then install and tighten flange nut to 176 271 N m 130 200 ft lbs torque 4 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVE...

Page 2559: ...y to the locating hole in the lower shift lever and install an appropri ately sized pin to retain the position Fig 108 2 Position shift lever on vehicle 3 Install nuts to hold shift lever to the under...

Page 2560: ...nnel on the shifter bracket assembly Fig 110 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...

Page 2561: ......

Page 2562: ...ore than 1 5 mm 060 inch measured at the center line of the tread may cause the vehicle to shake Lateral runout of more than 2 0 mm 080 inch measured near the shoulder of the tire may cause the vehicl...

Page 2563: ...e traction and maintain a smooth quiet ride The recommended method of tire rotation is Fig 4 Other methods can be used but may not provide the same tire longevity benefits Dual wheel vehicles require...

Page 2564: ...tor runout again Mark the tire to indicate the high spot 5 If runout is still excessive the following proce dures must be done If the high spot is within 101 6 mm 4 0 in of the first spot and is still...

Page 2565: ...le balancing equipment remove the opposite wheel tire Off vehicle balancing is recommended For static balancing find the location of the heavy spot causing the imbalance Counter balance wheel directly...

Page 2566: ...irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation Refer to 22 TIRES WHEELS STANDARD PROCEDURE This will help to achieve a greater tread l...

Page 2567: ...t are driven at speeds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct inflation pressure recommendations DESCRIPTION The original equipment tires prov...

Page 2568: ...uge is recommended to check tire pressure After checking the air pressure replace valve cap finger tight DIAGNOSIS AND TESTING TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of...

Page 2569: ...must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 16 The tire should be replaced if the puncture is located in the sidewall Deflate tire co...

Page 2570: ...inal 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 WHE...

Page 2571: ...AIL WITH OUT WARNING STARDARD PROCEDURE DUAL REAR WHEEL INSTALLATION Dual rear wheels use a special heavy duty lug nut wrench It is recommended to remove and install dual rear wheels only when the pro...

Page 2572: ...0 kilome ters of vehicle operation NOTE Wheel lug nuts should be tightened to spec ified torque at every maintenance interval thereafter SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N...

Page 2573: ...EAR 1 Install one 1 1 2 in valve stem extension on each rear inner wheel NOTE A 3 8 in drive 10mm deep wheel socket with a 10 in or greater extension can be used to remove the existing valve stem cap...

Page 2574: ...ION LOCK CYLINDERS Ignition door deck lid and rear hatch lock cylin ders are all codable to the key Lock barrels tum blers and tumbler springs are available to allow the technician to change replaceme...

Page 2575: ...ist the right side of the vehi cle For hoisting recommendations refer to Group 0 Lubrication and Maintenance General Information section WATER LEAK DETECTION To detect a water leak point of entry do a...

Page 2576: ...e moldings can flutter creating a buzzing or chattering noise An open cavity or protruding edge can create a whistling or howling noise Inspect the exterior of the vehicle to verify that these conditi...

Page 2577: ...SPECIFICATIONS WELD LOCATIONS BODY SIDE APERTURE CLUB CAB 23 4 BODY BR BE BODY Continued...

Page 2578: ...BODY SIDE APERTURE QUAD CAB BR BE BODY 23 5 BODY Continued...

Page 2579: ...BODY SIDE APERTURE QUAD CAB 23 6 BODY BR BE BODY Continued...

Page 2580: ...BODY SIDE APERTURE QUAD CAB BR BE BODY 23 7 BODY Continued...

Page 2581: ...BODY SIDE APERTURE QUAD CAB 23 8 BODY BR BE BODY Continued...

Page 2582: ...BODY SIDE APERTURE QUAD CAB BR BE BODY 23 9 BODY Continued...

Page 2583: ...BODY SIDE APERTURE QUAD CAB 23 10 BODY BR BE BODY Continued...

Page 2584: ...CAB BACK PANEL CLUB CAB BR BE BODY 23 11 BODY Continued...

Page 2585: ...CAB BACK PANEL QUAD CAB 23 12 BODY BR BE BODY Continued...

Page 2586: ...FLOOR PAN CLUB CAB BR BE BODY 23 13 BODY Continued...

Page 2587: ...FLOOR PAN CLUB CAB 23 14 BODY BR BE BODY Continued...

Page 2588: ...FLOOR PAN CLUB CAB BR BE BODY 23 15 BODY Continued...

Page 2589: ...FLOOR PAN CLUB CAB FLOOR PAN QUAD CAB 23 16 BODY BR BE BODY Continued...

Page 2590: ...FLOOR PAN QUAD CAB BR BE BODY 23 17 BODY Continued...

Page 2591: ...FLOOR PAN QUAD CAB 23 18 BODY BR BE BODY Continued...

Page 2592: ...FLOOR PAN QUAD CAB CARGO BOX OUTER SIDE PANEL BR BE BODY 23 19 BODY Continued...

Page 2593: ...CARGO BOX OUTER SIDE PANEL 23 20 BODY BR BE BODY Continued...

Page 2594: ...CARGO BOX INNER SIDE PANEL BR BE BODY 23 21 BODY Continued...

Page 2595: ...CARGO BOX INNER SIDE PANEL 23 22 BODY BR BE BODY Continued...

Page 2596: ...CARGO BOX INNER SIDE PANEL BR BE BODY 23 23 BODY Continued...

Page 2597: ...CARGO BOX INNER SIDE PANEL 23 24 BODY BR BE BODY Continued...

Page 2598: ...CARGO BOX INNER SIDE PANEL BR BE BODY 23 25 BODY Continued...

Page 2599: ...CARGO BOX INNER SIDE PANEL 23 26 BODY BR BE BODY Continued...

Page 2600: ...CARGO BOX FRONT PANELS BR BE BODY 23 27 BODY Continued...

Page 2601: ...CARGO BOX FLOOR 23 28 BODY BR BE BODY Continued...

Page 2602: ...FRONT FENDER AND INNER WHEELHOUSE BR BE BODY 23 29 BODY Continued...

Page 2603: ...COWL AND DASH PANEL 23 30 BODY BR BE BODY Continued...

Page 2604: ...ROOF PANEL CLUB CAB BR BE BODY 23 31 BODY Continued...

Page 2605: ...ROOF PANEL QUAD CAB 23 32 BODY BR BE BODY Continued...

Page 2606: ...BODY SIDE APERTURE CLUB CAB BR BE BODY 23 33 BODY Continued...

Page 2607: ...BODY SIDE APERTURE CLUB CAB 23 34 BODY BR BE BODY Continued...

Page 2608: ...BODY SIDE APERTURE CLUB CAB BR BE BODY 23 35 BODY Continued...

Page 2609: ...BODY SIDE APERTURE CLUB CAB 23 36 BODY BR BE BODY Continued...

Page 2610: ...BODY SIDE APERTURE CLUB CAB BR BE BODY 23 37 BODY Continued...

Page 2611: ...CAB BACK PANEL REG CAB 23 38 BODY BR BE BODY Continued...

Page 2612: ...FLOOR PAN REG CAB BR BE BODY 23 39 BODY Continued...

Page 2613: ...ROOF PANEL REG CAB 23 40 BODY BR BE BODY Continued...

Page 2614: ...BODY SIDE APERTURE REG CAB BR BE BODY 23 41 BODY Continued...

Page 2615: ...BODY SIDE APERTURE REG CAB 23 42 BODY BR BE BODY Continued...

Page 2616: ...BODY SIDE APERTURE REG CAB BR BE BODY 23 43 BODY Continued...

Page 2617: ...STRUCTURAL ADHESIVE LOCATIONS ROOF PANELS REGULAR CAB 23 44 BODY BR BE BODY Continued...

Page 2618: ...CLUB CAB BR BE BODY 23 45 BODY Continued...

Page 2619: ...QUAD CAB 23 46 BODY BR BE BODY Continued...

Page 2620: ...BODY SEALER LOCATIONS APPLICATION METHODS BR BE BODY 23 47 BODY Continued...

Page 2621: ...SEALER LOCATION 23 48 BODY BR BE BODY Continued...

Page 2622: ...CUT AWAY VIEW BR BE BODY 23 49 BODY Continued...

Page 2623: ...COWL AND DASH PANEL 23 50 BODY BR BE BODY Continued...

Page 2624: ...COWL AND DASH PANEL BR BE BODY 23 51 BODY Continued...

Page 2625: ...FLOOR PAN CAB BACK PANEL 23 52 BODY BR BE BODY Continued...

Page 2626: ...CAB REAR PANEL ROOF PANEL BR BE BODY 23 53 BODY Continued...

Page 2627: ...CARGO BOX 23 54 BODY BR BE BODY Continued...

Page 2628: ...DOORS BR BE BODY 23 55 BODY Continued...

Page 2629: ...d to Fender 6 0 1 0 1 5 1 0 C4 Hood to Fender 6 0 1 0 1 5 1 0 D Door to Hood Fender 5 0 1 0 0 0 1 0 E Door to Windshield Molding N A 2 0 2 0 F Door to Roof 6 0 1 5 2 0 1 0 G Door to Quarter 5 0 1 0 0...

Page 2630: ...Quarter top 5 0 1 0 3 5 1 5 D Quarter Glass to Quarter rear 5 0 2 0 3 25 1 5 E Cab to Box side view 31 0 3 0 3 25 2 5 F Quarter Glass to Quarter bottom 5 0 1 5 N A G Quarter Glass to Quarter front in...

Page 2631: ...oor Glass to Rear Door rear 5 0 2 0 3 25 1 5 F Rear Door to Quarter 5 5 1 0 0 0 1 0 G Rear Door Glass to Rear Door bottom 5 0 1 5 N A H Front Door to Rear Door 5 0 1 0 0 0 1 0 I Rear Door Glass to Rea...

Page 2632: ...Cab to Box Character Line U D N A 0 0 3 0 O Cargo to Box side 31 0 3 0 5 0 2 5 P Cab to Box at Centerline 34 0 3 0 N A Q Box to Tailgate U D N A 1 0 1 5 R Tailgate to Bumper 43 0 3 0 N A S Box to Tail...

Page 2633: ...BODY OPENING DIMENSIONS WINDSHIELD OPENING DOOR OPENING REGULAR CAB BACKLITE OPENING DOOR OPENING QUAD CAB 23 60 BODY BR BE BODY Continued...

Page 2634: ...9 28 Front shoulder belt lower anchor bolt 39 28 Front shoulder belt lower anchor bolt 45 33 Door hinge to A pillar bolt 28 21 Door latch screw 11 8 Door latch striker screw 28 21 Door glass to lift p...

Page 2635: ...om applique Clean back of applique with MOPAR Super Kleen solvent or equivalent Wipe molding dry with lint free cloth Apply new body side molding two sided adhesive tape to back of appli que 3 Clean t...

Page 2636: ...F warm decal with a heat lamp or gun to assure adhesion Do not exceed 65 C 150 F when heating emblem HANDLE ESCUTCHEON REMOVAL 1 Lift and hold tailgate latch release handle 2 Using a trim stick C 475...

Page 2637: ...latch and linkage rod from tailgate Fig 5 INSTALLATION 1 Position latch and linkage rod in tailgate 2 Install upper screw attaching latch to tailgate 3 Install lower screw attaching check cable and l...

Page 2638: ...on latch handle in tailgate 2 Install screws attaching latch handle to tail gate 3 Install linkage rods to latch handle 4 Engage clips to linkage rods 5 Install tailgate latch handle escutcheon LATCH...

Page 2639: ...ntil the notch in the right hand collar aligns with the pivot pin 5 Slip tailgate hinge collar from pivot pins 6 Slide tailgate to the right and separate left hand collar from the pivot pin 7 Separate...

Page 2640: ...STALLATION Installation equipment needed Lint free applicator cloth six inch applicator squeegee Piercing pin 1 Clean B pillar using Mopar Super Kleen or equivalent 2 Wipe surface with a lint free clo...

Page 2641: ...ng upper door hinge to hinge pillar 4 Install bolts attaching lower door hinge to hinge pillar Fig 3 5 Install hidden bolts attaching door hinge to hinge pillar from behind cowl panel Fig 2 6 Align do...

Page 2642: ...RDAM REMOVAL 2 Remove inner door belt weatherstrip Refer to 23 BODY WEATHERSTRIP SEALS FDR INNER BELT WEATHERSTRIP REMOVAL 3 Align door glass lift plate to access holes in inner door panel 4 Loosen bo...

Page 2643: ...m Refer to 23 BODY DOOR FRONT WATERDAM REMOVAL 2 Raise the window to the closed position 3 Remove bolts holding run channel to inner door panel Fig 6 and Fig 7 4 Slide channel downward to disengage it...

Page 2644: ...ge pil lar Tighten bolts to 28 N m 21 ft lbs torque 6 Install hidden bolt attaching door hinge to hinge pillar Tighten bolt to 28 N m 21 ft lbs torque 7 Remove support 8 Install cowl trim panel Refer...

Page 2645: ...h 5 Install the door waterdam Refer to 23 BODY DOOR FRONT WATERDAM INSTALLATION ADJUSTMENT FRONT DOOR LATCH 1 Insert a hex wrench through the elongated hole in the door end frame near the latch strike...

Page 2646: ...VAL 1 Remove outside door handle Refer to 23 BODY DOOR FRONT EXTERIOR HANDLE REMOVAL 2 Remove clip securing lock cylinder to outside door handle Fig 14 3 Pull lock cylinder from door handle INSTALLATI...

Page 2647: ...el away from door simultaneously lift upward and inboard 7 Disengage power mirror switch connector if equipped 8 Disengage power window lock switch connec tors from switch panel if equipped Fig 18 9 S...

Page 2648: ...OR FRONT WATERDAM REMOVAL 2 Remove nuts attaching door glass to window regulator 3 Remove glass from door or move glass to full up position and secure glass to door with tape 4 Disengage power window...

Page 2649: ...lts attaching window regulator to inner door panel 3 Engage power window motor wire connector to door harness if equipped 4 Install glass in lift plate 5 Install the door waterdam Refer to 23 BODY DOO...

Page 2650: ...VAL 84 INSTALLATION 84 VENT WINDOW REMOVAL 85 INSTALLATION 85 WATERDAM REMOVAL 85 INSTALLATION 85 AIR EXHAUSTER REMOVAL 1 Remove cargo door trim panel Refer to 23 BODY DOOR CARGO TRIM PANEL REMOVAL 2...

Page 2651: ...or on a suitable device 6 Remove the bolts attaching the hinges to the cargo door Fig 3 INSTALLATION 1 Support the cargo door on a suitable device 2 Using the alignment marks position the door at the...

Page 2652: ...the lower side of the vent towards the door until the tabs snap into place 4 Ensure vent is fully seated HINGE REMOVAL 1 Remove cargo door Refer to 23 BODY DOOR CARGO DOOR REMOVAL 2 Remove quarter tr...

Page 2653: ...d at shutface handle Fig 8 5 Remove nuts attaching lower latch to cargo door 6 Separate lower latch and latch rod from cargo door INSTALLATION 1 If installing a new replacement latch a Engage latch ro...

Page 2654: ...n bolt to 23 N m 17 ft lbs torque f Engage latch rod to shutface handle g Remove alignment set screw from lower hole h Align lower bolt with reference mark i Install bolt in lower hole Tighten bolt to...

Page 2655: ...r striker from roof INSTALLATION 1 Position upper striker on roof 2 Install bolts attaching striker to roof Fig 11 Tighten bolts to 23 N m 17 ft lbs torque 3 Install the screws attaching striker trim...

Page 2656: ...LATION 1 Position handle in cargo door 2 Install screws attaching shutface handle to cargo door Fig 15 3 Engage cargo door release cable CAUTION When engaging upper and lower latch release rods to shu...

Page 2657: ...replacing door trim panel installer must replace the X mas tree style pin 6506878aa 1 Engage the cargo door release cable to the inside release handle Fig 18 2 Position the trim panel on the cargo doo...

Page 2658: ...he latch to the cargo door 5 Install cargo door trim panel Refer to 23 BODY DOOR CARGO TRIM PANEL INSTALLA TION WATERDAM REMOVAL 1 Remove cargo door trim panel Refer to 23 BODY DOOR CARGO TRIM PANEL R...

Page 2659: ...N 98 SIDE VIEW MIRROR GLASS REMOVAL 98 INSTALLATION 98 EXTERIOR DESCRIPTION Exterior sheet metal components make up the exterior of the vehicle Some exterior metal systems are welded assemblies such a...

Page 2660: ...and molding see step one Firmly press molding to body surface to assure adhesion BODY STRIPES AND DECALS REMOVAL 1 Warm the panel to approximately 38 C 100 F using a suitable heat lamp or heat gun 2...

Page 2661: ...pe to aid installation 2 Warm the panel to approximately 38 C 100 F using a suitable heat lamp or heat gun 3 Peel tape stripe Fig 4 from body panel using an even pressure pull 4 Remove adhesive residu...

Page 2662: ...and to allow overlay to be stretched into concave surfaces 10 Edge turn overlay around doors or fenders 11 Install exterior trim if necessary 12 Small air or water bubbles under overlay can be pierce...

Page 2663: ...ge on front of cowl 6 Separate cowl cover from vehicle INSTALLATION 1 Position cowl cover on vehicle Ensure end seals are positioned correctly and in good condition 2 Install cowl seal 3 Install plast...

Page 2664: ...y molding to roof joint 5 Heat roof and molding see step one Firmly press molding into roof joint to assure adhesion GRILLE REMOVAL 1 Open hood 2 Remove bolts attaching bottom of grille to frame Fig 9...

Page 2665: ...vets attaching liner to the wheelhouse Fig 13 5 Separate front wheelhouse liner from wheel house INSTALLATION 1 Position front wheelhouse liner in wheelhouse 2 Install plastic rivets attaching liner t...

Page 2666: ...der from vehicle INSTALLATION 1 Position left front fender on vehicle 2 Install bolts attaching top of fender to radiator closure panel 3 Install bolt attaching front fender to hinge pil lar mounting...

Page 2667: ...olts attaching top of fender to radia tor closure panel Fig 17 15 Separate right front fender from vehicle INSTALLATION 1 Position fender on vehicle 2 Install bolts attaching top of fender to radiator...

Page 2668: ...o top of wheelhouse 13 Remove nuts attaching rear fender to cargo box through access hole in top of wheelhouse 14 Separate rear fender from cargo box side panel Fig 19 INSTALLATION Ensure the retainer...

Page 2669: ...in wheelhouse opening 2 Install plastic rivets attaching rear wheelhouse liner to rear wheelhouse 3 Working front to rear install plastic rivets attaching rear wheelhouse liner to rear wheel open ing...

Page 2670: ...s if equipped Fig 24 4 Remove nuts attaching sideview mirror to door frame Fig 25 5 Separate harness grommet form door frame if equipped 6 Separate sideview mirror from vehicle INSTALLATION 1 Position...

Page 2671: ...s holder if equipped INSTALLATION 1 Position the new mirror glass holder to the mirror assembly 2 Align the mirror glass holder s attaching fin gers to the mirror motor housing NOTE ENSURE THAT THE MO...

Page 2672: ...MOVAL 1 Open hood and support the side that requires hinge replacement 2 Mark all bolt and hinge attachment locations with a grease pencil or equivalent to provide refer ence marks for installation 3...

Page 2673: ...n nector if equipped 3 Connect the under hood lamp wire connector ADJUSTMENT 1 Loosen the hinge arm to hood panel bolts at each side of the vehicle 2 Loosen the hood latch screws 3 Close the hood Adju...

Page 2674: ...he hood release handle to the bot tom of the instrument panel Fig 4 6 Pull route the hood release cable through the dash panel hole and remove it via the inside of the vehicle INSTALLATION NOTE If rep...

Page 2675: ...Install bolts attaching hood latch striker to hood ADJUSTMENT 1 Open the hood 2 Loosen the latch striker screws 3 Slowly close the hood and observe the latching operation As necessary re adjust the st...

Page 2676: ...teners holding silencer to hood Fig 7 4 Separate hood silencer from hood INSTALLATION 1 Position hood silencer on hood 2 Install push in fasteners holding silencer to hood 3 Connect air temperature se...

Page 2677: ...de inner panel with a screw A stamped metal bracket supports the center of the instrument panel by securing it to the top of the floor panel transmis sion tunnel below the instrument panel with screws...

Page 2678: ...rbags and seat belts helps to improve occupant protection The instrument panel is also designed so that all of the various controls can be safely reached and the monitors can be easily viewed by the v...

Page 2679: ...BRAKE RELEASE REMOVAL b Disconnect the instrument panel wire har ness connector from the park brake switch on the park brake mechanism c Disconnect the three connectors one from the body wire harness...

Page 2680: ...rolled down position about 46 cm 18 inches from the dash panel 2 With the instrument panel supported in the roll down position reconnect the instrument panel wire harness connectors to the heater A C...

Page 2681: ...ment panel lower reinforcement 12 Install and tighten the two screws that secure the inside hood latch release handle to the instru ment panel lower reinforcement Tighten the screws to 2 8 N m 25 in l...

Page 2682: ...e pivot pins in the instrument panel until the open ash receiver snaps into place 7 Reconnect the battery negative cable CLUSTER BEZEL REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AI...

Page 2683: ...R PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove the cluster bezel from the instrument panel Refer...

Page 2684: ...TALLATION Vehicles equipped with an automatic transmission have a lighted fold down cup holder installed on the instrument panel just inboard of the glove box Vehi cles equipped with a manual transmis...

Page 2685: ...upward to dis engage the three glove box hinge hooks from the three hinge pins on the instrument panel DISASSEMBLY GLOVE BOX The only serviced component of the glove box is the glove box bin If any o...

Page 2686: ...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 WA...

Page 2687: ...EM 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...

Page 2688: ...the instrument panel into the vehicle Refer to 23 BODY INSTRUMENT PANEL INSTALLATION 4 Reinstall the passenger airbag into the instru ment panel Refer to 8 ELECTRICAL RE STRAINTS PASSENGER AIRBAG INS...

Page 2689: ...ove box Vehi cles equipped with a manual transmission have a lighted storage bin installed on the instrument panel in place of the fold down cup holder WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISAB...

Page 2690: ...IDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Position the storage bin unit onto the instru ment panel Fig 11 2 Engage the illumination lamp and hood retainer clip to the back of the instr...

Page 2691: ...AND FLOOR MATS REMOVAL 123 INSTALLATION 123 ASSIST HANDLE REMOVAL 124 INSTALLATION 124 COAT HOOK REMOVAL 124 INSTALLATION 125 HEADLINER REMOVAL 125 INSTALLATION 125 BODY VENT REMOVAL 126 INSTALLATION...

Page 2692: ...clip 4 Disengage speaker harness connector if equipped 5 Separate A pillar trim from vehicle INSTALLATION 1 Position A pillar trim in vehicle 2 Engage speaker harness connector if equipped 3 Align sp...

Page 2693: ...4 Install seat belt exit plug 5 Install bolt attaching turning loop to B pillar and reposition turning loop cover 6 Install bolt attaching seat belt anchor to floor 7 Install door sill cover Refer to...

Page 2694: ...oks on stowage tray from slots in rear closure panel trim 4 Separate rear floor stowage tray from vehicle INSTALLATION 1 Position rear floor stowage tray in vehicle 2 Engage hooks on stowage tray into...

Page 2695: ...ehicle shown manual transmission similar 5 Lift floor shift boot off shift lever INSTALLATION 1 Place shift boot over shifter 2 Engage retainers attaching boot to shifter base 3 Position shift knob on...

Page 2696: ...door sill covers Refer to 23 BODY INTERIOR DOOR SILL TRIM REMOVAL 3 Remove center console if equipped Refer to 23 BODY INTERIOR CENTER CONSOLE REMOVAL 4 If not equipped with a center console remove th...

Page 2697: ...if equipped 11 Install cowl trim covers Refer to 23 BODY INTERIOR COWL TRIM COVER INSTALLATION 12 Install door sill covers Refer to 23 BODY INTERIOR DOOR SILL TRIM INSTALLATION 13 Install front and re...

Page 2698: ...11 Separate headliner from roof panel Fig 14 12 Extract headliner through door opening INSTALLATION 1 Position headliner on roof panel Fig 14 Extended cab shown standard cab similar 2 Install passeng...

Page 2699: ...s torque 3 If equipped connect mirror harness wire con nector INSTALLATION REARVIEW MIRROR SUPPORT BRACKET 1 Mark the position for the mirror bracket on the outside of the windshield glass with a wax...

Page 2700: ...y 7 Allow the adhesive to cure for 8 10 minutes Remove any excess adhesive with an alcohol damp ened cloth 8 Allow the adhesive to cure for an additional 8 10 minutes before installing the mirror SUN...

Page 2701: ...anchor to floor 4 Unsnap turning loop push cover up and remove bolt attaching turning loop to C pillar 5 Remove seat belt exit plug 6 Disengage clips attaching C pillar trim to upper C pillar 7 Separ...

Page 2702: ...o part paint application base coat clear coat is used Color paint that is applied to primer is called base coat The clear coat protects the base coat from ultraviolet light and provides a dura ble hig...

Page 2703: ...on body surface Allow touch up paint to dry hard 5 On vehicles without clear coat the touch up color can be lightly finesse sanded 1500 grit and polished with rubbing compound 6 On vehicles with clea...

Page 2704: ...2 INSTALLATION 142 EASY ENTRY SEAT TRACK REMOVAL 142 INSTALLATION 142 SEAT TRACK ADJUSTER REMOVAL 143 INSTALLATION 143 STANCHION COVER REMOVAL 143 INSTALLATION 143 REAR SEAT REMOVAL 144 INSTALLATION 1...

Page 2705: ...4 Disengage the front edge of the cover then lower the arm rest 5 Remove the inertia latch cover by pulling the cover rearwards Fig 1 INSTALLATION 1 Slide the inertia latch cover onto the latch arm 2...

Page 2706: ...2 Hinge seat backs forward 3 Remove nuts attaching rear of seat tracks to floor Fig 4 4 Move seat track to rearward position 5 Remove bolts attaching front of seat tracks to floor 6 Separate seat fro...

Page 2707: ...in vehicle 2 Connect power seat wire connector to body har ness if equipped 3 Install bolts holding front of seat tracks to floor Tighten the bolts to 40 N m 30 ft lbs torque 4 Install bolt holding in...

Page 2708: ...SPLIT BENCH REMOVAL STANDARD CAB 1 Disconnect power seat switch connector if equipped 2 Remove center seat console armrest Refer to 23 BODY SEATS CENTER SEAT ARMREST CONSOLE REMOVAL 3 Disconnect rear...

Page 2709: ...e to the seat track adjuster Fig 13 10 Remove recliner lower bolt 11 Separate seat back from seat track adjuster INSTALLATION STANDARD CAB 1 Align seat cushion with seat back and install shoulder bolt...

Page 2710: ...sition roll cover upwards and remove INSTALLATION 1 With seat back in a normal vertical position roll cover downwards over seat back 2 Install hogrings if equipped 3 Secure J Straps at base of seat ba...

Page 2711: ...s removed 6 Remove the bolts attaching upper recliner to seat back frame Fig 15 7 Separate the recliner from the seat back INSTALLATION 1 Install seat dump handle if removed 2 Position the recliner in...

Page 2712: ...rom foam cushion INSTALLATION 1 Position cushion cover on cushion and roll cover over front and rear corners 2 Secure front J Strap Fig 17 3 Secure rear J Strap 4 Secure left and right side J Straps 5...

Page 2713: ...ront and rear corners Verify stitching lines are straight correct as necessary 2 Pull front J strap up align cover to foam notches and secure front J strap to frame Fig 21 3 Install seat backs Refer t...

Page 2714: ...45 N m 33 ft lbs torque 3 Install the seat in the vehicle Refer to 23 BODY SEATS SEAT BENCH SEAT INSTALLA TION or Refer to 23 BODY SEATS SEAT SPLIT BENCH INSTALLATION 4 Connect seat harness connector...

Page 2715: ...ed in all 6 functions to ensure the adjuster is working properly EASY ENTRY SEAT TRACK REMOVAL 1 Remove front passenger seat Refer to 23 BODY SEATS SEAT SPLIT BENCH REMOVAL 2 Remove recliner handle 3...

Page 2716: ...INER LEAD SCREW IS SPRING LOADED AND WILL EJECT IF EITHER THE HANDLE CABLE OR TOWEL BAR IS PULLED BEFORE THE LEAD SCREW IS REMOVED 3 Remove right and left risers INSTALLATION 1 Install the left and ri...

Page 2717: ...ks with loops on cab rear panel Fig 31 3 Align side support alignment tabs and lower seat into place 4 Install side support bracket screws Tighten the screws to 28 N m 250 in lbs torque 5 Turn release...

Page 2718: ...ent components BACKLITE REMOVAL It is difficult to salvage the backlite during the removal operation The backlite is part of the struc tural support for the roof The urethane bonding used to secure th...

Page 2719: ...r with MOPAR Super Clean or equivalent 10 Allow urethane to cure at least 24 hours full cure is 72 hours 11 Water test to verify repair before returning vehicle to service 12 Install rear closer panel...

Page 2720: ...long entire length of the lip retainer in lower run channel Fig 6 6 Slide vent glass panels into lower run channel 7 Latch vent glass panels 8 Insert upper ends of vent glass panels into upper run cha...

Page 2721: ...rethane adhesive The urethane adhesive is applied cold and seals the surface area between the window opening and the glass The primer adheres the urethane adhesive to the windshield It is difficult to...

Page 2722: ...nd shield 6 Apply black out primer onto the glass using the windshield molding as a guide The primer should be 15 mm 5 8 in wide on the top and sides of the glass and 25 mm 1 in on the bottom of winds...

Page 2723: ...lengths of 50 mm 2 in masking tape spaced 250 mm 10 in apart to hold molding in place until urethane cures 16 Install cowl grill Refer to 23 BODY EXTE RIOR COWL GRILLE INSTALLATION 17 Install rear vi...

Page 2724: ...screw to 6 N m 60 in lbs torque 2 Center the window glass at the opening insert the hinge studs in the B pillar holes and install the retaining nuts Tighten the nuts to 11 N m 95 in lbs torque 3 Attac...

Page 2725: ...xi mately 38 C 100 F using a suitable heat lamp or heat gun 2 Pull seal from painted surface Fig 1 INSTALLATION 1 Remove adhesive tape residue from painted surface of vehicle 2 If seal is to be reused...

Page 2726: ...to pinch flange around door open ing Fig 3 2 Install B pillar trim panel Refer to 23 BODY INTERIOR B PILLAR TRIM INSTALLA TION 3 Install cowl panel Refer to 23 BODY INTE RIOR COWL TRIM COVER INSTALLAT...

Page 2727: ...end of the belt weatherstrip lift upward 4 Separate outer door belt weatherstrip from door Fig 6 INSTALLATION 1 Position outer door belt weatherstrip on door 2 Press weatherstrip downward to seat 3 I...

Page 2728: ...sh in fasteners attaching the sec ondary seal to the inner door panel Fig 7 Upper Corner Seal Quad Cab 1 UPPER CORNER SEAL 2 PUSH IN FASTENER Fig 8 Front Door Secondary Seal Quad Cab 1 FRONT DOOR 2 SE...

Page 2729: ......

Page 2730: ...stem is not accidentally contaminated by the use of the wrong refrigerant R 12 or refrigerant system service equipment OPERATION HEATER AND AIR CONDITIONER The heater and optional air conditioner are...

Page 2731: ...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 heat the evaporator can absorb from the air H...

Page 2732: ...to 215 psi 1482 to 1862 kPa 215 to 270 psi 1862 to 2275 kPa 270 to 330 psi 2344 to 2551 kPa 340 to 370 psi 2758 to 2965 kPa 400 to 430 psi Note If pressures are lower than shown but center panel outl...

Page 2733: ...xcessive refrigerant oil in system 1 Refer to Plumbing Refrigerant Oil Standard Procedure Refrigerant Oil Level in this group Recover the refrigerant from the refrigerant system and inspect the refrig...

Page 2734: ...SIDE PRESSURE IS TOO HIGH AND HIGH SIDE PRESSURE IS TOO LOW 1 Accessory drive belt slipping 1 Refer to Cooling for more information Inspect the accessory drive belt condition and tension Tighten or r...

Page 2735: ...olant supply heater hose If the return hose is much cooler than the sup ply hose locate and repair the engine coolant flow obstruction in the cooling system Refer to Cooling for the procedures An alte...

Page 2736: ...Insufficient air flow through heater housing 6 Remove foreign material or obstructions from cowl air intake 7 Improper blower motor operation 7 Refer to Distribution Blower Motor Diagnosis and Testin...

Page 2737: ...iscous fan Clutch Control relay PCM Draw 2 3 9 amps 12V 6 0 5V 70 F Gap 0 0169 0 0319 DRB IIIT Reads TPS RPM A C switch test Actuators clutch relay TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPT...

Page 2738: ...WITCH 20 REMOVAL 21 INSTALLATION 21 A C LOW PRESSURE SWITCH DESCRIPTION 21 OPERATION 21 DIAGNOSIS AND TESTING 21 A C LOW PRESSURE SWITCH 21 REMOVAL 21 INSTALLATION 22 BLOWER MOTOR RELAY DESCRIPTION 22...

Page 2739: ...the vacuum supply tube black near the dash panel in the engine compart ment On diesel engines the vacuum check valve is integral to the engine vacuum pump nipple and is threaded into the vacuum pump T...

Page 2740: ...ermine the vacuum line color of the vacuum circuit that is leaking To determine the vacuum line colors see the Vacuum Circuits chart Fig 3 4 Disconnect and plug the vacuum line from the component fitt...

Page 2741: ...Fig 3 VACUUM CIRCUITS 24 12 CONTROLS BR BE CONTROLS Continued...

Page 2742: ...tor switch in the lowest speed position start the engine and run it at normal idle 3 The compressor clutch coil voltage should read within 0 2 volts of the battery voltage If there is voltage at the c...

Page 2743: ...Kit 6460 is used to remove the clutch plate Fig 6 This compressor also uses a shaft key which must be removed 6 Remove the external front housing snap ring with snap ring pliers Fig 7 7 Install the l...

Page 2744: ...OTECTOR 2 JAWS Fig 9 INSTALL PULLER PLATE 1 BOLT 2 PULLER PLATE AND BOLT 3 BOLT 4 JAWS Fig 10 CLUTCH COIL LEAD WIRE HARNESS 1 CLIP Fig 11 CLUTCH FIELD COIL SNAP RING REMOVE 1 FIELD COIL 2 SNAP RING BR...

Page 2745: ...cess to indicate the bottoming of the rotor 7 Install the external front rotor snap ring with snap ring pliers The bevel side of the snap ring must be facing outward Press the snap ring to make sure i...

Page 2746: ...m the a c heater control the a c low pressure switch and the a c high pressure switch The compressor clutch relay is located in the Power Distribution Center PDC in the engine compart ment Refer to th...

Page 2747: ...e 2 Remove the cover from the Power Distribution Center PDC Fig 17 3 Refer to the label on the PDC for compressor clutch relay identification and location 4 Unplug the compressor clutch relay from the...

Page 2748: ...control switch operation The heater and air conditioner systems should respond as described in the owner s manual in the vehicle glove box to each mode selected Reduce the engine speed to normal idle...

Page 2749: ...een ground and the Powertrain Control Module PCM The switch contacts open and close causing the PCM to turn the compressor clutch on and off This pre vents compressor operation when the discharge line...

Page 2750: ...witch contacts will close when the suction pressure rises to about 255 296 kPa 37 43 psi or above Lower ambient temperatures below about 1 C 30 F will also cause the switch contacts to open This is du...

Page 2751: ...ed the blower motor receives no battery current The blower motor relay is located in the PDC in the engine compartment Refer to the PDC label for blower motor relay identification and location The blo...

Page 2752: ...between the PDC cavity for relay terminal 85 and a good ground at all times If not OK repair the open circuit as required REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the cover...

Page 2753: ...d be continuity If OK repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required If not OK replace the faulty blower motor resistor REMO...

Page 2754: ...ck for continuity between the ground circuit ter minal and each of the blower motor driver circuit ter minals of the a c heater control as you move the blower motor switch knob to each of the four spe...

Page 2755: ...OLUMN 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 FORMIN...

Page 2756: ...ully snap the heat defrost door crank arm on the heat defrost door pivot 3 Plug in the two vacuum harness connectors to the heat defrost door actuator 4 Install the HVAC housing in the vehicle Refer t...

Page 2757: ...tion door actuator to the mounting bracket on the HVAC housing Tighten the mounting nuts until the recirculation air door actuator is seated to the mounting bracket 4 Plug in the vacuum harness connec...

Page 2758: ...eck valve to the vacuum line fittings not ing the proper orientation of the check valve in the line On models with a diesel engine screw the check valve and nipple unit into the engine vacuum pump Tig...

Page 2759: ...reservoir to the studs on the dash panel near the right end of the cowl plenum 8 Remove the vacuum reservoir from the dash panel studs INSTALLATION 1 Install the vacuum reservoir on the dash panel stu...

Page 2760: ...system to receive a sufficient volume of outside air It is also important to keep the air intake openings clear of debris because leaf particles and other debris that is small enough to pass through...

Page 2761: ...of both sides of the panel outlet barrel until the pivots snap into place BLOWER MOTOR DESCRIPTION The blower motor and blower wheel are located in the passenger side end of the HVAC housing below th...

Page 2762: ...the blower motor wire harness connector and operate the HVAC system If the noise goes away possible causes include Foreign material in the HVAC housing Improper blower motor mounting Improper blower...

Page 2763: ...oster outlets and cannot be serviced separately The demister tubes on each end of the main demister duct are only serviced in the instrument panel assembly 1 Remove the instrument panel top cover from...

Page 2764: ...COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS CHARGE BEFORE PERFORMI...

Page 2765: ...le to disengage the snap features from the cowl plenum opening 4 Remove the HVAC housing inlet baffle from the cowl plenum panel DISASSEMBLY 1 Place the HVAC housing upside down on a work bench 2 Remo...

Page 2766: ...to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 9 Reinstall the PCM to the dash panel Refer to Electronic Control Modules for the procedures 10 Reinstall the ins...

Page 2767: ...RFORMING THE FOLLOWING OPERATION Refer to 24 HEAT ING AIR CONDITIONING PLUMBING WARNING Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTION 1 Remove and disassemble the HVAC housing Refer to 24 HEAT...

Page 2768: ...ACITOR 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...

Page 2769: ...UMBING DESCRIPTION A C LINE COUPLERS Spring lock type refrigerant line couplers are used to connect many of the refrigerant lines and other components to the refrigerant system These couplers require...

Page 2770: ...integrity of the refrigerant system The refrigerant lines and hoses cannot be repaired and if faulty or damaged they must be replaced WARNING THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HI...

Page 2771: ...e refrigerant lines or tubes Refrigerant oil will absorb moisture from the atmo sphere if left uncapped Do not open a container of refrigerant oil until you are ready to use it Replace the cap on the...

Page 2772: ...r or replacement To detect a leak in the refrigerant system with an electronic leak detector perform one of the following procedures SYSTEM EMPTY 1 Evacuate the refrigerant system Refer to 24 HEATING...

Page 2773: ...frigerant oil of the type recom mended for the compressor in the vehicle 5 Fit the female half of the coupler fitting over the male half of the fitting 6 Push together firmly on the two halves of the...

Page 2774: ...pen to the atmosphere it must be evacuated before the system can be charged If moisture and air enters the system and becomes mixed with the refrigerant the com pressor head pressure will rise above a...

Page 2775: ...gh temperature refrigerant vapor which is then pumped to the condenser through the compressor dis charge port The compressor cannot be repaired If faulty or damaged the entire compressor assembly must...

Page 2776: ...ntinues replace the compressor and repeat Step 1 REMOVAL WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDIT...

Page 2777: ...ins thus causing the refrigerant to change to a liquid state OPERATION When the refrigerant gas gives up its heat it con denses When the refrigerant leaves the condenser it has become a high pressure...

Page 2778: ...the outside of the upper radiator crossmember Fig 6 b Tilt the condenser away from the engine compartment far enough to grasp the top of the condenser with both hands c Lift the condenser far enough t...

Page 2779: ...Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE NOTE If the condenser is replaced add 30 millili ters 1 fluid ounce of refrigerant oil to the refriger ant...

Page 2780: ...oupler to the accumulator Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE A C LINE COUPLERS 2 Install a new gasket and the discharge line block fitting over the stud on the condenser...

Page 2781: ...the dash panel Fig 10 5 Remove the liquid line from the vehicle INSTALLATION WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 2...

Page 2782: ...or coil into the bottom of the HVAC housing 2 Reassemble and reinstall the HVAC housing in the vehicle Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION HVAC HOUSING ASSEMBLY Refer to 24 HEATING AIR...

Page 2783: ...line assembly must be replaced Refer to 24 HEATING AIR CONDITIONING PLUMBING LIQUID LINE REMOVAL ACCUMULATOR DESCRIPTION The accumulator is mounted in the engine com partment between the a c evaporat...

Page 2784: ...negative cable 7 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 8 Charge the refrigerant system Refer to 24 HEATING AIR C...

Page 2785: ...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 re...

Page 2786: ...less there has been an oil loss An oil loss may occur due to a rupture or leak from a refrigerant line a connector fitting a compo nent or a component seal If a leak occurs add 30 milliliters 1 fluid...

Page 2787: ......

Page 2788: ...assume the entire switch circuit to the PCM functions properly Connect the DRB scan tool to the data link connector and access the state display screen Then access either State Display Inputs and Outp...

Page 2789: ...m detected in oxygen sensor heater relay circuit P0036 M 1 2 O2 Sensor Heater Relay Circuit Problem detected in oxygen sensor heater relay circuit P0106 Barometric Pressure Out of Range MAP sensor inp...

Page 2790: ...unction P0137 M 1 2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range P0138 M 1 2 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained abov...

Page 2791: ...P0175 M 2 1 Fuel System Rich A rich air fuel mixture has been indicated by an abnormally lean correction factor P0176 Loss of Flex Fuel Calibration Signal No calibration voltage present from flex fue...

Page 2792: ...ls Both Low Problem detected with idle validation circuits within APPS P0223 M Idle Validation Signals Both High Above 5 Volts Problem detected with idle validation circuits within APPS P0230 Transfer...

Page 2793: ...tion Coil Draws Too Much Current A coil 1 5 is drawing too much current P0351 M Ignition Coil 1 Primary Circuit Peak primary circuit current not achieved with maximum dwell time P0352 M Ignition Coil...

Page 2794: ...ed level P0432 M 1 2 Catalytic Converter Efficiency Catalyst 2 1 efficiency below required level P0441 M Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during evaporative emissi...

Page 2795: ...d P0604 RAM Check Failure Transmission control module RAM self test fault detected Aisin transmission P0605 ROM Check Falure Transmission control module ROM self test fault detected Aisin transmission...

Page 2796: ...Trans Relay Circuit in JTEC RE transmissions P0748 M Governor Pressure Sol Control Trans Relay Circuits An open or shorted condition detected in the governor pressure solenoid or relay circuits 4 spe...

Page 2797: ...condition detected P1284 M Fuel Injection Pump Battery Voltage Out Of Range Fuel injection pump module internal fault condition detected Engine power will be derated P1285 M Fuel Injection Pump Contr...

Page 2798: ...when the auto shutdown relay is energized P1389 M No ASD Relay Output Voltage at PCM An open condition detected In the ASD relay output circuit P1390 Timing Belt Skipped 1 Tooth or More Relationship...

Page 2799: ...ontrol circuit of the low speed radiator fan control relay P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan control relay control circuit This includes PWM...

Page 2800: ...ived No CCD J1850 messages received from the cluster control module P1682 G Charging System Voltage Too Low Battery voltage sense input below target charging voltage during engine operation and no sig...

Page 2801: ...s received from the electronic transmission control module EATX or the Aisin transmission controller P1698 No CCD Messages received from PCM Bus communication failure to PCM A 9Companion DTC9 was set...

Page 2802: ...onsible for efficiently coordinating the operation of all the emissions related compo nents The PCM is also responsible for determining if the diagnostic systems are operating properly The software de...

Page 2803: ...ed to test the heater by isolating the effect of the heater element on the O2S sensor output voltage from the other effects LEAK DETECTION PUMP MONITOR IF EQUIPPED The leak detection assembly incorpor...

Page 2804: ...t maintain the optimum A F ratio then the MIL will be illuminated CATALYST MONITOR To comply with clean air regulations vehicles are equipped with catalytic converters These converters reduce the emis...

Page 2805: ...is done by watching for a TPS indication of a greater or lesser throttle opening than MAP and engine rpm indicate In the case of the TPS if engine vacuum is high and engine rpm is 1600 or greater and...

Page 2806: ...p Certain DTC s will set a companion DTC in the opposite control module This means that after repair the DTC must be erased from both modules Certain criteria must be met before the ECM or PCM will st...

Page 2807: ...y the Task Manager may not allow a two trip fault to mature The Task Manager will sus pend the maturing of a fault if a condition exists that may induce an erroneous failure This prevents illuminating...

Page 2808: ...completed in the same drive cycle If the MIL is ON and a DTC was set by the Fuel Monitor or Misfire Monitor both continuous moni tors the vehicle must be operated in the Similar Condition Window for a...

Page 2809: ...m Good Trip the engine must be in the Similar Conditions Window Adaptive Memory Factor must be less than cali brated threshold and the Adaptive Memory Factor must stay below that threshold for a calib...

Page 2810: ...ver it might store diagnostic trouble codes as a result of spread connec tor pins OPERATION NON MONITORED CIRCUITS DIESEL The PCM and or the ECM will not monitor certain malfunctioning circuits or com...

Page 2811: ...e the ECM to store a Manifold Air Pressure MAP sensor DTC boost pressure problem detected PCM ECM SYSTEM GROUNDS The PCM ECM cannot directly determine poor sys tem grounds However one or more DTC s ma...

Page 2812: ...ING 30 TESTING ONE WAY CHECK VALVE 30 REMOVAL 30 INSTALLATION 30 AIR INJECTION DESCRIPTION AIR INJECTION SYSTEM The air injection system Fig 1 Fig 2 or Fig 3 is used on 5 9L V 8 and 8 0L V 10 heavy du...

Page 2813: ...ERTORS 2 2 ONE WAY CHECK VALVES 2 3 88Y CONNECTOR 4 PRESSURE RELIEF VALVE 5 HOSE 6 CLAMPS 7 HOSE 8 CLAMP 9 AIR INJECTION PUMP 10 INLET AIR FITTING 11 OUTLET AIR FITTING 12 METAL CONNECTING TUBE 13 HOS...

Page 2814: ...essure relief valve Fig 1 Pressure relief holes in the relief valve will prevent excess downstream pressure If excess down stream pressure occurs at the relief valve it will be vented into the atmosph...

Page 2815: ...AIR INJECTION PUMP The air injection system and air injection pump is not completely noiseless Under normal conditions noise rises in pitch as engine speed increases To determine if excessive noise i...

Page 2816: ...p pulley mounting bolts Fig 4 3 Relax the automatic belt tensioner and remove the engine accessory drive belt Refer to Cooling Sys tem See Belt Removal Installation 4 Remove the three air pump pulley...

Page 2817: ...and air injection pump The check valve will protect the system if the air injection pump belt fails an air hose ruptures or exhaust system pressure becomes abnormally high DIAGNOSIS AND TESTING ONE WA...

Page 2818: ...coal 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...

Page 2819: ...5 9L engine EVAP PURGE SOLENOID DESCRIPTION All 3 9L 5 2L 5 9L 8 0L gasoline powered engines use a duty cycle EVAP canister purge solenoid The solenoid regulates the rate of vapor flow from the EVAP...

Page 2820: ...est test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel position The vent seal will remain closed while the pump is cycling This is due to...

Page 2821: ...P filter to mounting bracket Tighten bolt to 7 N m 65 in lbs torque 3 Carefully install vapor vacuum lines to LDP and install hose to LDP filter The vapor vacuum lines and hoses must be firmly connect...

Page 2822: ...ke man ifold The PCV system manages crankcase pressure and meters blow by gases to the intake system reducing engine sludge formation The PCV valve contains a spring loaded plunger This plunger meters...

Page 2823: ...cover with noticeable force This will be after allowing approximately one minute for crank case pressure to reduce 4 Turn engine off and remove PCV valve from valve cover The valve should rattle when...

Page 2824: ...outside of right frame rail Fig 12 OPERATION Two maintenance free EVAP canisters are used with all 3 9L 5 2L 5 9L 8 0L gasoline powered engines The EVAP canisters are filled with granules of an activa...

Page 2825: ...t located below rear of vehicle cab on outside of right frame rail Fig 13 1 Place each canister to mounting bracket Fig 13 2 Install nuts and tighten to 9 N m 80 in lbs torque 3 Install fuel tubes lin...

Page 2826: ...ler products as well as upon your dealership and on yourself as a competent conscientious techni cian As manufacturing quality has improved prep pro cedures have come to serve as additional quality ch...

Page 2827: ...Fig 1 NEW VEHICLE PREPARATION FORM 30 2 NEW VEHICLE PREPARATION BR BE INTRODUCTION Continued...

Page 2828: ...uses and other items Ensure that IOD fuse is removed Check battery test indicator when easily visible or use voltmeter battery must be at 12 4 volts or greater Charge to ensure green dot visibility pe...

Page 2829: ...fter a fully warmed up engine is turned off or before starting the engine after it has been off over night For the most accurate readings the vehicle should be on level ground Wipe up any excess oil t...

Page 2830: ...ing Fluid are specially formulated for use with power steering hoses and seals Check the fluid level it should be maintained at the proper level indicated on the dipstick or as viewed through the tran...

Page 2831: ...tank must be between the minimum and maximun marks Fig 7 If coolant is added use a 50 50 309F protection con centration of the recommended Refer to the Service Information for specificate Mopart anti...

Page 2832: ...ed after prep should have the IOD fuse that activates the accessories pulled to prevent battery drain NOTE Ensure that the IOD fuse is removed to pre vent battery drain and possible damage Vehicles st...

Page 2833: ...he tire bead Be sure to adjust to proper specifica tion INSPECTION VISUAL CAUTION Before raising the vehicle on a hoist Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE for the proper lift...

Page 2834: ...Fig 16 EXHAUST HANGERS Fig 17 TAILPIPE HANGERS Fig 18 TRANSMISSION COOLER LINES Fig 19 TRANSFER CASE INSPECTION BR BE NEW VEHICLE PREPARATION 30 9 UNDER VEHICLE Continued...

Page 2835: ...Backlight INSPECTION FIT AND FINISH 1 Remove all protective coatings covers Remove protective film from body moldings 2 Make sure body is free from paint chips scratches sags run dirt or corrosion To...

Page 2836: ...from the door sills NOTE Windows should be in the full up position during these tests except for the lock tests Open each door inside and out to check the release mechanism and ease of operation Parti...

Page 2837: ...ps Glove box light Ashtray light Cigar lighter light All gauge lights Radio display Door mounted lights if equipped Illuminated entry system if equipped 3 Visually inspect and operate all exterior lig...

Page 2838: ...spect the operation of front seat mechanical slides and power adjusters Fig 31 Check the seatback recliner for ease of release and operation Check the rear seatback latches for ease of release On fold...

Page 2839: ...re that all doors open close easily Fig 33 6 Check that the glove box door opens closes eas ily Fig 34 7 Check that the console door opens closes easily Fig 35 INSTALLATION SHIPPED LOOSE ITEMS 1 Insta...

Page 2840: ...t that may not be included on the New Vehicle Preparation Form Fill fuel tank with specified grade of fuel INSPECTION FUEL Fill fuel tank with specified grade of gasoline reg ular midgrade or premium...

Page 2841: ...tly Be free from stalling Idle smoothly and at proper speed Be free from stumbling or hesitation Produce sufficient power Be free from unusual noises Operate within the proper temperature range Stop w...

Page 2842: ...der or vibration when braking INSPECTION SPEED CONTROL Check the following speed control functions Fig 42 Check on off switch Check set operation Check resume function Check accelerate and decelerate...

Page 2843: ...old output at outlets 15 Check that fan operation is quiet INSPECTION WINDSHIELD WIPERS WASHERS 1 Check washer spray pattern for proper opera tion and aim 2 Check intermittent wipe feature for proper...

Page 2844: ...e a brake interlock system On these vehicles be sure that you cannot shift out of PARK without pressing the brake pedal INSPECTION NEUTRAL SAFETY SWITCH 1 On vehicles with an automatic transmission or...

Page 2845: ...lable features Programma ble electronic features are subject to change and may be added or deleted from specific vehicle models 1 The programmable electronic features that may be provided on the vehic...

Page 2846: ...RKE transmitter to unlock the doors the driver s door only unlocks With the second press of the RKE transmitter the remaining doors and the liftgate unlock With the remote unlock feature enabled the f...

Page 2847: ...hicle Show the new owner where the controls and gauges are and explain how they operate STANDARD PROCEDURE INSPECTION INFORMATION LABELS Verify that the following labels are installed and legible Emis...

Page 2848: ...URE ADDING 7 16 ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL 23 44 ADJUSTER DIAGNOSIS TESTING POWER LUMBAR 8N 18 ADJUSTER INSTALLATION SEAT BELT TURNING LOOP 8O 29 ADJUSTER INSTALLATION SEAT TRACK 23...

Page 2849: ...8R 12 ARMREST CONSOLE INSTALLATION CENTER SEAT 23 132 ARMREST CONSOLE REMOVAL CENTER SEAT 23 132 ARMREST LATCH COVER INSTALLATION CENTER SEAT 23 132 ARMREST LATCH COVER REMOVAL CENTER SEAT 23 132 ASD...

Page 2850: ...GLASS INSTALLATION 23 147 BACKLITE VENT GLASS REMOVAL 23 147 BAFFLE INSTALLATION HVAC HOUSING INLET 24 37 BAFFLE REMOVAL HVAC HOUSING INLET 24 36 BALANCE STANDARD PROCEDURES TIRE AND WHEEL 22 4 BALL J...

Page 2851: ...ION SEAT BACK 23 135 BENCH SEAT REMOVAL SEAT 23 133 BENCH SEAT REMOVAL SEAT BACK 23 135 BETTS INSTALLATION CONNECTOR THOMAS 8W 01 10 BETTS REMOVAL CONNECTOR THOMAS 8W 01 9 BEZEL INSTALLATION CLUSTER 2...

Page 2852: ...P SWITCH OPERATION 8L 4 BRAKE LAMP SWITCH REMOVAL 8L 5 BRAKE ROTOR DIAGNOSIS AND TESTING DISC 5 20 BRAKE SHOES 2500 3500 INSTALLATION REAR DRUM IN HAT PARK 5 42 BRAKE SHOES 2500 3500 REMOVAL REAR DRUM...

Page 2853: ...JOINTS REMOVAL SINGLE 3 33 3 65 CAREFUL NEW VEHICLE PREPARATION DESCRIPTION THE IMPORTANCE OF 30 1 CARGO BOX INSTALLATION 23 97 CARGO BOX REMOVAL 23 96 CARGO DOOR ADJUSTMENT 23 78 CARPETS AND FLOOR MA...

Page 2854: ...SE 7 2 CLAMPS OPERATION HOSE 7 2 CLASSIFICATION OF LUBRICANTS STANDARD PROCEDURE 0 3 CLEANER ELEMENT INSTALLATION AIR 9 245 CLEANER ELEMENT REMOVAL AIR 9 244 CLEANING AND INSPECTION OIL COOLER LINES 9...

Page 2855: ...PASS HOSE WITHOUT AIR 7 78 CONDITIONING REMOVAL WATER PUMP BYPASS HOSE WITH AIR 7 74 CONDITIONING REMOVAL WATER PUMP BYPASS HOSE WITHOUT AIR 7 77 CONDITIONS DIAGNOSIS AND TESTING SPARK PLUG 8I 16 CONN...

Page 2856: ...R 8 0L DESCRIPTION TRANS 7 82 COOLER 8 0L INSTALLATION TRANS 7 85 COOLER 8 0L OPERATION TRANS 7 82 COOLER 8 0L REMOVAL TRANS 7 84 COOLER INSTALLATION AIR TO OIL 7 88 COOLER LINES CLEANING AND INSPECTI...

Page 2857: ...ECTION 9 138 9 194 9 24 9 253 9 81 CYLINDER HEAD COVER S INSTALLATION 9 138 9 194 9 24 9 253 9 81 CYLINDER HEAD COVER S REMOVAL 9 138 9 194 9 24 9 253 9 81 CYLINDER HEAD GASKET FAILURE DIAGNOSIS AND T...

Page 2858: ...DIESEL FUEL DELIVERY SYSTEM DESCRIPTION 14 54 DIESEL FUEL INJECTION SYSTEM DESCRIPTION 14 87 DIESEL FUEL SYSTEM SPECIAL TOOLS 14 59 DIESEL FUEL TANK DESCRIPTION 14 78 DIESEL SPECIFICATIONS 5 9L 9 242...

Page 2859: ...32 DRUM DIAGNOSIS AND TESTING BRAKE 5 33 DRUM INSPECTION 5 33 DRUM OPERATION 5 32 DRUM BRAKES INSTALLATION REAR PARK BRAKE CABLE 2500 3500 SERIES WITH 5 39 DRUM BRAKES REMOVAL REAR PARK BRAKE CABLES 2...

Page 2860: ...ATURE GAUGE OPERATION 8J 19 ENGINES DESCRIPTION COMPONENT MONITORS DIESEL 25 18 ENGINES DESCRIPTION COMPONENT MONITORS GAS 25 18 ENGINES DESCRIPTION FUEL REQUIREMENTS GAS 0 1 ENGINES DESCRIPTION V 6 V...

Page 2861: ...LOOR SHIFT BOOT INSTALLATION 4WD 23 122 FLOOR SHIFT BOOT REMOVAL 4WD 23 122 FLOOR STOWAGE TRAY INSTALLATION REAR 23 121 FLOOR STOWAGE TRAY REMOVAL REAR 23 121 FLOW 3 9L 5 2L 5 9L ENGINE DESCRIPTION CO...

Page 2862: ...ATION 25 33 FUEL FILTER STANDARD PROCEDURES WATER DRAINING AT 14 56 FUEL FILTER WATER SEPARATOR DESCRIPTION 14 59 FUEL FILTER WATER SEPARATOR INSTALLATION 14 61 FUEL FILTER WATER SEPARATOR OPERATION 1...

Page 2863: ...ARY 21 240 21 410 21 585 21 757 GENERAL WARNINGS 8W 01 5 GENERATOR DESCRIPTION 8F 29 GENERATOR INSTALLATION 8F 30 GENERATOR OPERATION 8F 29 GENERATOR REMOVAL 8F 30 GENERATOR CARTRIDGE FUSE DESCRIPTION...

Page 2864: ...S AND TESTING A C 24 19 HEATER CONTROL INSTALLATION A C 24 20 HEATER CONTROL OPERATION A C 24 18 HEATER CONTROL REMOVAL A C 24 19 HEATER CORE DESCRIPTION 24 55 HEATER CORE INSTALLATION 24 56 HEATER CO...

Page 2865: ...41 I F S STANDARD PROCEDURES ALIGNMENT 2 2 IGNITION SPECIFICATIONS TORQUE 8I 2 IGNITION CIRCUIT SENSE DESCRIPTION 8E 17 IGNITION CIRCUIT SENSE OPERATION 8E 19 IGNITION COIL RESISTANCE 3 9L 5 2L 5 9L E...

Page 2866: ...ARTRAIN OUTPUT SHAFT 21 241 21 411 21 587 21 760 INSPECTION PUSHRODS 9 250 INSPECTION RADIATOR 3 9L 5 2L 5 9L 7 61 INSPECTION RADIATOR 5 9L DIESEL 7 65 INSPECTION RADIATOR 8 0L 7 62 INSPECTION RADIATO...

Page 2867: ...DERHOOD 8L 31 LAMP REMOVAL VANITY 8L 37 LAMP AND SWITCH INSTALLATION GLOVE BOX 8L 35 LAMP AND SWITCH REMOVAL GLOVE BOX 8L 35 LAMP MIL DESCRIPTION MALFUNCTION INDICATOR 8J 24 LAMP MIL OPERATION MALFUNC...

Page 2868: ...YLINDER 8N 5 LOCK SWITCH DESCRIPTION POWER 8N 8 LOCK SWITCH DIAGNOSIS TESTING DOOR CYLINDER 8N 5 LOCK SWITCH DIAGNOSIS AND TESTING POWER 8N 8 LOCK SWITCH INSTALLATION DOOR CYLINDER 8N 6 LOCK SWITCH OP...

Page 2869: ...14 MODULE DESCRIPTION AIRBAG CONTROL 8O 6 MODULE DESCRIPTION BODY CONTROL CENTRAL TIMER 8E 1 MODULE DESCRIPTION DAYTIME RUNNING LAMP 8L 9 MODULE DESCRIPTION FUEL PUMP 14 12 MODULE DESCRIPTION FUEL TA...

Page 2870: ...SPECIFICATIONS 21 83 NV5600 ASSEMBLY MANUAL 21 110 NV5600 DESCRIPTION MANUAL 21 91 NV5600 DISASSEMBLY MANUAL 21 95 NV5600 INSTALLATION MANUAL 21 125 NV5600 OPERATION MANUAL 21 93 NV5600 REMOVAL MANUA...

Page 2871: ...569 21 741 OVERDRIVE UNIT INSTALLATION 21 234 21 404 21 577 21 750 OVERDRIVE UNIT REMOVAL 21 216 21 387 21 560 21 733 OVERFLOW VALVE DESCRIPTION 14 83 OVERFLOW VALVE DIAGNOSIS AND TESTING 14 84 OVERF...

Page 2872: ...AM OVERDRIVE 21 236 21 406 21 581 21 752 PISTON RETAINER CLEANING OVERRUNNING CLUTCH CAM OVERDRIVE 21 236 21 406 21 580 21 752 PISTON RETAINER DESCRIPTION OVERRUNNING CLUTCH CAM OVERDRIVE 21 235 21 40...

Page 2873: ...KY TEST DIAGNOSIS AND TESTING 3 161 PRE DELIVERY STORAGE DESCRIPTION 30 19 PRE DELIVERY STORAGE STANDARD PROCEDURE 30 20 PRE ALIGNMENT DIAGNOSIS AND TESTING 2 2 PRECAUTIONS CAUTION REFRIGERANT HOSES L...

Page 2874: ...Y DESCRIPTION FUEL 14 41 PUMP RELAY DESCRIPTION FUEL INJECTION 14 99 PUMP RELAY INSTALLATION FUEL 14 41 PUMP RELAY OPERATION FUEL 14 41 PUMP RELAY OPERATION FUEL INJECTION 14 99 PUMP RELAY REMOVAL FUE...

Page 2875: ...VIEW MIRROR REMOVAL 23 126 REAR WHEEL INSTALLATION STARDARD PROCEDURE DUAL 22 10 REAR WHEELHOUSE LINER INSTALLATION 23 96 REAR WHEELHOUSE LINER REMOVAL 23 96 REARVIEW MIRROR SUPPORT BRACKET INSTALLATI...

Page 2876: ...24 24 RESISTOR BLOCK OPERATION BLOWER MOTOR 24 23 RESISTOR BLOCK REMOVAL BLOWER MOTOR 24 24 RESONATOR INSTALLATION 11 13 RESONATOR REMOVAL 11 13 RESTRAINTS DESCRIPTION 8O 1 RESTRAINTS INSPECTION SEAT...

Page 2877: ...TALLATION REAR 23 144 SEAT INSTALLATION SEAT BENCH 23 133 SEAT INSTALLATION SEAT BACK BENCH 23 135 SEAT REMOVAL REAR 23 144 SEAT REMOVAL SEAT BENCH 23 133 SEAT REMOVAL SEAT BACK BENCH 23 135 SEAT SPLI...

Page 2878: ...RE 9 298 SEPARATOR DESCRIPTION FUEL FILTER WATER 14 59 SEPARATOR INSTALLATION FUEL FILTER WATER 14 61 SEPARATOR OPERATION FUEL FILTER WATER 14 59 SEPARATOR REMOVAL FUEL FILTER WATER 14 60 SERIES INSTA...

Page 2879: ...RK PLUG OPERATION 8I 16 SPARK PLUG REMOVAL 8I 18 SPARK PLUG CABLE DESCRIPTION 8I 19 SPARK PLUG CABLE INSTALLATION 8I 20 SPARK PLUG CABLE OPERATION 8I 19 SPARK PLUG CABLE REMOVAL 8I 20 SPARK PLUG CABLE...

Page 2880: ...INSTALLATION 23 116 STEERING COLUMN OPENING COVER REMOVAL 23 115 STEERING FLOW AND PRESSURE DIAGNOSIS AND TESTING POWER 19 4 STEERING GEAR HOUSING PLUG INSTALLATION 19 27 STEERING GEAR HOUSING PLUG R...

Page 2881: ...ER MIRROR 8N 12 SWITCH OPERATION POWER WINDOW 8N 24 SWITCH OPERATION PTO 14 104 14 48 SWITCH OPERATION SEAT BELT 8O 28 SWITCH OPERATION WASHER FLUID LEVEL 8R 7 SWITCH REMOVAL 8P 13 SWITCH REMOVAL A C...

Page 2882: ...PERATION ENGINE COOLANT 7 54 THERMOSTAT 5 9L DIESEL REMOVAL ENGINE COOLANT 7 55 THERMOSTAT 8 0L DESCRIPTION ENGINE COOLANT 7 52 THERMOSTAT 8 0L INSTALLATION ENGINE COOLANT 7 53 THERMOSTAT 8 0L OPERATI...

Page 2883: ...ALLATION 21 847 TRANSFER CASE NV231HD OPERATION 21 820 TRANSFER CASE NV231HD REMOVAL 21 822 TRANSFER CASE NV241HD ASSEMBLY 21 904 TRANSFER CASE NV241HD CLEANING 21 902 TRANSFER CASE NV241HD DESCRIPTIO...

Page 2884: ...19 TWEETER SPEAKER REMOVAL A PILLAR 8A 19 UNDERHOOD LAMP INSTALLATION 8L 32 UNDERHOOD LAMP REMOVAL 8L 31 UNDERHOOD LAMP UNIT INSTALLATION 8L 32 UNDERHOOD LAMP UNIT REMOVAL 8L 32 UNIT ADJUSTMENTS FOG...

Page 2885: ...RIPTION 8P 1 VEHICLE THEFT SECURITY DESCRIPTION 8Q 1 VEHICLE THEFT SECURITY OPERATION 8Q 2 VEHICLE THEFT SECURITY SYSTEM DIAGNOSIS AND TESTING 8Q 3 VENT INSTALLATION BODY 23 126 VENT INSTALLATION EXHA...

Page 2886: ...1 WHEEL CYLINDERS INSPECTION 5 31 WHEEL CYLINDERS INSTALLATION 5 32 WHEEL CYLINDERS REMOVAL 5 31 WHEEL INSPECTION DIAGNOSIS AND TESTING 22 10 WHEEL INSTALLATION STARDARD PROCEDURE DUAL REAR 22 10 WHEE...

Page 2887: ......

Page 2888: ...Please include page number What topics are hard to locate confusing or not covered completely What comments or suggestions do you have Your Name Dealership Address Manual Name Year and Number All comm...

Page 2889: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

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