Dodge Dakota 2001 Service Manual Download Page 983

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Fig. 21 MANUAL TRANSMISSION CONNECTORS 3.9L

8W - 90 - 24

8W-90 CONNECTOR/GROUND LOCATIONS

CONNECTOR/GROUND LOCATIONS (Continued)

Summary of Contents for Dakota 2001

Page 1: ...ontrol 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 Bumpe...

Page 2: ...vehicle The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards The label also lists Month and year of vehicle manufacture Gross Vehicle Weight Rating G...

Page 3: ...N 1 Country of Origin 1 USA 2 Make B Dodge 3 Vehicle Type 7 Truck 4 Gross Vehicle Weight Rating F 4001 5000 lbs G 5001 6000 lbs H 6001 7000 lbs 5 Vehicle Line G Dakota Dakota Sport Dakota 4x4 L Dakota...

Page 4: ...the body code plate There are seven lines of information on the body code plate Lines 5 6 and 7 are not used to define service information Informa tion reads from left to right starting with line 4 in...

Page 5: ...for proper breakdown of VIN code BODY CODE PLATE LINE 1 DIGITS 1 THROUGH 6 Body in white assembly sequence DIGITS 7 THROUGH 9 Open Space DIGITS 10 THROUGH 12 Cargo box code XBS Sweptline DIGITS 13 THR...

Page 6: ...RY Figure art specifications and tightening torque ref erences in this manual are identified in metric and SAE format During any maintenance or repair procedures it is important to salvage all fastene...

Page 7: ...Fig 7 FASTENER IDENTIFICATION 6 INTRODUCTION AN FASTENER USAGE Continued...

Page 8: ...Fig 8 FASTENER STRENGTH AN INTRODUCTION 7 FASTENER USAGE Continued...

Page 9: ...lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7376 ft lbs Inches Hg 60 F x 3 377 Kilopascals kPa kPa x 0 2961 Inches Hg psi x 6 895 Kilopascals kPa kPa x 0 145 psi Inches x 25 4 Millimeters mm mm x 0...

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

Page 11: ...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 Fig 10 Fig 10 TORQUE SPEC...

Page 12: ...GINE OIL WITH FILTER 2 5L Engine 4 3L 4 5 qts 3 9L Engine 3 8L 4 0 qts 4 7L Engine 5 7L 6 0 qts 5 9L Engine 4 7L 5 0 qts COOLING SYSTEM 2 5L Engine 9 3L 9 8 qts 3 9L Engine 13 3L 14 0 qts 4 7L Engine...

Page 13: ...on the front of an oil container means that the oil has been certified by the American Petroleum Institute API to meet all the lubrication requirements specified by DailmlerChrysler Corporation Refer...

Page 14: ...nths to reduce carbon monoxide emissions Fuels blended with these oxygenates may be used in your vehicle CAUTION DO NOT use gasoline containing METH ANOL Gasoline containing methanol may damage critic...

Page 15: ...eze protection and less corrosion protection The cooling system is designed around the coolant The coolant must accept heat from engine metal in the cylinder head area near the exhaust valves and engi...

Page 16: ...INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT PO...

Page 17: ...uch 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 eventually become...

Page 18: ...ades as required Once A Month Check tire pressure and look for unusual wear or damage Inspect battery and clean and tighten terminals as required Check fluid levels of coolant reservoir power steering...

Page 19: ...and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change Inspect auto tension drive belt and replace if required 3 9L 5 9L 82 500 Miles 132 000 km or at 66 month...

Page 20: ...ront axle fluid 4x4 Inspect brake linings 15 000 Miles 24 000 km Change engine oil Replace engine oil filter Inspect engine air cleaner element replace as necessary 18 000 Miles 29 000 km Change engin...

Page 21: ...ange filter 4 7L only Lubricate front suspension ball joints if required Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings Inspect auto tension drive belt and replace if require...

Page 22: ...l filter Lubricate front suspension ball joints if required Drain and refill automatic transmission fluid Replace filter and adjust bands 3 9L 5 9L Drain and refill automatic transmission fluid and ch...

Page 23: ...UPPORTED WHEN THE VEHICLE IS LIFTED WITH THE PARKING BRAKE APPLIED NOTE When a frame contact type hoist is used verify that the lifting pads are positioned properly Fig 7 A vehicle can be lifted with...

Page 24: ...ne in the vehicle which has the booster battery let the engine idle a few minutes then start the engine in the vehicle with the dis charged battery CAUTION Do not crank starter motor on disabled vehic...

Page 25: ...e vehicle Install lug nuts on wheel attaching studs to retain brake drums RAMP ANGLE If a vehicle with flat bed towing equipment is used the approach ramp angle should not exceed 15 degrees TOWING WHE...

Page 26: ...e vehicle off the ground and install tow dollies under front wheels 2 Attach wheel lift device to rear wheels 3 Attach safety chains to frame rails Route chains so not to interfere with tail pipe when...

Page 27: ......

Page 28: ...er camber and toe Fig 1 CAUTION Never attempt to modify suspension or steering components by heating or bending NOTE Periodic lubrication of the front suspension steering system components may be requ...

Page 29: ...heels for excessive radial or lat eral runout and balance 4 Inspect ball studs linkage pivot points and steering gear for looseness roughness or binding 5 Inspect suspension components for wear and no...

Page 30: ...y before performing wheel alignment on a 4x4 vehicle Also when front suspen sion components have be replaced This measure must be performed with the vehicle supporting it s own weight and taken on bot...

Page 31: ...of the pivot bar in or out Then move the front of the pivot bar slightly in the opposite direction For example to increase a positive caster angle move the rear position of the pivot bar inward towar...

Page 32: ...LE WHEEL BASE CASTER 6 0 50 CAMBER 6 0 50 TOTAL TOE 6 0 06 4x2 111 9 2 99 0 25 0 10 130 9 3 13 0 25 0 10 4x4 111 9 3 16 0 25 0 10 130 9 3 27 0 25 0 10 MAXIMUM RT to LT DIFFERENCE 0 50 0 50 0 06 DAKOTA...

Page 33: ...n the cast iron steering knuckle spindles The double row hub bearings are sealed and lubricated for life The steering knuckles turn pivot on ball joints riv eted to the outboard portion of the suspens...

Page 34: ...the shock absorber SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Shock Absorber Upper Nut 26 19 Shock Absorber Lower Bolts 28 21 Lower Suspension Arm Front Nut 175 1...

Page 35: ...rol arm and inserted over the shaft 2 Install the bushing tool Fig 3 3 Press the bushing into the control arm 4 Install the washer and nut to the control arm shaft Tighten the nut to 167 N m 130 ft lb...

Page 36: ...L 4 Remove tie rod from steering knuckle arm Refer to 19 STEERING LINKAGE TIE ROD END REMOVAL 5 Remove the hub bearing Refer to 2 SUS PENSION FRONT HUB BEARING REMOVAL 6 Remove the shock absorber Refe...

Page 37: ...o the dial indicator 6 Reposition the pry bar under the upper suspen sion arm and on top of the frame rail Pry up on the upper suspension arm and record the dial indicator reading 7 If the travel exce...

Page 38: ...ist A squeaking noise from the shock absorber may 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 absorbe...

Page 39: ...stall Spring Compressor DD 1278 up through the lower suspension arm coil spring and upper shock mounting hole Fig 9 6 Tighten the tool lower nut to compress the coil spring 7 Remove the lower ball joi...

Page 40: ...rom the stabilizer bar INSTALLATION 1 Install the bushings on the stabilizer bar 2 Install the stabilizer bar on the frame and install the retainers and the bolts 3 Tighten the bolts to 60 N m 45 ft l...

Page 41: ...e installation insure pivot bar adjust ment bolts are in their original location Fig 12 1 Position suspension arm pivot bar on adjust ment bolts Install nuts and tighten to 210 N m 155 ft lbs 2 Positi...

Page 42: ...LATION 24 BUSHINGS CONTROL ARM REMOVAL 24 INSTALLATION 24 FRONT 4WD DESCRIPTION 4WD The front suspension is designed to allow each wheel to adapt to different road surfaces indepen dently The wheels a...

Page 43: ...ension 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 The suspension arm travel jounce is...

Page 44: ...with Remover C 4150A Fig 2 9 Remove the suspension arm pivot bolts and suspension arm from frame rail brackets Fig 3 INSTALLATION 1 Position the lower suspension arm at the frame rail brackets Install...

Page 45: ...wheel and tire assembly 3 Remove the brake caliper rotor shield and ABS wheel speed sensor if equipped Refer to 22 TIRES WHEELS WHEELS STANDARD PROCE DURE 4 Remove the front halfshaft Refer to 3 DIF...

Page 46: ...the chassis and connects to the frame crossmember The ends of the bar mount to the lower suspension arm All mounting points of the stabilizer bar are isolated by bushings OPERATION The stabilizer bar...

Page 47: ...166 N m 123 ft lbs 2 Install the brake rotor and caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION 3 Install the ABS wheel speed sensor if equipped Refer to 5 BRAKES ELECTRICAL FRONT...

Page 48: ...indicator plunger against the back side of the upper ball joint boss of the steering knuckle Fig 10 4 Grasp the top of the tire and pull outward then zero the dial indicator 5 Grasp the top of the tir...

Page 49: ...caused by movement between mounting bushings and metal brackets or attaching compo nents These noises can usually be stopped by tight ening the attaching nuts If the noise persists inspect for damaged...

Page 50: ...chor adjustment bolt that increases or decreases the angle of the torsion bar Increasing or decreasing the bar angle changes the angle of the suspension arms REMOVAL CAUTION The left and right side to...

Page 51: ...REMOVAL 1 Remove the control arm from the vehicle Refer to 2 SUSPENSION FRONT UPPER CON TROL ARM REMOVAL Refer to 2 SUSPEN SION FRONT LOWER CONTROL ARM REMOVAL 2 Mount the control arm securely in a vi...

Page 52: ...HOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo nents These noises can usually be stopped by tight eni...

Page 53: ...Absorber Lower Bolt 95 70 Shock Absorber Upper Bolt 95 70 Stabilizer Bar Frame Bracket Nuts 54 40 Stabilizer Bar Link Nuts 54 40 Stabilizer Bar Retainer Bolts 54 40 Spring U Bolt Nuts 2WD 149 110 Spr...

Page 54: ...spring and shackles use rubber bush ings The bushing help to isolate road noise OPERATION The springs control ride quality and maintain vehi cle ride height The shackles allow the springs to change t...

Page 55: ...ighten the spring eye pivot bolt nut and all shackle nuts to 163 N m 120 ft lbs STABILIZER BAR DESCRIPTION The stabilizer bar optional extends across the underside of the vehicle and is bolted to the...

Page 56: ...the shaft which connects the transmission transfer case to the axle differential This is the link through which the engine power is transmitted to the axle The propeller shaft is designed and built wi...

Page 57: ...Bearing 1 REAR AXLE 2 REAR PROPELLER SHAFT 3 TRANSMISSION EXTENSION HOUSING 4 CENTER BEARING Fig 3 Rear Propeller Shaft 1 REAR AXLE 2 REAR PROPELLER SHAFT 3 TRANSMISSION EXTENSION HOUSING 3 2 PROPELL...

Page 58: ...or expansion Before undercoating a vehicle the propeller shaft and the U joints should be covered to pre vent an out of balance condition and driveline vibration CAUTION Use original equipment replace...

Page 59: ...lean all the foreign material from the propel ler shaft and the universal joints 3 Inspect the propeller shaft for missing balance weights broken welds and bent areas If the pro peller shaft is bent i...

Page 60: ...y and re measure propeller shaft runout 8 Replace the propeller shaft if the runout still exceeds the limits RUNOUT SPECIFICATIONS Front of Shaft 0 020 in 0 50 mm Center of Shaft 0 025 in 0 63 mm Rear...

Page 61: ...bble in sight glass and 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 Re...

Page 62: ...l 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 12 Universal Joint Angle Two Piece Shaft 1 YOKES MUST BE IN SAME PLANE AN PROPELLER SHAFT 3 7 PROPELLER S...

Page 63: ...flange for installation reference 4 Remove companion flange bolts Fig 13 5 Remove transfer case flange bolts and remove propeller shaft INSTALLATION 1 Install propeller shaft with with all reference m...

Page 64: ...insulated in rubber and is mounted to the frame crossmember OPERATION The propeller shaft center bearing serves to divide the required propeller shaft length into two smaller shafts which has several...

Page 65: ...must be replaced as an assembly 1 Remove the propeller shaft 2 Using a soft drift tap the outside of the bear ing cap assembly to loosen snap ring 3 Remove snap rings from both sides of yoke Fig 15 4...

Page 66: ...r the trunnion and align the cap with the yoke bore Fig 19 Keep the needle bearings upright in the bearing assembly A needle bearing lying at the bottom of the cap will prevent proper assembly 4 Press...

Page 67: ...afts are located on either side of the differential and transmits power to the drive wheels while allowing for vertical movement in the vehicle s suspension DIAGNOSIS AND TESTING HALF SHAFT Check for...

Page 68: ...Fig 1 C V Drive Shaft Components AN HALF SHAFT 3 13 HALF SHAFT Continued...

Page 69: ...vehicle is on the surface with the brakes applied Fig 2 2 Raise the vehicle 3 Remove the skid plate if equipped 1 RETAINER HOUSING ASM 2 C CLIP 3 TRIPOD JOINT SPIDER 4 SEAL RETAINING CLAMP 5 INNER BO...

Page 70: ...wheel bearing grease on the axle shaft splines 3 Install the inner C V joint onto the axle shaft flange Push firmly on the shaft until the axle shaft snap ring engages with the groove on the inside of...

Page 71: ...osition the clamp locating tabs in the slots and tighten the clamp 4 Compress the clamp bridge with Remover In staller C 4124 Squeeze the tool handles to complete the tightening of the clamp Fig 8 Car...

Page 72: ...Fig 9 6 Remove slinger from the joint if damaged Use a brass drift and a hammer and tap slinger ring off the joint 7 Mark alignment marks on the bearing hub bearing cage and housing with dabs of paint...

Page 73: ...erence marks 3 Insert one of the bearing hub lands into a bear ing cage window Roll the hub into the cage Fig 14 Rotate the bearing hub 90 to complete the installa tion Fig 15 4 Insert bearing cage hu...

Page 74: ...nterconnecting shaft Retain the boot with a replacement clamp 9 Apply the required amount of lubricant to the outer C V joint and boot Fig 16 Bearing Cage Hub Installation 1 BALL RACE 2 BEARING CAGE W...

Page 75: ...L 1 Remove the axle driveshaft 2 Place the C V joint housing in a vise 3 Remove the inner boot retaining clamps Pull the inner boot back onto the interconnecting shaft Discard the retaining clamps 4 P...

Page 76: ...g 23 7 Insert small lip onto locating groove in shaft 8 Install small boot clamp in the boot groove Verify that the boot and lip are properly positioned on the shaft Position the clamp locating tabs i...

Page 77: ...if ferential pinion mate shaft is retained with a roll pin Differential bearing preload and ring gear backlash is adjusted by the use of shims select thick ness The shims are located between the diffe...

Page 78: ...es at a faster rate Drive the vehicle and load the differen tial If bearing noise occurs the rear pinion bearing is the source of the noise If the bearing noise is heard during a coast the front pinio...

Page 79: ...oise DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1 Wheel loose 1 Tighten loose nuts 2 Faulty brinelled wheel bearing 2 Replace bearing Axle Shaft Noise 1 Misaligned axle tube 1 I...

Page 80: ...ity 2 Improper grade of lubricant 2 Replace scored gears Fill differential with the correct fluid type and quantity 3 Excessive spinning of one wheel tire 3 Replace scored gears Inspect all gears pini...

Page 81: ...ps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Raise and support the vehicle 2 Remove the skid plate if equipped 3 Remove skid plate support cro...

Page 82: ...ar set is being installed note the depth variance marked on both the original and replace ment pinion Add or subtract the thickness of the original depth shims to compensate for the difference in the...

Page 83: ...adles Fig 8 Install differential bearing caps on arbor discs and tighten cap bolts Refer to the Torque Specifications in this section 5 Assemble Dial Indicator C 3339 into Scooter Block D 115 2 and se...

Page 84: ...ear backlash and tooth contact patterns After the overall shim thickness to take up differential side play is measured the pinion is installed and the gear backlash shim thickness is measured The over...

Page 85: ...thicknesses to determine the total shim thickness necessary to achieve zero differential end play 13 Add 0 2 mm 0 008 in to the zero end play total This new total represents the thickness of shims nec...

Page 86: ...ess of shim required to achieve proper backlash 24 Subtract the backlash shim thickness from the total preload shim thickness The remainder is the shim thickness required on the pinion side of the axl...

Page 87: ...002 in If readings vary more than specified the ring gear or the differential case is defective After the proper backlash is achieved perform the Gear Contact Pattern procedure GEAR CONTACT PATTERN T...

Page 88: ...Fig 19 Gear Tooth Contact Patterns AN FRONT AXLE C205F 3 33 FRONT AXLE C205F Continued...

Page 89: ...ear Runout 0 12 mm 0 005 in Pinion Std Depth 99 69 mm 3 925 in Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearings 17 2 5 N m 15 22 in lbs TORQUE SPECIFIC...

Page 90: ...Puller C 452 Holder 6719A Installer C 3972 A Installer Screw 8112 Cup 8109 Handle C 4171 Installer 8236 Installer D 145 Installer D 145 AN FRONT AXLE C205F 3 35 SPECIAL TOOLS Continued...

Page 91: ...mover 8401 Remover 8401 Installer 6448 Bearing Remover C 4660 Cup 8150 Installer 5063 Installer 8402 Gauge Block 8177 Pinion Depth Set Adapter Kit 6987A 3 36 FRONT AXLE C205F AN SPECIAL TOOLS Continue...

Page 92: ...gear lubricant Insert axle shaft through seal bearing and engage it into side gear splines NOTE Use care to prevent shaft splines from dam aging axle shaft seal lip 2 Push firmly on the axle shaft unt...

Page 93: ...with Remover C 452 Fig 21 9 Position Holder 6719 against the companion flange and install a four bolts and washers into the threaded holes and tighten the bolts 10 Remove the pinion nut 11 Remove the...

Page 94: ...ut in 6 8 N m 5 ft lbs increments until the proper rotating torque is achieved CAUTION If the maximum tightening torque is reached prior to reaching the required rotating torque the collapsible spacer...

Page 95: ...differential from the housing Ensure that the differential bearing cups and shims remain in position on the differential bearings 13 Tag differential bearing cups and shims to indicate their location...

Page 96: ...the housing Ensure differential bearing cups remain in position on the bearings and the differential preload shims are seated in the housing Tap differential case to ensure bearings cups are seated in...

Page 97: ...rify flange rotates smoothly 8 Record rotating torque of the companion flange with an inch pound torque wrench for installation reference Fig 31 9 Install bolts into two of the threaded holes in the c...

Page 98: ...nion bearing cup with Remover D 103 and Handle C 4171 Fig 34 17 Remove rear bearing cup from housing Fig 35 with Remover 8401 and Handle C 4171 Fig 32 Companion Flange Remover 1 COMPANION FLANGE 2 PUL...

Page 99: ...r pinion bearing cup with Installer D 145 and Driver Handle C 4171 Fig 38 and verify cup is seated 3 Apply Mopar Door Ease or equivalent lubricant to outside surface of bearing cup 4 Install front pin...

Page 100: ...e with Installer C 3718 and Holder 6719 13 Install new pinion nut and tighten to 271 N m 200 ft lbs Fig 43 14 Using Holder 6719 and a torque wrench set at 474 N m 350 ft lbs Tighten pinion nut until b...

Page 101: ...ase to ring gear bolt hole alignment 17 Invert the differential case in the vise 18 Install new ring gear bolts and alternately tighten to 108 N m 80 ft lbs Fig 45 CAUTION Do not reuse the bolts that...

Page 102: ...tag and a gear ratio tag The tags are attached to the differential housing by a cover bolt The differential case is a one piece design The dif ferential pinion mate shaft is retained with a threaded...

Page 103: ...acks transfer additional torque to the wheel having the most traction Trac loky differentials resist wheel spin on bumpy roads and provide more pulling power when one wheel looses traction Pulling pow...

Page 104: ...pinion bearing 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 genera...

Page 105: ...alignment Correct as necessary 2 Bent or sprung axle shaft 2 Inspect and correct as necessary Axle Shaft Broke 1 Misaligned axle tube 1 Replace the broken shaft after correcting tube mis alignment 2 V...

Page 106: ...oke 5 Replace yoke and seal 6 Axle cover not properly sealed 6 Remove clean and re seal cover Axle Overheating 1 Lubricant level low 1 Fill differential to correct level 2 Improper grade of lubricant...

Page 107: ...reference 11 Remove propeller shaft 12 Disconnect shock absorbers from axle 13 Remove the spring clamps and spring brack ets Refer to Suspension for procedures 14 Separate the axle from the vehicle IN...

Page 108: ...r is positive subtract that value from the thickness of the depth shim If the number is 0 no change is nec essary PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear...

Page 109: ...and tight Fig 7 4 Place Arbor Disc 8541 on Arbor D 115 3 in posi tion in the housing side bearing cradles Fig 9 Install differential bearing caps on arbor discs and tighten cap bolts to 41 N m 30 ft l...

Page 110: ...he maximum ring gear backlash variation is 0 003 inch 0 076 mm Mark the gears so the same teeth are meshed during all backlash measurements Maintain the torque while adjusting the bearing preload and...

Page 111: ...hten the left side threaded adjuster until 102 N m 75 ft lbs torque is indicated Seat the bearing rollers with the procedure described above Do this until the torque remains constant 10 Install the th...

Page 112: ...Fig 13 Gear Tooth Contact Patterns AN REAR AXLE 8 1 4 3 57 REAR AXLE 8 1 4 Continued...

Page 113: ...is preventing the side gear from sliding on the axle shaft 5 If there is no side gear clearance remove the C lock from the axle shaft Use a micrometer to mea sure the thrust washer thickness Record th...

Page 114: ...g Cap Bolts 95 70 Ring Gear Bolts 102 75 Pinion Nut Minimum 285 210 Adjuster Lock Screw 10 7 5 90 Backing Plate Bolts 65 48 SPECIAL TOOLS 8 1 4 AXLE Puller 6790 Remover 6310 Installer C 4198 Handle C...

Page 115: ...Puller C 452 Installer C 3718 Adjustment Wrench C 4164 Puller Press C 293 PA Adapters C 293 48 Adapter Plug SP 3289 Adapters C 293 47 Installer C 4340 Fixture 8138 3 60 REAR AXLE 8 1 4 AN SPECIAL TOOL...

Page 116: ...4345 Remover C 4307 Installer C 4308 Installer D 130 Installer 6448 Trac lokY Tools 8140 Trac lokY Tools 6960 Pinion Block 8540 Arbor Discs 8541 Pinion Gauge Set AN REAR AXLE 8 1 4 3 61 SPECIAL TOOLS...

Page 117: ...lock in side gear 3 Insert pinion shaft into differential case and through thrust washers and differential pinions 4 Align hole in shaft with hole in the differential case and install lock screw with...

Page 118: ...raight and the tool is in contacts with the axle tube when seating the bearing NOTE Install bearing with part number against the installer 3 Install a new axle seal with Installer C 4076 B and Handle...

Page 119: ...1 Apply a light coating of gear lubricant on the lip of pinion seal 2 Install new pinion seal with Installer C 4076 B and Handle C 4735 1 Fig 22 3 Install companion flange on the end of the shaft wit...

Page 120: ...s and lower the vehicle DIFFERENTIAL REMOVAL 1 Raise and support vehicle 2 Remove the lubricant fill hole plug from the differential housing cover 3 Remove the differential housing cover and drain the...

Page 121: ...he pinion shaft 4 Align the hole in the pinion shaft with the hole in the differential case and install the pinion shaft lock screw 5 Lubricate all differential components with hypoid gear lubricant F...

Page 122: ...clutch discs to eliminate a possible chat ter noise complaint DIFFERENTIAL TRAC LOK DIAGNOSIS AND TESTING TRAC LOKY The most common problem is a chatter noise when turning corners Before removing a Tr...

Page 123: ...35 6 Assemble Threaded Adapter C 6960 1 into top side gear Thread Forcing Screw C 6960 4 into adapter until it becomes centered in adapter plate 7 Position a small screw driver in slot of Threaded Ada...

Page 124: ...ars Fig 38 Fig 35 Step Plate 1 LOWER SIDE GEAR 2 DIFFERENTIAL CASE 3 STEP PLATE Fig 36 Threaded Adapter Disc 1 SOCKET 2 SLOT IN ADAPTER 3 SCREWDRIVER 4 DISC 5 FORCING SCREW 6 THREADED ADAPTER DISC Fig...

Page 125: ...t Dry com ponents with compressed air Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one component in either pack is damaged Inspect side gears and pinions Repl...

Page 126: ...on mate 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 ion gears 11 Tighten forcing screw to 122 N m 90 ft l...

Page 127: ...llation alignment 3 Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody 4 Place differential case in a suitable vise with soft metal jaw protectors Fig 46 5 Remov...

Page 128: ...ide hammer mounted screw 13 Remove oil slinger if equipped and front pin ion bearing 14 Remove front pinion bearing cup with Remover C 4345 and Handle C 4171 Fig 49 Fig 46 Ring Gear 1 CASE 2 RING GEAR...

Page 129: ...for Pin ion Gear Depth Setting 1 Apply Mopar Door Ease or stick lubricant to outside surface of bearing cup 2 Install rear pinion bearing cup Fig 53 with Installer C 4308 and Driver Handle C 4171 and...

Page 130: ...he pinion shaft 8 Install the rear bearing and slinger if equipped on the pinion Fig 56 with Installer 6448 and a press Fig 53 Rear Pinion Bearing Cup 1 INSTALLER 2 HANDLE Fig 54 Front Pinion Bearing...

Page 131: ...n pinion nut to decrease pin ion bearing rotating torque and never exceed spec ified preload torque If preload torque or rotating torque is exceeded a new collapsible spacer must be installed 15 Slowl...

Page 132: ...lbs Fig 60 CAUTION Do not reuse the bolts that held the ring gear to the differential case The bolts can fracture causing extensive damage 22 Install differential in housing and verify gear mesh and...

Page 133: ...ear ratio 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...

Page 134: ...Fig 1 9 1 4 Axle AN REAR AXLE 9 1 4 3 79 REAR AXLE 9 1 4 Continued...

Page 135: ...ahead driving when the gears are unloaded The side gears are loaded during vehi cle turns A worn pinion shaft can also cause a snap ping or a knocking noise 1 HUB 2 AXLE SHAFT 3 VENT FITTING 4 DIFFER...

Page 136: ...xcessive pinion yoke run out Bent axle shaft s Check for loose or damaged front end components or engine transmission mounts These components can contribute to what appears to be a rearend vibra tion...

Page 137: ...ores and shaft for damage Service as necessary Loss Of Lubricant 1 Lubricant level too high 1 Drain lubricant to the correct level 2 Worn axle shaft seals 2 Replace seals 3 Cracked differential housin...

Page 138: ...se at the axle junction block Do not disconnect the brake hydraulic lines at the wheel cylinders Refer to Brakes for procedures 8 Remove parking brake cables and cable brack ets 9 Disconnect the vent...

Page 139: ...eing installed note the depth variance painted onto both the original and replace ment pinion Add or subtract the thickness of the original depth shims to compensate for the difference in the depth va...

Page 140: ...assembled height gauge components rear bearing and screw into the housing through pinion bearing cups Fig 6 3 Install front pinion bearing and Cone Nut 6740 hand tight Fig 5 4 Place Arbor Disc 8541 on...

Page 141: ...ll introduce a high bearing load and cause premature bearing failure Insufficient adjuster torque can result in excessive differential case free play and ring gear noise Insufficient adjuster torque w...

Page 142: ...l 102 N m 75 ft lbs torque is indicated Seat the bearing rollers with the procedure described above Do this until the torque remains constant 10 Install the threaded adjuster locks and tighten the loc...

Page 143: ...Fig 11 Gear Tooth Contact Patterns 3 88 REAR AXLE 9 1 4 AN REAR AXLE 9 1 4 Continued...

Page 144: ...nd washer thickness will determine required thickness of replacement thrust washer Fig 13 In some cases the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted...

Page 145: ...8 in Ring Gear Runout 0 12 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...

Page 146: ...4171 Installer C 4076 B Handle C 4735 1 Holder 6719 Puller C 452 Installer C 3718 Adjustment Wrench C 4164 Puller Press C 293 PA Adapters C 293 48 Plug SP 3289 AN REAR AXLE 9 1 4 3 91 SPECIAL TOOLS C...

Page 147: ...C 293 47 Installer C 4340 Fixture 8138 Installer C 4345 Remover C 4307 Installer C 4308 Installer D 130 Installer 6448 Trac lokY Tools 8140 Trac lokY Tools 6960 3 92 REAR AXLE 9 1 4 AN SPECIAL TOOLS C...

Page 148: ...g and engage it into side gear splines NOTE Use care to prevent shaft splines from dam aging axle shaft seal 2 Insert C lock in end of axle shaft then push axle shaft outward to seat C lock in side ge...

Page 149: ...Install the bear ing with the bearing part number against the installer Verify the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing 3 Install a new axle...

Page 150: ...e 180 apart 9 Position Holder 6719A against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes Tighten the bolt and washer so that the Holder 6719 is...

Page 151: ...ring rollers are seated 9 Rotatepinion using an inch pound torque wrench Rotating torque should be equal to the read ing recorded during removal plus an additional 0 56 N m 5 in lbs Fig 24 Fig 21 Comp...

Page 152: ...n the lubricant 4 Clean the housing cavity with a flushing oil light engine oil or lint free cloth Do not use water steam kerosene or gasoline for cleaning 5 Remove the axle shafts 6 Remove RWAL ABS s...

Page 153: ...ntil the bolt head is seated 5 Perform the differential bearing preload and adjustment procedure NOTE Be sure that all bearing cap bolts are tight ened to their final torque of 136 N m 100 ft lbs befo...

Page 154: ...IFFERENTIAL TEST The differential can be tested without removing the differential case by measuring rotating torque Make sure brakes are not dragging during this measure ment 1 Place blocks in front a...

Page 155: ...ighten screw to 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs Fig 37 9 With a feeler gauge remove thrust washers from behind the pinion gears Fig 38 10 Insert Turning Bar C...

Page 156: ...OD 6 THREADED ADAPTER DISC Fig 37 Compress Belleville Spring 1 TORQUE WRENCH 2 FORCING SCREW 3 DIFFERENTIAL CASE Fig 38 Pinion Gear Thrust Washer 1 THRUST WASHER 2 FEELER GAUGE Fig 39 Differential Pin...

Page 157: ...or damaged Lubricate each component with gear lubricant before assembly 1 Assemble the clutch discs into packs and secure disc packs with retaining clips Fig 41 NOTE New Plates and discs with fiber c...

Page 158: ...ind pinion gears and align washers with a small screw driver Insert mate shaft into each pinion gear to ver ify alignment 13 Remove Forcing Screw Step Plate and Threaded Adapter 14 Install pinion gear...

Page 159: ...ring gear off the differential case with a rawhide hammer Fig 46 10 Install bolts into two of the threaded holes in the companion flange 180 apart 11 Position Holder 6719 against the companion flange...

Page 160: ...hed set Do not replace the pinion without replacing the ring gear If ring and pinion gears or bearings are replaced Refer to Adjustments for Pin ion Gear Depth Setting 1 Apply Mopar Door Ease or stick...

Page 161: ...rear bearing on the pinion Fig 56 with Installer 6448 and a press Fig 51 Collapsible Spacer 1 COLLAPSIBLE SPACER 2 SHOULDER 3 PINION GEAR 4 DEPTH SHIM 5 REAR BEARING Fig 52 Rear Pinion Bearing 1 PULLE...

Page 162: ...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 163: ...ase The 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 Inst...

Page 164: ...VE DESCRIPTION 12 OPERATION 12 DIAGNOSIS AND TESTING 13 COMBINATION VALVE 13 REMOVAL 13 INSTALLATION 13 DISC BRAKE CALIPERS DESCRIPTION 13 OPERATION 13 REMOVAL 14 DISASSEMBLY 14 CLEANING 15 INSPECTION...

Page 165: ...CUUM CLEANER IS NOT AVAIL ABLE CLEANING SHOULD BE DONE WITH A WATER DAMPENED CLOTH DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE DISPOSE OF ALL RESIDU...

Page 166: ...re 3 During road test make normal and firm brake stops in 25 40 mph range Note faulty brake opera tion such as low pedal hard pedal fade pedal pulsa tion pull grab drag noise etc 4 Attempt to stop the...

Page 167: ...This causes pull to switch direction in favor of the normally functioning brake unit An additional point when diagnosing a change in pull condition concerns brake cool down Remember that pull will ret...

Page 168: ...DOT 3 standards only Use fresh clean fluid from a sealed container at all times Do not pump the brake pedal at any time while bleeding Air in the system will be compressed into small bubbles that are...

Page 169: ...ool jaws until tube contacts recessed notch in gauge that matches tube diameter 7 Tighten the tool bar on the tube 8 Insert plug on gauge in the tube Then swing compression disc over gauge and center...

Page 170: ...he tube Fig 5 8 Turn the yoke screw in until the adaptor is squarely seated on the tool bar Fig 4 Inverted Fig 5 ISO Flaring 1 ADAPTER 2 LUBRICATE HERE 3 PILOT 4 FLUSH WITH BAR 5 TUBING 6 BAR ASSEMBLY...

Page 171: ...79 x 57 mm 11 x 2 25 in Drum Brake Max Runout 0 20 mm 0 008 in Drum Brake Max Diameter Variation 0 076 mm 0 003 in Brake Booster Type Tandem Diaphragm TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N...

Page 172: ...com pensation for lining wear OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston The fluid pressure is exerted equally and in all directions This means pressur...

Page 173: ...never the vehicle is in for service Inspect the hoses for surface cracking scuffing or worn spots Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasi...

Page 174: ...liper piston 4 Insert outboard brake shoe in caliper Fig 11 5 Insure the outboard shoe retainer spring are seated in the caliper Fig 12 6 Install caliper Refer to 5 BRAKES HY DRAULIC MECHANICAL DISC B...

Page 175: ...ressure differ ential valve and switch and a rear brake proportion ing valve The valve is not repairable and must be replaced as an assembly if diagnosis indicates this is necessary OPERATION PRESSURE...

Page 176: ...switch is faulty Replace combination valve assembly bleed brake system and verify proper switch and valve operation REMOVAL 1 Disconnect wire from the pressure differential switch 2 Disconnect rear b...

Page 177: ...fluid 3 Raise and support vehicle 4 Remove front wheel and tire assemblies 5 Bottom caliper pistons in bores with large C clamp Position clamp frame on rear of caliper and clamp screw on outboard bra...

Page 178: ...install the same type of piston in the caliper Never inter change phenolic resin and steel caliper pistons The pistons seals seal grooves caliper bore and piston tolerances are different The bore can...

Page 179: ...properly into the caliper holes 5 Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 N m 18 ft lbs CAUTION Verify brake hose is not twisted or kinked before tightening...

Page 180: ...NING The brake drums can be machined on a drum lathe when necessary Initial machining cuts should be lim ited to 0 12 0 20 mm 0 005 0 008 in at a time as heavier feed rates can produce taper and surfa...

Page 181: ...oe contact pads on the sup port plate with fine sandpaper INSPECTION As a general rule riveted brake shoes should be replaced when worn to within 0 78 mm 1 32 in of the rivet heads Bonded lining shoul...

Page 182: ...anchor pin 10 Install cable guide in secondary shoe and posi tion cable in guide 11 Assemble adjuster screw Fig 30 Then install and adjuster screw between the brake shoes CAUTION Be sure the adjuster...

Page 183: ...Position gauge legs at shoe centers as shown Fig 32 If gauge does not fit too loose too tight adjust shoes 6 Pull shoe adjuster lever away from adjuster screw star wheel 7 Turn adjuster screw star wh...

Page 184: ...n of the brake fluid If brake fluid is contaminated drain and thor oughly flush system Replace master cylinder propor tioning valve caliper seals wheel cylinder seals Antilock Brakes hydraulic unit an...

Page 185: ...ricate new grommets with clean brake fluid and Install new grommets in cylinder body Fig 38 Use finger pressure to install and seat grommets Fig 34 Reservoir Retaining Pins 1 PIN PUNCH 2 RESERVOIR 3 B...

Page 186: ...and hold brake pedal under light foot pressure The pedal should hold firm if the pedal falls away master cylinder is faulty internal leak age 5 Start engine and note pedal action It should fall away...

Page 187: ...r on booster mounting studs 2 Install mounting nuts and tighten to 18 N m 160 in lbs Fig 39 Typical Booster Vacuum Test Connections 1 TEE FITTING 2 SHORT CONNECTING HOSE 3 CHECK VALVE 4 CHECK VALVE HO...

Page 188: ...brake pedal and install push rod retainer clip 6 Install stop lamp switch Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH INSTALLATION POWER BRAKE BOOSTER DESCRIPTION All models use a...

Page 189: ...e center of the brake shoe contact surface Replace the rotor if worn below minimum thickness or if machining would reduce thickness below the allowable minimum Rotor minimum thickness is usually speci...

Page 190: ...DISC BRAKE CALIPERS INSTALLATION 3 Install wheel and tire assembly Refer to 22 TIRES WHEELS WHEELS STANDARD PROCE DURE 4 Remove support and lower vehicle 5 Depress brake pedal several time to seat br...

Page 191: ...and tire assembly Refer to 22 TIRES WHEELS WHEELS STANDARD PROCE DURE 7 Bleed base brake system Refer to 5 BRAKES STANDARD PROCEDURE SUPPORT PLATE REMOVAL 1 Remove wheel and tire assembly and brake dr...

Page 192: ...ousing through the left cable connec tor 6 Remove the left cable connector from the left cable 7 Pull both cables Fig 51 through the cable bracket 8 Remove the right cable mounting retainers from the...

Page 193: ...rakes are in good condition and operat ing properly 5 Verify park brake cables operate freely and are not binding or seized 6 Check rear brake shoe adjustment with stan dard brake gauge 7 Install drum...

Page 194: ...e rod to pedal assembly 6 Install left side kick panel RELEASE REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUM...

Page 195: ...ond pivot pin on the instrument panel 4 Press firmly on the park brake release handle over the second hinge tab until it snaps over the sec ond pivot pin on the instrument panel 5 Reach under the driv...

Page 196: ...heel lockup and maintain steering control during periods of high wheel slip when braking Preventing lockup is accom plished by modulating fluid pressure to the wheel brake units The hydraulic system i...

Page 197: ...etain greater control of the vehicle during braking The RWAL components include RWAL Valve Controller Antilock brake CAB Rear Wheel Speed Sensor WSS OPERATION Battery voltage is supplied to the CAB ig...

Page 198: ...f this initial action is not enough to prevent rear wheel lock up the CAB will momen tarily energize a dump solenoid This opens the dump valve to vent a small amount of isolated rear brake pressure to...

Page 199: ...noids A second base brake bleed ing procedure is then required to remove any air remaining in the system 1 Perform base brake bleeding Refer to 5 BRAKES STANDARD PROCEDURE 2 Connect scan tool to the D...

Page 200: ...to determine a deceleration rate that would indicate a possible wheel locking tendency The signal strength of any magnetic induction sen sor is directly affected by Magnetic field strength the stronge...

Page 201: ...sor wire and remove sensor INSTALLATION 4X2 CAUTION Special bolts are used to attach the front sensor The bolts have a special shoulder thread length and surface treatment If the original bolts must b...

Page 202: ...curely in place between sensor and wiring connector 2 Install O ring on sensor if removed 3 Insert sensor in differential housing 4 Install sensor shield 5 Install the sensor mounting stud and tighten...

Page 203: ...e channel pressure control to the front and rear brakes One channel controls the rear wheel brakes in tandem The two remaining channels control the front wheel brakes individually During antilock brak...

Page 204: ...ential and Driveline For tire rev olutions per mile Refer to 22 TIRES WHEELS TIRES SPECIFICATIONS To program the CAB refer to the Chassis Diagnostic Manual 1 Disconnect battery negative cable 2 Remove...

Page 205: ...ed in the CAB memory If during a RWAL stop the driver releases the brake pedal the reset switch contacts will open This signal to the CAB is an indication that pressure has equalized across the RWAL v...

Page 206: ...sts of a flywheel a sin gle dry type disc and a diaphragm style clutch cover Fig 1 A hydraulic linkage is used to operate the clutch release bearing and fork The flywheel is bolted to the rear flange...

Page 207: ...OR USE A VAC UUM CLEANER SPECIFICALLY DESIGNED FOR REMOVING ASBESTOS FIBERS AND DUST DO NOT CREATE DUST BY SANDING A CLUTCH DISC REPLACE THE DISC IF THE FRICTION MATERIAL IS DAMAGED OR CONTAMINATED D...

Page 208: ...Fig 3 Clutch Components And Inspection AN CLUTCH 6 3 CLUTCH Continued...

Page 209: ...manually through the inspection plate open ing Engagement problems usually result in slip chat ter shudder and noisy operation The primary causes are clutch disc contamination clutch disc wear mis ali...

Page 210: ...elow 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 dis...

Page 211: ...spect clutch and correct as necessary Install 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...

Page 212: ...sure plate position incorrect 1 Replace clutch disc and cover 2 Clutch cover spring or release fingers bent or distorted 2 Replace clutch disc and cover 3 Clutch disc damaged or distorted 2 Replace cl...

Page 213: ...sition of cover on fly wheel with small punch marks Fig 5 4 Loosen clutch cover bolts evenly and in rotation to relieve spring tension Loosen bolts a few threads at a time to avoid warping cover 5 Rem...

Page 214: ...salignment may also be caused by housing mounting surfaces that are not completely parallel Misalignment can be corrected with shims REMOVAL 1 Raise vehicle and support vehicle 2 Remove transmission a...

Page 215: ...lave cylinder force causes the release lever to move the release bearing into contact with the diaphragm spring As additional force is applied the bearing presses the diaphragm spring fingers inward o...

Page 216: ...a one piece spring and multiple release fin gers Fig 11 The pressure plate release fingers are preset during manufacture and are not adjustable The assembly also contains the cover pressure plate and...

Page 217: ...is severe and deeper than 0 076 mm 0 003 in Excessive stock removal can result in flywheel cracking or warpage after installation it can also weaken the flywheel and interfere with proper clutch rele...

Page 218: ...nder operates the clutch release lever The slave cylinder has an integral spring which preloads the release bearing against the clutch dia phragm fingers to maintain zero free play Slave cylinder forc...

Page 219: ...utch pedal pin Secure rod with retaining clip 8 Connect clutch pedal position switch connector from wiring harness 9 Raise vehicle 10 Insert slave cylinder push rod through clutch housing opening and...

Page 220: ...ushings in pedal bore and on pin 3 Install pedal on pivot shaft 4 Secure pedal on shaft with washer and snap ring 5 Apply light coating of grease to the inner diam eter of the master cylinder push rod...

Page 221: ...lutch pedal be fully depressed in order to start the engine Switch cir cuitry and operation is provided in section 8 Electrical Fig 16 Clutch Pedal 1 PIVOT ROD 2 PEDAL SUPPORT 3 BRAKE PEDAL 4 BOOSTER...

Page 222: ...the auto matic transmission fluid if equipped The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system An optional factory installed maximum duty...

Page 223: ...oling System Flow 1 WATER CONTROL VALVE 2 TO WATER PUMP 3 THERMOSTAT HOUSING 4 RADIATOR CAP 5 RADIATOR 6 TO COOLANT RESERVE BOTTLE 7 TO WATER PUMP 8 TO HEATER CORE 9 FROM HEATER CORE 7 2 COOLING AN CO...

Page 224: ...Fig 2 Engine Cooling System Flow 1 HEATER 2 BYPASS 3 CROSSFLOW RADIATOR AN COOLING 7 3 COOLING Continued...

Page 225: ...sure cap Thermostat Coolant reserve overflow system integral to upper fan shroud Transmission oil cooler if equipped with an automatic transmission Coolant Water pump Hoses and hose clamps Fig 3 Engin...

Page 226: ...in control module PCM has been programmed to monitor certain cooling system com ponents If the engine has remained cool for too long a period such as with a stuck open thermostat a Diag nostic Trouble...

Page 227: ...ester 7700 or an equivalent to radiator filler neck Fig 6 or Fig 7 Operate tester pump to apply 103 4 kPa 15 psi pressure to system If hoses enlarge excessively or bulges while testing replace as nece...

Page 228: ...t of coolant or steam This would be emitting from exhaust pipe Coolant or steam from exhaust pipe may indicate a faulty cylinder head gas ket cracked engine cylinder block or cylinder head A convenien...

Page 229: ...ting a stuck open thermostat 1 Refer to 25 EMISSIONS CONTROL DESCRIPTION for On Board Diagnostics and DTC information Replace thermostat if necessary 2 Is the temperature sending unit connected 2 Chec...

Page 230: ...CTRICAL INSTRUMENT CLUSTER SCHEMATIC ELECTRICAL 4 Coolant low in coolant reserve overflow tank and radiator 4 Check for coolant leaks and repair as necessary Refer to 7 COOLING DIAGNOSIS AND TESTING 5...

Page 231: ...tion system problems 13 Refer to 14 Fuel System or 8 Electrical for diagnosis and testing procedures 14 Dragging brakes 14 Check and correct as necessary Refer to 5 BRAKES DIAGNOSIS AND TESTING for co...

Page 232: ...rect coolant leaks Refer to 7 COOLING DIAGNOSIS AND TESTING 6 Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing a thermostat to open late 6 a Check for cylinder head ga...

Page 233: ...if necessary b Hose between coolant reserve overflow tank and radiator is kinked Repair as necessary c Vent at coolant reserve overflow tank is plugged Clean vent and repair as necessary d Reserve ove...

Page 234: ...IS COMING FROM THE FRONT OF VEHICLE NEAR THE GRILL AREA WHEN WEATHER IS WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE GAUGE IS IN NORMAL RANGE 1 During wet weather moisture...

Page 235: ...both the radiator cap and reserve overflow tank cap in place After the engine has reached the normal operating tempera ture shut the engine off and allow it to cool 4 Add coolant to the reserve overfl...

Page 236: ...Open draincock and drain coolant from radiator This will empty the coolant reserve overflow tank The coolant does not have to be removed from the tank unless the system is being refilled with a fresh...

Page 237: ...reeze and water ONE QUART AT A TIME Repeat this pro cedure until the coolant level is at the FULL mark STANDARD PROCEDURE COOLING SYSTEM CLEANING REVERSE FLUSHING CLEANING Drain cooling system and ref...

Page 238: ...illing the Cooling System CHEMICAL CLEANING In some instances use a radiator cleaner Mopar Radiator Kleen or equivalent before flushing This will soften scale and other deposits and aid flushing opera...

Page 239: ...ar and install the ten sioner adjustment bolt 2 Position the spacer idler pulley bushing and bolt 3 Install the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION BELT TE...

Page 240: ...67 N m 50 ft lbs torque 3 Connect all wiring to ignition coil CAUTION To prevent damage to coil case coil mounting bolts must be torqued 4 Install coil to coil bracket If nuts and bolts are used to s...

Page 241: ...se Misalignment of an engine accessory Belt incorrectly routed NOTE A used belt should be replaced if tensioner indexing arrow has moved to the minmum tension indicator Tensioner travel stops at this...

Page 242: ...CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING One or more ribs has separated from belt body 1 Foreign objects imbedded in pulley grooves 1 Remove foreign objects from pulley grooves Replace...

Page 243: ...OISE Objectionable squeal squeak 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 Bel...

Page 244: ...lished from the latest information available at the time of publica tion Vehicles not equipped with Power Steering have an idler pulley in place of the power steering pump pulley If anything differs b...

Page 245: ...serpentine or a V type belt Refer to the instructions supplied with the gauge Use the correct gauge when checking belt ten sion Place gauge in the middle of the section of belt being tested between t...

Page 246: ...ten sion Adjust if necessary DRIVE BELTS 3 9L 5 9L DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts small cracks that run across the ribbed...

Page 247: ...ailure 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 Repla...

Page 248: ...tween 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 betwee...

Page 249: ...7L DIAGNOSIS AND TESTING ACCESSORY DRIVE 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 17 are c...

Page 250: ...ulley 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...

Page 251: ...OISE Objectionable squeal squeak 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 Bel...

Page 252: ...g in the wrong direction Fig 18 2 Install new belt Fig 18 Route the belt around all pulleys except the idler pulley Rotate the tensioner arm until it contacts it s stop position Route the belt around...

Page 253: ...4 7L 5 9L DESCRIPTION 44 OPERATION 45 DIAGNOSIS AND TESTING 45 VISCOUS FAN DRIVE 45 REMOVAL 45 INSTALLATION 47 RADIATOR DESCRIPTION 47 OPERATION 47 DIAGNOSIS AND TESTING 47 RADIATOR COOLANT FLOW CHEC...

Page 254: ...roper level in the radiator ENGINE BLOCK HEATER 3 9L 5 9L DESCRIPTION WARNING DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE THE POWER CORD...

Page 255: ...screw to 2 N m 17 in lbs 5 Fill cooling system with recommended coolant Refer to 7 COOLING STANDARD PROCE DURE 6 Start and warm the engine 7 Check block heater for leaks ENGINE BLOCK HEATER 4 7L DESCR...

Page 256: ...components that may cause abrasion or damage such as linkages exhaust components etc REMOVAL 1 Disconnect negative battery cable from battery 2 Drain coolant from radiator Refer to 7 COOLING STANDARD...

Page 257: ...g O2 sensor closed loop times Purge solenoid on off times EGR solenoid on off times if equipped Leak Detection Pump operation if equipped Radiator fan relay on off times if equipped Target idle speed...

Page 258: ...PROCEDURE INSTALLATION 4 7L 1 Install sensor 2 Tighten to 11 N m 8 ft lbs torque 3 Connect electrical connector to sensor 4 Replace any lost engine coolant Refer to 7 COOLING STANDARD PROCEDURE INSTA...

Page 259: ...opriate Powertrain Diag nostic Procedures information for diagnostic informa tion and operation of the DRB scan tool REMOVAL WARNING DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRES S...

Page 260: ...l cause the thermostat to fail in the open position Thermo stats very rarely stick Do not attempt to free a ther mostat with a prying device The same thermostat is used for winter and sum mer seasons...

Page 261: ...onnect negative battery cable at battery 2 Drain cooling system until coolant level is below thermostat Refer to 7 COOLING STAN DARD PROCEDURE 3 Air Conditioned vehicles Remove support bracket generat...

Page 262: ...pump rotating in wrong direction Refer to Fig 20 for correct 3 9L and 5 9L engine belt routing The correct belt with correct length must be used 7 Air Conditioned vehicles Install generator Tighten b...

Page 263: ...tion can result in sludge formation OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat When heated the pellet expands overcoming closing spring tension and w...

Page 264: ...g bolts thermostat housing and thermostat Fig 22 INSTALLATION 1 Clean mating areas of timing chain cover and thermostat housing 2 Install thermostat spring side down into recessed machined groove on t...

Page 265: ...es an electrical cooling fan located in the fan shroud aids in low speed cooling It is designed to augment the viscous fan However it does not replace the viscous fan A thermostatic bimetallic spring...

Page 266: ...the air flow is blocked 5 Be sure that the air conditioner if equipped is turned off WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOU...

Page 267: ...ous fan drive could drain into its bearing assembly and contaminate lubricant 8 Remove four bolts securing fan blade assembly to viscous fan drive Fig 27 Fig 25 Fan Blade and Viscous Fan Drive Removal...

Page 268: ...pper radiator hose is warm to the touch thermostat is opening and coolant is flowing to radi ator WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING USING A RAG TO COVER RADIATOR PRESSURE CA...

Page 269: ...cooling fan motor connector 7 Remove radiator upper mounting screws Fig 35 Lift radiator upward and away from vehicle Do not allow cooling fins of radiator to contact any other vehicle component Radia...

Page 270: ...cooling system will operate at pressures slightly above atmospheric pressure This results in a higher coolant boiling point allowing increased radi ator cooling capacity The cap contains a spring loa...

Page 271: ...g service procedures 4 Checking for vacuum leaks WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP WITH A RAG SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTE...

Page 272: ...hragm spring and a rubber gasket This gasket is used to seal to radiator filler neck top surface Use of proper cap will allow coolant return to radiator RADIATOR FAN MOTOR DIAGNOSIS AND TESTING ELECTR...

Page 273: ...on to using coolant temperatures to control cooling fan operation the cooling fan will also be engaged when the air con ditioning system has been activated Refer to 24 HEATING AIR CONDITIONING for add...

Page 274: ...this time the four fan hub to water pump pulley mounting nuts 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove power steering pump WARNING CONSTANT TENSIO...

Page 275: ...o water pump hub Tighten or nuts to 27 N m 20 ft lbs torque 7 Install power steering pump CAUTION When installing the serpentine engine accessory drive belt the belt MUST be routed cor rectly If not t...

Page 276: ...or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only an original equipment clamp with matching number or letter 4 Remove upper radiator hose clamp and h...

Page 277: ...ming chain case cover INSTALLATION 1 Clean gasket mating surfaces 2 Using a new gasket install water pump to engine as follows Guide water pump nipple into bypass hose as pump is being installed Insta...

Page 278: ...er and is equipped with a non serviceable integral pulley Fig 49 DESCRIPTION WATER PUMP BYPASS The 4 7L engine uses an internal water coolant bypass system The design uses galleries in the tim ing cha...

Page 279: ...ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 SNAP ON CLAMP TOOL NUMBER HPC 20 MAY BE USED FO...

Page 280: ...to damage the gasket sealing surface INSPECTION Inspect the water pump assembly for cracks in the housing Water leaks from shaft seal Loose or rough turning bearing or Impeller rubbing either the pum...

Page 281: ...sembly to water pump shaft Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 11 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 12 Connect negative battery cable 13 Start and w...

Page 282: ...fan motor wire connector to harness connector 3 Connect battery negative cable 4 Start engine and check fan operation RADIATOR FAN VISCOUS CLEANING Clean the fan blades using a mild soap and water Do...

Page 283: ...RESSURE EVEN WITH ENGINE OFF REFER TO REFRIGER ANT WARNINGS IN GROUP 24 HEATING AND AIR CONDITIONING 1 Disconnect battery negative cable 2 Partially drain cooling system Refer to 7 COOLING STANDARD PR...

Page 284: ...nter of hose 2 Install bypass hose to engine 3 Secure both hose clamps Fig 59 4 Install generator A C mounting bracket assem bly to engine Tighten bolts number 1 and 2 Fig 61 to 54 N m 40 ft lbs torqu...

Page 285: ...ed This will insure that metal particles or sludged oil are not later trans ferred back into the reconditioned or replaced trans mission The only recommended procedure for flushing cool ers and lines...

Page 286: ...erse flushing the system A suitable replacement hose can be found in the adapter kit supplied with the flushing tool 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Connect the CLEA...

Page 287: ......

Page 288: ...LATION 21 AUDIO DESCRIPTION An audio system is standard factory installed equipment on this model unless the vehicle is ordered with an available radio delete option The standard equipment audio syste...

Page 289: ...t receives by adjusting the radio settings as requested Refer to 8 ELECTRICAL ELECTRONIC CON TROL MODULES BODY CONTROL CENTRAL TIMER MODUL DESCRIPTION for more informa tion on the high line CTM Refer...

Page 290: ...POOR RADIO RECEPTION 1 Antenna faulty 1 Refer to Antenna in the Diagnosis and Testing section of this group 2 Ground faulty 2 Check for continuity between radio chassis and a known good ground There s...

Page 291: ...NG For complete circuit diagrams refer to the appropriate wiring information The wiring information includes wiring diagrams proper wire and connector repair procedures details of wire har ness routin...

Page 292: ...ody ground to coaxial shield test The ohmmeter test lead connections for each test are shown in Antenna Tests Fig 1 NOTE This model has a special coating on the antenna mast which is not electrically...

Page 293: ...negative cable 2 Remove the trim cover from the right cowl side inner panel Refer to 23 BODY INTERIOR COWL TRIM COVER REMOVAL 3 Reach under the instrument panel outboard of the glove box to access an...

Page 294: ...f the fender 6 Install and tighten the antenna cap nut using an antenna nut wrench Special Tool C 4816 Tighten the antenna cap nut to 8 N m 70 in lbs 7 Install and tighten the antenna mast onto the an...

Page 295: ...iring information includes wiring dia grams proper wire and connector repair procedures details of wire harness routing and retention connec tor pin out information and location views for the various...

Page 296: ...RE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PER...

Page 297: ...out information and location views for the various wire harness connec tors splices and grounds Inspect the ground paths and connections at the following locations Blower motor Electric fuel pump Engi...

Page 298: ...EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COU...

Page 299: ...es only remove the screw that secures the right engine to body ground strap eyelet terminal to the rear of the right cylinder head Fig 10 or Fig 11 Fig 9 Engine To Body Ground Strap Remove Install 1 L...

Page 300: ...the top of the right frame rail 2 Engage the clip that secures the exhaust sys tem to body ground strap in the hole on the top of the right frame rail 3 Install and tighten the screw that secures the...

Page 301: ...strap eyelet terminal to the stud on the left rear corner of the engine cylinder head Tighten the nut to 2 8 N m 25 in lbs 11 On 6 and 8 cylinder engines only position the right engine to body ground...

Page 302: ...ors splices and grounds WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVIC...

Page 303: ...ctor from the connector receptacle of the remote radio switch Fig 16 5 Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel re...

Page 304: ...on The wiring information includes wiring diagrams proper wire and connector repair procedures details of wire harness routing and retention connector pin out information and location views for the va...

Page 305: ...cuit cavity of the power amplifier wire harness connector If OK go to Step 12 If not OK repair the open radio 12 volt output circuit to the radio receiver as required 12 Turn the radio receiver off Tu...

Page 306: ...TION 6 Connect the battery negative cable SPEAKER REAR DOOR REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the trim panel from the rear door Refer to 23 BODY DOORS REAR TRIM PANE...

Page 307: ...r cab side inner panel 4 Install and tighten the three screws that secure the speaker to the rear cab side inner panel Tighten the screws to 2 N m 17 in lbs 5 Install the trim panel onto the rear cab...

Page 308: ...im 2 Install and tighten the two screws that secure the speaker to the back of the B pillar trim Tighten the screws to 2 N m 17 in lbs 3 Reconnect the body wire harness connector to the speaker connec...

Page 309: ......

Page 310: ...tegral to 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 t...

Page 311: ...llowing The Airbag indicator is illuminated The ACM sends a chime request to the CTM at the same time it sends an airbag lamp on request to the EMIC The chimes will continue to sound for a duration of...

Page 312: ...ime warning system inputs to the Central Timer Module CTM as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures WARNING ON...

Page 313: ...URES OK 1 Ignition switch ground circuit open 1 Check for continuity between the ground circuit cavity of the instrument panel wire harness connector for the ignition switch and a good ground Repair t...

Page 314: ...ss connector Connector C3 for the CTM Repair the open fused B circuits if required 3 CTM fused ignition switch output run start and or run acc circuit s open 3 With the ignition switch in the On posit...

Page 315: ......

Page 316: ...nd switched circuits These failures are difficult to detect when a double fault has occurred and only one DTC has been set When a PCM JTEC and the SKIM are replaced at the same time perform the follow...

Page 317: ...the key cannot be transferred to another vehicle 5 Obtain ignition keys to be programmed from the customer 8 keys maximum 6 Using the DRBIIIt erase all ignition keys by selecting MISCELLANEOUS and ER...

Page 318: ...nterior lighting delay courtesy illumina tion defeat and battery saver features Intermittent Wipe Control The CTM pro vides control of the intermittent wipe delay and wipe after wash features for the...

Page 319: ...strument panel wire har ness with an eyelet terminal connector that is secured by a nut to a ground stud on the left inner cowl side panel near the CTM while the third circuit is grounded through a ta...

Page 320: ...e DRBIIIt scan tool can provide confirmation that the PCI data bus network is functional that all of the electronic modules are sending and receiving the proper mes sages over the PCI data bus and tha...

Page 321: ...wire harness connector Connector C1 for the CTM and a good ground In each case there should be continuity If OK use a DRBIIIt scan tool to perform further diag nosis of the CTM Refer to the appropriat...

Page 322: ...tal A D converter in order to 9read9 these sensor inputs Multiplexing reduces wire harness complexity sensor current loads and controller hardware because each sensing device is connected to only one...

Page 323: ...smitting different messages at the same time When a module is transmitting on the bus it is read ing the bus at the same time to ensure message integrity When a collision is detected the module that t...

Page 324: ...icle is started approximately 50 times Stored faults are not erased if the battery is disconnected CAB INPUTS The CAB continuously monitors the speed of the differential ring gear by monitoring signal...

Page 325: ...4 Install the CAB harness connector into the con troller and push down on the connector lock DATA LINK CONNECTOR DESCRIPTION The data link connector is located at the lower edge of the instrument pane...

Page 326: ...e open throttle modes are Open Loop modes The idle and cruise modes with the engine at operating tem perature are Closed Loop modes IGNITION SWITCH KEY ON MODE This is an Open Loop mode When the fuel...

Page 327: ...signal if equipped Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TP...

Page 328: ...e is applied to the fuel injectors with the ASD relay via the PCM The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on...

Page 329: ...ensor Overdrive override switch Oxygen sensors Park neutral switch auto trans only Power ground Sensor return Signal ground Speed control multiplexed single wire input Throttle position sensor Transmi...

Page 330: ...DIAGNOSTIC TROUBLE CODE DTC MAY BE SET 1 Install PCM and mounting bolts to vehicle 2 Tighten bolts to 3 5 N m 30 40 in lbs 3 Check pin connectors in the PCM and the three 32 way connectors for corros...

Page 331: ...KIM so that new keys will not be required In the event that the original Secret Key code cannot be recovered SKIM replacement will also require new Sentry Keys The DRBIIIt scan tool will alert the tec...

Page 332: ...e SKIM to the steering column lock housing 11 Disengage the SKIM antenna ring from around the ignition lock cylinder housing INSTALLATION 1 Position the Sentry Key Immobilizer Module SKIM onto the ste...

Page 333: ...demand This is possible through the control of various direct and indirect outputs Some examples of TCM direct outputs are Transmission Control Relay Solenoids Torque Reduction Request Some examples o...

Page 334: ...volume of fluid used to apply or release a friction element The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls As friction material...

Page 335: ...Delayed 3 4 upshift Early 4 3 coastdown shift High speed 4 2 3 2 2 1 kickdown shifts are prevented Shifts at high throttle openings willl be early No EMCC Cold Oil temperature between 10 F and 36 F S...

Page 336: ...e sen sor the instrument panel mounted selector switch and the following information from the vehicle s PCI serial bus to determine if a shift is allowed Engine RPM and Vehicle Speed Diagnostic Reques...

Page 337: ...s per hour Ignition key switch is in the RUN position engine off Foot Brake is applied A valid mode sensor signal is being sensed by the TCCM A shift out of transfer case Neutral will be allowed only...

Page 338: ...e original position until the switch debounce timer expires then a shift will need to be requested again The TCCM will not prevent shifts on the basis of a block in the destination direction If the mo...

Page 339: ...an be assumed to have cooled down and the system will revert to normal operation The following rules also apply to the shift limit The attempt limit will not include shifts coming out of Neutral they...

Page 340: ...12 volt battery system is standard factory installed equipment on this model All of the compo nents of the battery system are located within the engine compartment of the vehicle The service infor ma...

Page 341: ...rical components or circuits in the vehicle DIAGNOSIS AND TESTING BATTERY SYSTEM The battery starting and charging systems in the vehicle operate with one another and must be tested as a single comple...

Page 342: ...Standard 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 proce...

Page 343: ...ing capacity Refer to Standard Procedures for the proper test procedures Replace the faulty battery as required 6 The starting system is faulty 6 Determine if the starting system is performing to spec...

Page 344: ...s man ual it is recommended that these procedures be per formed any time the battery or related components must be removed for vehicle service 1 Clean the battery cable terminal clamps of all corrosi...

Page 345: ...e any battery thermal guard that has been damaged 5 Inspect the battery built in test indicator sight glass for an indication of the battery condition If the battery is discharged charge as required R...

Page 346: ...m its terminals As the battery discharges a gradual chemical change takes place within each cell The sulfuric acid in the elec trolyte combines with the plate materials causing both plates to slowly c...

Page 347: ...ttery has no built in test 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...

Page 348: ...AND OR VEHICLE DAMAGE MAY RESULT WARNING EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BAT TERY PERSONAL INJURY AND OR VEHICLE DAM AGE MAY RES...

Page 349: ...y System Inspection for the proper battery system inspection procedures CHARGING A COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery Unle...

Page 350: ...the battery state of charge however it will not reveal the cranking capacity of the battery A load test must be performed to determine the battery cranking capacity Refer to Standard Procedures for t...

Page 351: ...electro lyte by weight or 24 by volume In a fully charged battery the electrolyte will have a temperature cor rected specific gravity of 1 260 to 1 290 However a specific gravity of 1 235 or above is...

Page 352: ...ty tests taken at one hour intervals are constant If the cell specific grav ity variation is more than fifty points 0 050 at the end of the charge period replace the battery When the specific gravity...

Page 353: ...TE 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 CONTACT WITH THE SKIN EYES OR CLOTHING IN...

Page 354: ...N OFF DRAW TEST The term Ignition Off Draw IOD identifies a nor mal condition where power is being drained from the battery with the ignition switch in the Off position A normal vehicle electrical sys...

Page 355: ...ween the disconnected battery negative cable ter minal clamp and the battery negative terminal post Make sure that the doors remain closed so that the illuminated entry system is not activated The mul...

Page 356: ...he bat tery Refer to Battery Hold Downs in this section for the location of the proper battery hold down removal procedures WARNING WEAR A SUITABLE PAIR OF RUBBER GLOVES NOT THE HOUSEHOLD TYPE WHEN RE...

Page 357: ...a vehicle without a battery holddown device properly installed Damage to the vehicle components and battery could result REMOVAL 1 Turn the ignition switch to the Off position Be certain that all ele...

Page 358: ...battery cable wire harnesses for the vehicle being serviced The battery cables feature a stamped brass clamp ing type female battery terminal crimped onto one end of the battery cable wire and then so...

Page 359: ...OSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BATTERY PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT THE BATTERY CONTAINS SULFURIC ACID WHICH IS...

Page 360: ...id B terminal stud Repeat the test If the reading is still above 0 2 volt replace the faulty battery positive cable 4 Connect the voltmeter to measure between the battery negative cable terminal clamp...

Page 361: ...e operation Unrestrained battery movement during vehicle operation could result in damage to the vehi cle the battery or both REMOVAL 1 Remove the battery from the battery tray Refer to Battery in the...

Page 362: ...Be certain that the battery temperature sensor wiring is properly routed 7 Install and tighten the two screws rear screw first that secure the outboard side of the battery tray to the front extension...

Page 363: ...or located in the bat tery tray housing is used to sense battery tempera ture This temperature data along with data from monitored line voltage is used by the PCM to vary the battery charging rate Thi...

Page 364: ...alled and tight Repair or replace as required 4 Inspect generator mounting bolts for tightness Replace or tighten bolts if required Refer to the Gen erator Removal Installation section of this group f...

Page 365: ...1 Feed pigtail harness through hole in top of bat tery tray and press sensor into top of battery tray 2 Connect pigtail harness 3 Install battery Refer to 8 Battery for proce dures GENERATOR DESCRIPT...

Page 366: ...rs 6 Remove B terminal mounting nut at rear of generator Fig 5 or Fig 6 Disconnect terminal from generator 7 Disconnect field wire connector at rear of gen erator by pushing on connector tab and pulli...

Page 367: ...the Powertrain Control Module PCM The EVR is not serviced separately If replacement is necessary the PCM must be replaced OPERATION The amount of DC current produced by the generator is controlled by...

Page 368: ...for additional information and a list of codes OPERATION The starting system components form two separate circuits A high amperage feed circuit that feeds the starter motor between 150 and 350 ampere...

Page 369: ...pinion gear from the starter ring gear DIAGNOSIS 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...

Page 370: ...ch 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 eq...

Page 371: ...ble 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...

Page 372: ...terminal 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 at...

Page 373: ...starter control circuit components should be tested in the order in which they are listed as fol lows Starter Relay Refer to Starter Relay Diag nosis and Testing Starter Solenoid Refer to Starter Moto...

Page 374: ...ion system consists of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with a larger gear that is splined to the input end of the starter...

Page 375: ...tarter motor assembly REMOVAL 2 5L Engine 1 Disconnect and isolate negative battery cable 2 Raise and support vehicle 3 Remove bolt and washer forward facing secur ing starter to clutch housing Fig 11...

Page 376: ...enoid wire solenoid terminal stud 8 Disconnect battery cable solenoid wire from receptacle on starter solenoid 9 Remove starter motor from transmission hous ing 4 7L With Automatic Transmission 1 Disc...

Page 377: ...install the washers bolt and nut to starter Tighten bolt and nut to 67 8 N m 50 ft lbs 8 Lower vehicle 9 Connect negative battery cable 4 7L With Automatic Trans 1 Position starter motor to transmissi...

Page 378: ...when ignition switch is held in Start position On vehicles with manual transmission clutch pedal must be fully depressed for this test Check for battery voltage at cavity for relay terminal 86 with i...

Page 379: ...th terminal cavities in PDC receptacle 4 Push down firmly on starter relay until termi nals are fully seated in terminal cavities in PDC receptacle 5 Install cover onto PDC 6 Reconnect negative batter...

Page 380: ...r lamp in the HVAC Con trol assembly will light to indicate when the defogger system is turned on The rear window switch also contains the defogger system control circuitry includ ing the timer logic...

Page 381: ...On position produces a severe voltmeter deflection check for a short circuit between the rear window switch defog ger relay output and the rear glass heating grid REAR WINDOW DEFOGGER GRID DESCRIPTION...

Page 382: ...RE HARMFUL IF SWAL LOWED AVOID CONTACT WITH THE SKIN AND EYES FOR SKIN CONTACT WASH THE AFFECTED AREAS WITH SOAP AND WATER FOR CONTACT WITH THE EYES FLUSH WITH PLENTY OF WATER DO NOT TAKE INTERNALLY I...

Page 383: ...d The momentary type rear window defogger switch provides a hard wired ground signal to the rear win dow defogger logic and timer circuitry each time it is depressed OPERATION The rear window defogger...

Page 384: ...ogger system control circuitry including the timer logic and the defogger relay OPERATION The heated mirror system only operates in concert with the rear defogger system and will be automat ically tur...

Page 385: ......

Page 386: ...in the horn system OPERATION The horn system is activated by a horn switch con cealed beneath the driver side airbag module trim cover in the center of the steering wheel Depressing the center of the...

Page 387: ...ir relaxed positions and closing the con tact points again This cycle continues repeating at a very rapid rate producing the vibration and move ment of air that creates the sound that is directed thro...

Page 388: ...is de energized DIAGNOSIS AND TESTING HORN RELAY The horn relay Fig 2 is located in the Junction Block JB on the left end of the instrument panel in the passenger compartment of the vehicle If a prob...

Page 389: ...attery negative cable 2 Remove the fuse access panel by inserting a finger in the finger recess molded into the panel and then pulling the panel sharply away from the left outboard end of the instrume...

Page 390: ...he appro priate wiring information The wiring information includes wiring diagrams proper wire and connector repair procedures details of wire harness routing and retention connector pin out informati...

Page 391: ...f OK go to Step 7 If not OK replace the faulty horn switch 7 Depress the center of the driver side airbag module trim cover and check for continuity between the horn switch feed wire and the horn swit...

Page 392: ...ING 20 SPARK PLUG CABLES 20 REMOVAL 21 INSTALLATION 21 IGNITION CONTROL DESCRIPTION Two different ignition systems are used One type of system is for the 2 5L 4 cylinder the 3 9L V 6 engine and the 5...

Page 393: ...Ignition timing is not adjustable on any engine ENGINE FIRING ORDER 2 5L 4 CYLINDER ENGINE ENGINE FIRING ORDER 3 9L V 6 ENGINE ENGINE FIRING ORDER 4 7L V 8 ENGINE ENGINE FIRING ORDER 5 2L 5 9L V 8 EN...

Page 394: ...N COIL RESISTANCE 4 7L V 8 ENGINE PRIMARY RESISTANCE 21 27 C 70 80 F SECONDARY RESISTANCE 21 27 C 70 80 F 0 6 0 9 Ohms 6 000 9 000 Ohms SPECIFICATIONS IGNITION COIL RESISTANCE EXCEPT 4 7L COIL MANUFAC...

Page 395: ...gnal to the PCM that is lower than pre determined values DIAGNOSIS AND TESTING ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown ASD and fu...

Page 396: ...and PDC connector terminals 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 i...

Page 397: ...EPT 4 7L The camshaft position sensor is located in the dis tributor on all 2 5 3 9 5 2 5 9L engines Fig 6 Distributor removal is not necessary to remove camshaft position sensor 1 Remove air cleaner...

Page 398: ...ply a small amount of engine oil to sensor o ring 3 Install sensor into cylinder head with a slight rocking action Do not twist sensor into position as damage to o ring may result CAUTION Before tight...

Page 399: ...r Distributor removal is not necessary for sensor removal Refer to Fig 10 for an exploded view of the dis tributor A fork with a slot is supplied on the bottom of the distributor housing where the hou...

Page 400: ...o not have built in centrif ugal or vacuum assisted advance Base ignition timing and timing advance are controlled by the Powertrain Control Module PCM Because a con ventional timing light can not be...

Page 401: ...step 4 If original distributor is to be reinstalled such as during engine overhaul the plastic pin will not be available A 3 16 inch drift pin punch tool may be substituted for plastic pin 5 Remove ca...

Page 402: ...ectly installed when rotor is pointed at the 3 o clock position plastic alignment pin or pin punch tool is still installed to distributor number 1 cylinder piston is set at top dead cen ter TDC compre...

Page 403: ...torque 8 Connect camshaft position sensor wiring har ness to main engine harness 9 Install distributor cap Tighten mounting screws 10 Refer to the following Checking Distributor Position Checking Dis...

Page 404: ...mounted on the engine DESCRIPTION 4 7L The 4 7L V 8 engine uses 8 dedicated and individ ually fired coil Fig 22 for each spark plug Each coil is mounted directly to the top of each spark plug Fig 23 O...

Page 405: ...heat and vibration resistance that allows the ignition coil to be mounted on the engine Because of coil design spark plug cables second ary cables are not used REMOVAL 2 5L The ignition coil is an epo...

Page 406: ...d the top of the spark plug These rubber boots and springs are a permanent part of the coil and are not serviced separately An o ring Fig 26 is used to seal the coil at the opening into the cyl inder...

Page 407: ...umber spark plug must be used OPERATION Remove the spark plugs and examine them for burned electrodes and fouled cracked or broken por celain insulators Keep plugs arranged in the order in which they...

Page 408: ...e guide seals or excessive cylinder wear can cause wet fouling In new or recently overhauled engines wet fouling may occur before break in nor mal oil control is achieved This condition can usu ally b...

Page 409: ...e correct heat range rating for the engine Determine if ignition timing is over advanced or if other operating conditions are causing engine over heating The heat range rating refers to the operat ing...

Page 410: ...ON Never use a motorized wire wheel brush to clean spark plugs Metallic deposits will remain on spark plug insulator and will cause plug misfire INSTALLATION CAUTION The 4 7L V 8 engine is equipped wi...

Page 411: ...e possible heat damage to the catalytic converter Total test time must not exceed ten minutes With the engine running remove spark plug cable from spark plug one at a time and hold next to a good engi...

Page 412: ...k it loose Fig 37 Grasp the boot not the cable and pull it off with a steady even force Install cables into the proper engine cylinder firing order Refer to Firing Order in Specifications INSTALLATION...

Page 413: ......

Page 414: ...21 OPERATION 22 DIAGNOSIS AND TESTING 22 HIGH BEAM INDICATOR 22 LOW FUEL INDICATOR DESCRIPTION 23 OPERATION 23 MALFUNCTION INDICATOR LAMP MIL DESCRIPTION 23 OPERATION 24 ODOMETER DESCRIPTION 24 OPERAT...

Page 415: ...ind the cluster bezel The molded plastic EMIC housing has four integral mounting tabs two each on the upper and lower edges of the housing The EMIC is secured to the molded plastic instru ment panel c...

Page 416: ...he EMIC through the use of a combination of soldered splices splice block connectors and many different types of wire harness terminal connectors and insulators Refer to the appropriate wiring infor m...

Page 417: ...nual in the vehicle glove box for more information on the fea tures use and operation of the EMIC GAUGES All gauges receive battery current through the EMIC circuitry when the ignition switch is in th...

Page 418: ...e EMIC The seatbelt indicator is controlled by the EMIC pro gramming PCI data bus messages from the Airbag Control Module ACM and the hard wired seat belt switch input to the EMIC The security indicat...

Page 419: ...to 8 ELECTRICAL CHIME BUZZER OPERATION Proper testing of the EMIC the CTM and the PCI data bus chime request message functions requires the use of a DRBIIIt scan tool Refer to the appro priate diagnos...

Page 420: ...on the park lamps and adjust the panel lamps dimmer thumbwheel on the headlamp switch to the full bright position The cluster illumination lamps should light If OK go to Step 10 If not OK repair the o...

Page 421: ...ion 110 A failure has been identified in the instrument cluster CPU RAM or EEPROM 1 Replace the faulty instrument cluster 900 The PCI data bus is not operational 1 Check the PCI data bus connection at...

Page 422: ...o installation problems are found replace the faulty bulb and bulb holder unit If all of the cluster illumination lamps are inoperative and the problem being diagnosed includes inoperative exterior li...

Page 423: ...r enough to disengage the two self docking instrument panel wire harness connectors from the cluster con nector receptacles 5 Roll the bottom of the instrument cluster upward and rearward to remove it...

Page 424: ...CLUSTER HOUSING REAR COVER 1 Disconnect 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...

Page 425: ...the lens and hood unit to the cluster housing Tighten the screws to 2 2 N m 20 in lbs 3 Reinstall the instrument cluster onto the instrument panel Refer to 8 ELECTRICAL IN STRUMENT CLUSTER INSTALLATI...

Page 426: ...tting Diode LED receives battery current on the instru ment cluster electronic circuit board through the fused ignition switch output run start circuit when ever the ignition switch is in the On or St...

Page 427: ...ion Error If the cluster receives no airbag messages for three consecutive seconds the airbag indicator is illuminated The indicator remains illuminated for about twelve seconds or until the cluster r...

Page 428: ...t clus ter The brake pressure switch on the brake combina tion valve provides a hard wired ground input to the CAB circuitry through the brake pressure switch sense circuit whenever the pressures in t...

Page 429: ...osition whichever occurs first Actuator Test Each time the cluster is put through the actuator test the indicator will be turned on then off again during the bulb check por tion of the test to confirm...

Page 430: ...lectronic circuit board The cruise indicator is serviced as a unit with the VFD in the instrument cluster OPERATION The cruise indicator gives an indication to the vehi cle operator when the speed con...

Page 431: ...s turned to the Off position whichever occurs first Actuator Test Each time the cluster is put through the actuator test the door ajar indicator will be turned on then off again during the bulb check...

Page 432: ...uges indicator is cycled off and then on again by the appropriate engine temperature mes sages from the PCM Message Failure If the cluster fails to receive an engine temperature message it will hold t...

Page 433: ...the same igni tion cycle if the low fuel indicator is cycled off and then on again by the appropriate percent tank full messages from the PCM Less Than Empty Percent Tank Full Mes sage Each time the...

Page 434: ...cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor If the cluster has configured itself for the...

Page 435: ...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 INDICATOR DOES NOT ILL...

Page 436: ...s for 10 consecutive seconds and the vehicle speed is zero or for 60 consecutive seconds and the vehicle speed is greater than zero the low fuel indicator is illuminated and a single chime tone is sou...

Page 437: ...cator remains controlled and illuminated by the cluster until a valid lamp on message is received from the PCM or ECM Actuator Test Each time the cluster is put through the actuator test the indicator...

Page 438: ...curs first If the cluster does not receive a distance message within one sec ond after the ignition switch is turned to the On posi tion it will display the last distance message stored in the cluster...

Page 439: ...f position whichever occurs first The cluster will only turn the check gauges indicator lamp on in response to an engine oil pressure low message if the engine speed message is greater than zero Engin...

Page 440: ...ive off indicator or the instrument cluster circuitry that controls the indicator Refer to 8 ELECTRI CAL INSTRUMENT CLUSTER DIAGNOSIS AND TESTING For proper diagnosis of the overdrive con trol system...

Page 441: ...driver circuit and if the vehicle is so equipped by a transistor on the instrument cluster circuit board based upon elec tronic messages received by the cluster from the Sen try Key Immobilizer Modul...

Page 442: ...e circuit or component malfunction This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and elec tronic messages received by the cluster...

Page 443: ...ometer message is not received after about four seconds the 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...

Page 444: ...erature indicator is ser viced as a unit with the instrument cluster OPERATION The transmission over temperature indicator gives an indication to the vehicle operator when the trans mission fluid temp...

Page 445: ...tion of the other circuits in the turn signal and hazard warning system For more information on the turn signal and hazard warning system Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR OPERATION TURN S...

Page 446: ...load conditions to determine the proper fuel and ignition requirements The PCM then sends the proper messages to the instrument cluster For fur ther diagnosis of the upshift indicator or the instru me...

Page 447: ...START INDICATOR DESCRIPTION A wait to start indicator is only found in the instrument clusters of vehicles equipped with an optional diesel engine The wait to start indicator is located in the Informa...

Page 448: ...ect the instrument panel wire harness connector Connector C1 for the ECM from the ECM connector receptacle Check for conti nuity between the wait to start indicator driver cir cuit cavity of the instr...

Page 449: ...per wire and connector repair procedures details of wire harness routing and retention connec tor pin out information and location views for the various wire harness connectors splices and grounds WAR...

Page 450: ...nition switch is in any posi tion except On or Start The LED only illuminates when it is provided a path to ground by the instru ment cluster transistor The instrument cluster will turn on the water i...

Page 451: ......

Page 452: ...TION 11 REMOVAL 12 INSTALLATION 12 FOG LAMP REMOVAL 13 INSTALLATION 13 FOG LAMP UNIT REMOVAL 13 INSTALLATION 13 ADJUSTMENTS 13 HEADLAMP SWITCH DESCRIPTION 14 OPERATION 14 DIAGNOSIS AND TESTING 15 HEAD...

Page 453: ...d warning switch is integral to the multi function switch on the left side of the steering column The hazard warning switch button protrudes from a dedicated opening in the shroud on the top of the st...

Page 454: ...to provide the turn signal on warning the ElectroMechanical Instrument Cluster EMIC moni tors vehicle speed and distance messages received from the Powertrain Control Module PCM over the Programmable...

Page 455: ...d replace the faulty fuse s 3 Check for battery voltage at the fused B fuse Fuse 1 30 ampere in the PDC If OK go to Step 4 If not OK repair the open B circuit between the PDC and the battery as requir...

Page 456: ...1 Loose or corroded battery cables 1 Clean and secure battery cable clamps and posts OR IGNITION TURNED OFF 2 Loose or worn generator drive belt 2 Adjust or replace generator drive belt 3 Charging sys...

Page 457: ...AM DO NOT ILLUMINATE 1 No ground for low beam circuit 1 Ground should be present according to Multifunction switch position Check wiring circuit from Multifunction switch to headlamp Trace open circui...

Page 458: ...ground 1 Check wiring circuit from right headlamp fuse to headlamp Repeat for left side Trace short circuit in wiring and repair 2 Faulty CTM 2 Replace CTM HEADLAMP SWITCH ON HIGH BEAMS ON ONE HIGH B...

Page 459: ...M 4 Replace CTM FOG LAMPS FLASH RANDOMLY 1 Poor lighting circuit Z1 ground 1 Test for voltage drop across Z1 ground locations 2 High resistance in fog lamp circuit 2 Test amperage draw of fog lamp cir...

Page 460: ...b life will be reduced The following Bulb Application Table lists the lamp title on the left side of the column and trade number or part number on the right BULB APPLICATION TABLE LAMP BULB BACK UP 31...

Page 461: ...2 Press and hold brake pedal in applied position 3 Rotate switch counterclockwise about 30 to align switch lock tab with notch in bracket 4 Pull switch rearward out of mounting bracket and release bra...

Page 462: ...his application These ten terminals are intended for the following inputs and outputs fused B fused ignition switch output right turn signal sense left turn signal sense hazard flasher signal brake la...

Page 463: ...BLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND C...

Page 464: ...negative cable 2 Disengage fog lamp harness connector 3 Remove the bolts attaching the fog lamp to the bumper Fig 6 4 Separate fog lamp from bumper INSTALLATION 1 Position fog lamp in bumper 2 Instal...

Page 465: ...ule CTM when the park or head lamps are on and the driver door ajar switch is closed driver door is open The headlamp switch opens the ground path when the headlamp switch is turned off The ground pat...

Page 466: ...s and grounds HEADLAMP SWITCH CONTINUITY TABLE SWITCH POSITION CONTINUITY BETWEEN OFF PIN 2 AND 4 PIN 1 AND 14 PARK PIN 3 AND 4 HEAD PIN 4 AND 6 FOG LAMP PIN 5 AND 4 INTERIOR LAMPS DIMMER PIN 12 AND 9...

Page 467: ...ly 5 Connect the battery negative cable HEADLAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the bolts attaching headlamp to the inner fender panel Fig 11 3 Grasp the hea...

Page 468: ...loor 7 62 meters 25 ft away from and parallel to the wall 3 Measure from the floor up 1 27 meters 5 ft and tape a line on the wall at the centerline of the vehicle Sight along the centerline of the ve...

Page 469: ...battery negative cable 2 Remove license plate lamp bulb socket 3 From the underside of the bumper and using a small flat blade push in retaining tab to release the lamp from the bumper 4 Separate lam...

Page 470: ...cated on the left cowl side inner panel near the left instrument panel end bracket When the ignition switch is in the Accessory or On positions battery current from a fuse in the Junction Block JB is...

Page 471: ...l input to the CTM The CTM then pro vides a battery current output to operate the washer pump motor If the wipers are not operating when the washer switch is actuated the CTM will operate the wiper mo...

Page 472: ...rew that secures the lower shroud to the steering column lock housing 8 Remove the lower shroud from the steering col umn 9 Disconnect the instrument panel wire harness connector for the multi functio...

Page 473: ...nd lower shrouds 7 Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together 8 From below the steering column install and tight...

Page 474: ...rews 4 Connect the battery negative cable TAIL LAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Release tailgate latch and open tailgate 3 Remove screw holding tail lamp to carg...

Page 475: ...o 8 ELECTRICAL RESTRAINTS CLOCKSPRING REMOVAL OPERATION The turn signal cancel cam has two lobes and is secured to the lower hub opening of the clockspring rotor When the turn signals are activated by...

Page 476: ...Center ASC after the component is removed from the vehicle The following Bulb Application Tables lists the lamp title on the left side of the column and trade number or part number on the right BULB A...

Page 477: ...integral to the door latches on each door The switches close a path to ground for the Central Timer Module CTM when a door is opened and open the ground path when a door is closed The door ajar switch...

Page 478: ...or the Central Timer Module CTM from the CTM connector receptacle Check for conti nuity between the driver or passenger door ajar switch sense circuit cavity of the body wire harness connector Connect...

Page 479: ...wire harness connector to the glove box lamp and switch connector receptacle 3 Feed the instrument panel wire harness back into the glove box lamp and switch mounting hole in the glove box opening upp...

Page 480: ...mation on the use and operation of the various overhead console features SUNGLASS STORAGE BIN A sunglasses storage bin is included in the over head console The storage bin is located near the cen ter...

Page 481: ...e Step push buttons and hold the buttons down until VAR appears in the display This takes about five seconds 4 Release both of the push buttons VAR along with the current variance zone will appear in...

Page 482: ...e in another location STANDARD PROCEDURE COMPASS DEMAGNETIZING A degaussing tool Special Tool 6029 is used to demagnetize or degauss the overhead console for ward mounting screw and the roof panel abo...

Page 483: ...y and evenly to disengage the two snap clips that secure the rear of the unit from their receptacles in the overhead console bracket 5 Lower the overhead console from the headliner far enough to acces...

Page 484: ...erhead console housing 3 Install and tighten the four screws that secure the paperclip to the overhead console housing Tighten the screws to 2 2 N m 20 in lbs 4 Install the overhead console onto the h...

Page 485: ...distance is computed using the average miles per gallon from the last 30 gallons of fuel used Elapsed time ET shows the accumulated ignition on time since the last trip computer reset Blank screen the...

Page 486: ...he On position the trip computer information that can be reset is reset However the reset will only occur if the function currently displayed is a function that can be reset The functions that can be...

Page 487: ...ration The required J1850 messages are Dimming message Fuel Used message Distance Pulses message Percentage Fuel Tank Full message Fuel Type message VIN Vehicle Identification Number Vehicle Speed mes...

Page 488: ...age to the HVAC control head unit Based upon the resistance in the sensor the HVAC control head unit senses a specific voltage on the temperature sensor signal circuit which it is programmed to corres...

Page 489: ...mbient temperature sensor from the radiator yoke INSTALLATION 1 Position the ambient temperature sensor onto the radiator yoke 2 Install and tighten the one screw that secures the ambient temperature...

Page 490: ...ter within one inch of the uni versal transmitter and push the buttons on both transmitters The red light on the universal trans mitter will begin to flash slowly 4 When the red light on the universal...

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Page 492: ...l factory installed equipment on this model The power lock system is offered only on models that are also equipped with power windows On vehicles equipped with power locks the power lock motors are co...

Page 493: ...ctor 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 splices and grounds Many of the electronic f...

Page 494: ...nlock all doors when either front door is locked or unlocked using a key Door Lock Inhibit The CTM receives inputs from the key in ignition switch the headlamp switch and the door ajar switches The lo...

Page 495: ...n the CTM software is Flash compatible which means it can be reprogrammed using Flash reprogramming proce dures However if any of the CTM hardware compo nents are damaged or faulty the entire CTM unit...

Page 496: ...esistors One resistor is used for the neutral switch position one for the Lock position and one for the Unlock posi tion The door cylinder lock switches cannot be adjusted or repaired and if faulty or...

Page 497: ...open ing near the forward end of the arm rest in the driver side front door trim panel so that the DDM can be serviced without removing the front door trim panel Two integral connector receptacles on...

Page 498: ...depressed a second time in either the Up or Down direction When the two position window lockout switch in the DDM is depressed and latched in the lockout posi tion the battery current feed to each of...

Page 499: ...TED UP PINS 1 3 DOWN PINS 2 3 RIGHT PINS 2 3 LEFT PINS 3 6 RIGHT MIRROR SELECTED UP PINS 3 7 DOWN PINS 2 3 RIGHT PINS 2 3 LEFT PINS 3 4 POWER WINDOW SWITCH SWITCH POSITION CONTINUITY BETWEEN PINS OF C...

Page 500: ...ck and unlock relay outputs The driver side front door power lock motor also shares the common lock relay output from the CTM This circuit arrangement makes the Remote Keyless Entry RKE system driver...

Page 501: ...door is connected in series between ground and the passenger door switch mux input of the Central Timer Module CTM The power lock switch on the driver side front door trim panel is integral to the dr...

Page 502: ...s down on the power lock switch it snaps into place in the power window and lock switch bezel receptacle 3 Position the power window and lock switch bezel to the opening in the passenger side front do...

Page 503: ...lace the faulty RKE transmitter NOTE Be certain to perform the RKE Transmitter Programming procedure again following this test This procedure will erase the access code of the test transmitter from th...

Page 504: ...r the vehicle is being driven in reverse Following is a general description of the automatic day night mirror Refer to the owner s manual in the vehicle glove box for more information on the fea tures...

Page 505: ...nnector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness connec tors splices and grounds 1 Check the fuse i...

Page 506: ...ttery negative cable 2 Unplug the wire harness connector from the automatic day night mirror Fig 2 3 Remove the set screw that secures the auto matic day night mirror to the windshield support button...

Page 507: ...irror wire harness connector If the power mirror s 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 t...

Page 508: ...ns cleaned and tightened to ensure proper continuity and grounds For circuit descriptions and diagrams refer to Wiring Diagrams With the dome lamp on apply the power seat switch in the direction of th...

Page 509: ...enough to access the power seat switch module wire harness connector 6 Unplug the wire harness connector from the power seat switch module 7 Remove the seat cushion side shield and power seat switch m...

Page 510: ...track fails to operate in only one direction move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit If the power seat tr...

Page 511: ...bolts that secure the power seat track assembly to the seat cushion frame Torque the bolts to 27 N m 20 ft lbs 4 Install the power seat wire harness retainers on the seat track assembly 5 Connect the...

Page 512: ...scriptions of the major components in the power window system Refer to the owner s manual in the vehicle glove box for more information on the features use and operation of the power window system OPE...

Page 513: ...DIAGNOSIS AND TESTING If not OK repair the circuit to the junction block as required ONE WINDOW INOPERATIVE The window glass must be free to slide up and down for the power window motor to function p...

Page 514: ...but no power windows operate refer to ALL WINDOWS INOPERATIVE POWER WINDOW SWITCH DIAGNOSIS AND TESTING POWER WINDOW SWITCH CONVENTIONAL CAB AND CLUB CAB The Light Emitting Diode LED illumination lamp...

Page 515: ...im panel passenger doors only For diag nosis of the driver side power window switch Refer to 8 ELECTRICAL POWER LOCKS DOOR MOD ULE DIAGNOSIS AND TESTING Unplug the wire harness connector from the swit...

Page 516: ...or full down position the motor will not operate in that direction by design If OK repair the circuits from the power window motor to the power window switch as required If not OK replace the faulty...

Page 517: ......

Page 518: ...WITCH DESCRIPTION 30 OPERATION 30 DIAGNOSIS AND TESTING 30 SEAT BELT SWITCH 30 SEAT BELT TENSIONER DESCRIPTION 31 OPERATION 31 SEAT BELT TURNING LOOP ADJUSTER REMOVAL 32 INSTALLATION 32 TURNING LOOP H...

Page 519: ...hese circuits may be connected to each other to the vehicle electrical system and to the air bag system components through the use of a combi nation of soldered splices splice block connectors and man...

Page 520: ...conds Within one to two seconds from the moment of impact both airbags are almost entirely deflated The times cited for these events are approximations which apply only to a barrier impact at the give...

Page 521: ...e body to minimize injury in the event of an accidental deployment If the airbag unit is placed on a bench or any other surface the trim cover or airbag cushion side of the unit should be face up to m...

Page 522: ...aner to remove any residual powder from the vehicle interior Clean from outside the vehicle and work your way inside so that you avoid kneeling or sitting on a non cleaned area Be certain to vacuum th...

Page 523: ...system fault or malfunction Refer to the appropriate diag nostic information to diagnose the problem SPECIAL TOOLS SPECIAL TOOLS AIRBAG SYSTEM AIRBAG CONTROL MODULE DESCRIPTION The Airbag Control Mod...

Page 524: ...t supply to the ACM during an impact The capacitor is only serviced as a unit with the ACM Two sensors are contained within the ACM an electronic impact sensor and a safing sensor The electronic impac...

Page 525: ...S IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT AND POSSIBLE PERSONAL INJURY WARNING THE AIRBAG CONTROL MODULE...

Page 526: ...TTEMPT TO REPAIR A SEAT BELT COMPONENT ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT COMPONENTS WITH THE COR RECT NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG 1 Remove the screw tha...

Page 527: ...irbag has been deployed the clockspring must be replaced OPERATION The clockspring is a mechanical electrical circuit component that is used to provide continuous electri cal continuity between the fi...

Page 528: ...g com pletion of such service or the clockspring tape may be damaged Service replacement clocksprings are shipped pre centered and with a plastic locking pin installed Fig 8 This locking pin should no...

Page 529: ...pecial Tool C 3428 B 6 Remove the steering column opening cover from the instrument panel Refer to 23 BODY IN STRUMENT PANEL STEERING COLUMN OPEN ING COVER REMOVAL 7 If the vehicle is so equipped gras...

Page 530: ...ring column install and tighten the one center screw that secures the lower shroud to the steering column lock housing Tighten the screw to 2 N m 20 in lbs 6 Position the upper shroud onto the steerin...

Page 531: ...n the upper right inflator mounting stud The other horn switch pigtail wire is routed between the upper left inflator mount ing stud and the inflator where it is captured by a small plastic retainer t...

Page 532: ...ITATION TO THE SKIN AND EYES 1 Disconnect and isolate the battery negative cable If either of the airbags has not been deployed wait two minutes for the system capacitor to dis charge before further s...

Page 533: ...twelve windows of the trim cover receptacle from the twelve hook formations on the perimeter of the airbag housing 5 Remove the housing inflator cushion and horn switch as a unit from the driver airba...

Page 534: ...DEALER SERVICE TECHNICIANS FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCI DENTAL INCOMPLETE OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJU RIE...

Page 535: ...e airbag housing away from each other This action will fully seat the edges of the windows into the cra dles of the hooks 9 After all of the windows in the walls of the trim cover receptacle have been...

Page 536: ...position the driver airbag in the steering wheel Be certain that the clockspring pig tail wire and steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag...

Page 537: ...anchor plate to the front seat adjuster 4 Remove the screw that secures the lower seat belt anchor plate to the seat adjuster Fig 17 5 Unsnap and remove the front shoulder belt turning loop cover to...

Page 538: ...ew that secures the retractor to the B pillar 11 Remove the front shoulder belt and retractor from the B pillar INSTALLATION QUAD CAB WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYST...

Page 539: ...PLACEMENT PARTS LISTED IN THE MOPAR PARTS CATALOG 1 Position the retractor into the B pillar Fig 18 2 Install and tighten the screw that secures the retractor to the B pillar Tighten the screw to 40 N...

Page 540: ...g standards to deploy with less force than those used in some prior models The pas senger airbag is located in the instrument panel in front of the front seat passenger seating position where it is se...

Page 541: ...are irri tated move to another area where there is plenty of clean fresh air to breath If the irritation is not alle viated by these actions contact a physician immedi ately REMOVAL WARNING DISABLE TH...

Page 542: ...HANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT 1 Carefully position t...

Page 543: ...r Off to accommodate certain uses of the right front seating position where airbag protection may not be desired See the owner s manual in the vehicle glove box for specific recommendations on when to...

Page 544: ...Y 1 Position the passenger airbag on off switch and face plate unit to the back of the cluster bezel Fig 23 2 Install and tighten the three screws that secure the passenger airbag on off switch face p...

Page 545: ...Y BELT THAT IS TWISTED TIGHTEN ANY LOOSE FASTENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE NEVER...

Page 546: ...STENERS REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE NEVER ATTEMPT TO REPAIR A SEAT BELT COMPONENT ALW...

Page 547: ...Install and tighten the screw that secures the rear seat belt buckle anchor plate to the rear of the left seat cushion frame Tighten the screw to 40 N m 29 ft lbs 3 Fold down the rear seat cushions S...

Page 548: ...b versions of this model The seat belt tensioners are integral to the front seat belt retrac tors which are secured within each B pillar in the vehicle where they are concealed behind the B pillar tri...

Page 549: ...B PILLAR TRIM REMOVAL or Refer to 23 BODY INTERI OR QUARTER TRIM PANEL REMOVAL 4 Remove the screw that secures the upper end of the height adjuster to the B pillar 5 Pull the upper end of the height...

Page 550: ...ble trim tool Fig 27 INSTALLATION WARNING DURING AND FOLLOWING ANY SEAT BELT SERVICE CAREFULLY INSPECT ALL SEAT BELTS BUCKLES MOUNTING HARDWARE AND RETRACTORS FOR PROPER INSTALLATION OPERATION OR DAMA...

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Page 552: ...brakes cannot be applied nor can the gear selector be indicating the transmission is in Park or Neutral The speed control can be disengaged manually by Stepping on the brake pedal Depressing the OFF...

Page 553: ...le road test to verify reports of speed control system malfunction The road test should include attention to the speedometer Speed ometer operation should be smooth and without flut ter at all speeds...

Page 554: ...tially removed to gain access to speed control cable 3 Using finger pressure only disconnect accelera tor cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards...

Page 555: ...able plastic mount into bracket Continue sliding until tab Fig 4 is aligned to hole in mounting bracket 5 Route accelerator cable over top of cable cam Fig 3 6 Install accelerator cable connector onto...

Page 556: ...and decelerate the vehicle To increase throttle opening the PCM grounds the vacuum and vent solenoids To decrease throttle opening the PCM removes the grounds from the vacuum and vent solenoids When...

Page 557: ...e following conditions An indication of Park or Neutral The VSS signal increases at a rate of 10 mph per second indicates that the co efficient of friction between the road surface and tires is extrem...

Page 558: ...gative battery cable 2 Remove airbag module Refer to 8 Passive Restraint Systems for procedures 3 Remove switch to steering wheel mounting screws Fig 8 4 Remove switch 5 Remove electrical connector at...

Page 559: ...reservoir is located under the plastic cowl plenum cover at lower base of windshield Fig 9 or Fig 11 1 Disconnect and isolate negative battery at cable 2 Remove both windshield wiper arm blade assembl...

Page 560: ...trip at front edge of cowl grill 7 Install windshield wiper arms Refer to 8 Wiper and Washer Systems 8 Connect negative battery to cable Fig 11 Cowl Plenum Cover Grille Panel Remove Install 1 PLASTIC...

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Page 562: ...door ajar switch is inte gral to the latch of each door in the vehicle These switches provide an input to the VTSS indicating whether each door is opened or closed Refer to 8 ELECTRICAL LAMPS LIGHTIN...

Page 563: ...eives inputs indicating the status of the door ajar switches the door cylinder lock switch and the igni tion switch The programming in the CTM allows it to process the information from all of these in...

Page 564: ...that the VTSS alarm was activated while the vehicle was unattended OPERATION SENTRY KEY IMMOBILIZER SYSTEM The Sentry Key Immobilizer System SKIS is designed to provide passive protection against unau...

Page 565: ...ED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATT...

Page 566: ...m resulting in the loss of battery current or ground to the Sentry Key Immobilizer Module SKIM should be suspected and the following procedure should be used for diagnosis Refer to the appropriate wir...

Page 567: ...e Off position then back to the On position 4 Using the DRBIIIt scan tool read any faults that are now present in the SKIM These are the active faults 5 Using this active fault information refer to th...

Page 568: ...n replace the valid Sentry Key with a blank Sentry Key transponder and turn the ignition switch back to the On position 6 About ten seconds after the completion of Step 5 the security indicator will s...

Page 569: ...SKIM over the PCI data bus the engine will be dis abled after about two seconds of operation The Elec troMechanical Instrument Cluster EMIC will also respond to the invalid key message on the PCI data...

Page 570: ...here in this ser vice information Central Timer Module The Central Timer Module CTM is located on the left cowl side inner panel under the driver side outboard end of the instrument panel The CTM cont...

Page 571: ...l operate the washer pump motor and the wipers for as long as the washer system is activated then provide several additional wipe cycles after the washer system is deactivated before parking the wiper...

Page 572: ...ndshield when the Off position is selected the park switch that is integral to the wiper motor is closed to ground and the wiper motor ceases to operate If the wiper blades are not in the down positio...

Page 573: ...problem being diagnosed involves all wiper modes or only the Low and or High speed modes go to Step 7 5 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable D...

Page 574: ...nents as required Refer to 8 ELECTRICAL WIPERS WASHERS INSPECTION Refer to the appropriate wiring information The wiring information includes wiring diagrams proper wire and connector repair procedure...

Page 575: ...nozzle CAUTION Never introduce petroleum based clean ers solvents or contaminants into the washer sys tem These products can rapidly deteriorate the rubber seals and hoses of the washer system as well...

Page 576: ...astic body with a round center section Three barbed hose nipples are formed in a wye configuration on the outside circum ference of the center section of the valve body Within the check valve body a s...

Page 577: ...When the float pivots the changing proxim ity of its magnetic field will cause the contacts of the small stationary reed switch to open or close When the fluid level in the washer reservoir is at or a...

Page 578: ...fitting with barbed nipples joins the engine compartment hose to a cowl plenum cover grille panel hose The cowl plenum cov er grille panel hose is routed through locating clips molded to the undersid...

Page 579: ...ated on the out board side of the washer reservoir near the bottom in the right front corner of the engine compartment A small permanently lubricated and sealed electric motor is coupled to the rotor...

Page 580: ...ht end of the upper radiator shroud in the right front corner of the engine compartment Fig 4 A bright yellow plastic filler cap with a rubber seal and an International Control and Display Symbol icon...

Page 581: ...the battery negative cable 2 Disconnect the headlamp and dash wire har ness connector for the washer fluid level switch from the switch connector receptacle Fig 6 3 Disconnect the headlamp and dash w...

Page 582: ...Concealed within the stamped steel channel one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end while the other end of the spring is hooked through the smal...

Page 583: ...uperstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element The driver side and passenger side wiper blades are not interchangeable The supers...

Page 584: ...b under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to dis engage the pivot block from the hook Fig 10 4 Extract the hook formation on the tip...

Page 585: ...upper end of each pivot shaft where the wiper arms will be fastened each has an externally serrated drum secured to it The wiper module cannot be adjusted or repaired If any component of the module is...

Page 586: ...relay control coil 87 Normally Open This terminal is con nected to the normally open fixed contact point of the relay 87A Normally Closed This terminal is con nected to the normally closed fixed cont...

Page 587: ...have continuity between terminals 87A and 30 and no continuity between terminals 87 and 30 If OK go to Step 3 If not OK replace the faulty relay 3 Resistance between terminals 85 and 86 elec tromagnet...

Page 588: ...e open wiper relay control circuit between the PDC and the CTM as required REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the cover from the Power Distribution Center PDC Fig 13...

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Page 590: ...FT 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 MODULE 8W 45...

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Page 592: ...d 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 b...

Page 593: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION AN WIRING DIAGRAM INFORMATION Continued...

Page 594: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 AN 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued...

Page 595: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION AN WIRING DIAGRAM INFORMATION Continued...

Page 596: ...H ING DIAGNOSIS AND TESTING WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below...

Page 597: ...s occurring and where the diagnosis will continue 4 Isolate the problem area 5 Repair the problem area 6 Verify the proper operation For this step check for proper operation of all items on the repair...

Page 598: ...fuse 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...

Page 599: ...g 8 4 Using special 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...

Page 600: ...Pull 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 repai...

Page 601: ...e 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...

Page 602: ...ess starting at 1 1 2 inches behind the connector and 2 inches past the repair 7 Connect battery and test all affected systems WIRE STANDARD PROCEDURE WIRE SPLICING When splicing a wire it is importan...

Page 603: ...joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing Fig 22 Fig 19 SPLICE CLIP Fig 20 CRIMPING TOOL Fig 21 SOLDER Fig 22 H...

Page 604: ...irbag 8W 43 Driver Cylinder Lock Switch 8W 61 Driver Door Ajar Switch 8W 39 Driver Door Module 8W 60 61 62 Driver Door Power Lock Motor Ajar Switch 8W 39 61 Component Page Driver Door Power Window Mot...

Page 605: ...adiator Fan Relay 8W 42 Radio 8W 47 Rear Wheel Speed Sensor 8W 34 35 Rear Window Defogger Relay 8W 48 Rear Window Defogger 8W 48 Component Page Recirculation Door Actuator 8W 42 6 Remote Radio Switch...

Page 606: ...C 8W 10 14 26 Fuse 8 PDC 8W 10 14 26 Fuse 9 PDC 8W 10 15 17 Fuse 10 PDC 8W 10 15 17 Fuse 11 PDC 8W 10 15 27 Fuse 12 PDC 8W 10 15 32 Fuse 13 PDC 8W 10 15 17 Fuse 14 PDC 8W 10 15 32 Fuse 15 PDC 8W 10 15...

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Page 646: ...ox Lamp And Switch 8W 12 6 Headlamp Switch 8W 12 9 11 20 High Note Horn 8W 12 8 Horn Relay 8W 12 8 Horn Switch 8W 12 8 Instrument Cluster 8W 12 6 11 13 18 20 22 Joint Connector No 1 8W 12 15 16 21 Joi...

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Page 668: ...eft Front Park Turn Signal Lamp No 2 8W 15 7 Left Front Side Marker Lamp 8W 15 7 Left Headlamp 8W 15 6 Left License Lamp 8W 15 5 Left Tail Stop Turn Signal Lamp 8W 15 5 License Lamp 8W 15 5 Low Note H...

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Page 682: ...r 8W 18 2 3 Diagnostic Junction Port 8W 18 2 3 Fuse 1 JB 8W 18 2 G208 8W 18 2 Component Page Instrument Cluster 8W 18 3 Joint Connector No 1 8W 18 2 Junction Block 8W 18 2 Overhead Console 8W 18 3 Pow...

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Page 686: ...8W 20 4 Fuse 2 PDC 8W 20 2 Fusible Link 8W 20 2 G110 8W 20 2 G111 8W 20 2 Component Page Generator 8W 20 2 Joint Connector No 1 8W 20 2 3 Joint Connector No 2 8W 20 4 Joint Connector No 3 8W 20 4 Leak...

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Page 690: ...JB 8W 21 2 Fuse 16 PDC 8W 21 2 G105 8W 21 3 G110 8W 21 2 G111 8W 21 2 Component Page G113 8W 21 3 Joint Connector No 2 8W 21 2 3 Joint Connector No 3 8W 21 2 Junction Block 8W 21 2 Power Distribution...

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Page 694: ...0 28 Fuse U 8W 30 6 10 16 Fuse U PDC 8W 30 5 9 15 G100 8W 30 2 G105 8W 30 11 17 27 Component Page G113 8W 30 4 G115 8W 30 2 G207 8W 30 28 G208 8W 30 30 Generator 8W 30 22 Idle Air Control Motor 8W 30...

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Page 726: ...ctor No 1 8W 31 2 3 4 8 Component Page Joint Connector No 2 8W 31 12 Joint Connector No 3 8W 31 8 Junction Block 8W 31 8 10 Line Pressure Sensor 8W 31 7 Output Speed Sensor 8W 31 2 7 Overdrive Switch...

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Page 738: ...ector 8W 33 2 Diagnostic Junction Port 8W 33 2 G112 8W 33 2 Instrument Cluster 8W 33 2 Component Page Joint Connector No 3 8W 33 3 Left Speed Control Switch 8W 33 3 Powertrain Control Module 8W 33 2 3...

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Page 742: ...onnector 8W 34 3 Diagnostic Junction Port 8W 34 3 Fuse 27 JB 8W 34 2 Fuse 8 PDC 8W 34 2 Component Page G113 8W 34 2 3 Joint Connector No 2 8W 34 2 Junction Block 8W 34 2 Power Distribution Center 8W 3...

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Page 746: ...Port 8W 35 3 Fuse 27 JB 8W 35 2 Fuse 8 PDC 8W 35 2 G113 8W 35 2 Component Page Joint Connector No 2 8W 35 2 Junction Block 8W 35 2 Left Front Wheel Speed Sensor 8W 35 3 Power Distribution Center 8W 35...

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Page 750: ...8W 39 4 5 6 7 8 9 High Note Horn 8W 39 3 Component Page Horn Relay 8W 39 3 Instrument Cluster 8W 39 2 3 Junction Block 8W 39 2 3 6 Left Headlamp 8W 39 2 Left Rear Door Ajar Switch 8W 39 4 Left Rear D...

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Page 760: ...2 6 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 Component Page Joint Connector No 1 8W 40 9 Joint Connector No 4 8W 40 8 Junction Block 8W 40 2 3 4 6 7 8 9 Left Back Up Lamp 8W 40 9 Left Turn Indicator 8...

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Page 770: ...8W 41 3 Fuse 17 JB 8W 41 3 Fuse D PDC 8W 41 3 G112 8W 41 2 G113 8W 41 2 G207 8W 41 3 Component Page G307 8W 41 3 Headlamp Switch 8W 41 3 High Note Horn 8W 41 2 Horn Relay 8W 41 2 Horn Switch 8W 41 2...

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Page 774: ...B 8W 42 3 Fuse 10 JB 8W 42 9 Fuse 11 JB 8W 42 5 Fuse 24 JB 8W 42 4 8 Fuse 25 JB 8W 42 4 8 Fuse 13 PDC 8W 42 2 Component Page Fuse 15 PDC 8W 42 9 Fuse B PDC 8W 42 5 G105 8W 42 5 G112 8W 42 9 G207 8W 42...

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Page 784: ...Diagnostic Junction Port 8W 43 2 Driver Airbag 8W 43 2 Driver Seat Belt Tensioner 8W 43 4 Fuse 20 JB 8W 43 2 3 Component Page Fuse 21 JB 8W 43 2 G201 8W 43 2 Junction Block 8W 43 2 3 Passenger Airbag...

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Page 788: ...W 44 10 11 12 14 Glove Box Lamp And Switch 8W 44 9 Component Page Headlamp Switch 8W 44 2 3 4 Ignition Switch 8W 44 10 Instrument Cluster 8W 44 4 Joint Connector No 1 8W 44 13 14 Joint Connector No 4...

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Page 802: ...G208 8W 45 2 4 5 8 Component Page G307 8W 45 11 12 13 14 15 16 18 Glove Box Lamp And Switch 8W 45 3 Headlamp Switch 8W 45 3 4 5 High Note Horn 8W 45 3 Horn Relay 8W 45 3 Ignition Switch 8W 45 2 Instr...

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Page 822: ...5 7 8 Junction Block 8W 47 2 5 Junction Block 8W 47 7 8 Component Page Left Front Door Speaker 8W 47 3 4 Left Front Door Tweeter 8W 47 5 Left Front Door Woofer 8W 47 5 Left Rear Speaker 8W 47 3 4 7 Le...

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Page 830: ...15 JB 8W 48 3 Fuse 24 JB 8W 48 2 Fuse 4 PDC 8W 48 2 G307 8W 48 3 Component Page Joint Connector No 3 8W 48 2 Junction Block 8W 48 2 3 Passenger Power Mirror 8W 48 3 Power Distribution Center 8W 48 2...

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Page 834: ...Timer Module 8W 49 2 3 Data Link Connector 8W 49 3 Diagnostic Junction Port 8W 49 3 Fuse 1 JB 8W 49 2 3 Fuse 9 JB 8W 49 3 Component Page Fuse 11 JB 8W 49 3 G307 8W 49 3 Headlamp Switch 8W 49 3 Junctio...

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Page 838: ...Block 8W 50 2 3 Left Fog Lamp 8W 50 2 Component Page Left Front Park Turn Signal Lamp No 1 8W 50 3 Left Front Park Turn Signal Lamp No 2 8W 50 3 Left Front Side Marker Lamp 8W 50 3 Left Headlamp 8W 5...

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Page 842: ...G113 8W 51 3 7 G205 8W 51 3 G307 8W 51 5 Component Page Joint Connector No 1 8W 51 2 3 5 Joint Connector No 3 8W 51 4 Junction Block 8W 51 2 3 4 5 Left Back Up Lamp 8W 51 3 Left License Lamp 8W 51 7 L...

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Page 850: ...ion Block 8W 52 2 4 Component Page Left Front Park Turn Signal Lamp No 1 8W 52 4 Left Front Park Turn Signal Lamp No 2 8W 52 4 Left Tail Stop Turn Signal Lamp 8W 52 3 Power Distribution Center 8W 52 2...

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Page 854: ...2 Diagnostic Junction Port 8W 53 2 Front Washer Pump Motor 8W 53 2 Front Wiper Motor 8W 53 2 3 Front Wiper Relay 8W 53 2 3 Component Page Fuse 5 JB 8W 53 2 3 G112 8W 53 2 G113 8W 53 3 Joint Connector...

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Page 858: ...8W 54 2 Fuse C PDC 8W 54 2 Fuse T PDC 8W 54 2 G113 8W 54 2 Component Page G305 8W 54 3 Joint Connector No 1 8W 54 2 3 Joint Connector No 3 8W 54 2 Junction Block 8W 54 2 Park Lamp Relay 8W 54 2 Power...

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Page 862: ...0 2 4 G307 8W 60 2 4 Junction Block 8W 60 2 4 Left Rear Power Window Motor 8W 60 6 Component Page Left Rear Power Window Switch 8W 60 4 6 Passenger Door Power Window Motor 8W 60 3 5 Passenger Door Pow...

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Page 870: ...Fuse 11 JB 8W 61 2 Fuse 26 JB 8W 61 4 5 G208 8W 61 2 G307 8W 61 3 4 5 7 Component Page Junction Block 8W 61 2 4 5 Left Rear Door Power Lock Motor Ajar Switch 8W 61 6 Park Lamp Relay 8W 61 2 Passenger...

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Page 878: ...2 POWER MIRRORS Component Page Driver Door Module 8W 62 2 Driver Power Mirror 8W 62 2 Fuse 1 JB 8W 62 2 Component Page Junction Block 8W 62 2 Passenger Power Mirror 8W 62 2 AN 8W 62 POWER MIRRORS 8W 6...

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Page 880: ...8W 63 POWER SEAT Component Page Fuse 14 PDC 8W 63 2 G307 8W 63 2 Power Distribution Center 8W 63 2 Component Page Power Seat Motors 8W 63 2 Power Seat Switch 8W 63 2 AN 8W 63 POWER SEAT 8W 63 1...

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Page 882: ...1 3 S183 8W 10 30 S184 8W 10 30 S187 8W 10 27 S207 8W 47 6 S208 8W 47 6 S240 8W 10 24 Component Page S240 8W 12 19 S300 8W 62 2 S301 8W 15 11 S302 8W 61 7 S303 8W 39 4 8 S303 8W 44 11 12 S305 8W 61 3...

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Page 886: ...8W 80 20 C361 2 Door 8W 80 20 C361 2 Door 8W 80 21 C361 4 Door 8W 80 21 C361 4 Door 8W 80 21 C362 2 Door 8W 80 22 C362 2 Door 8W 80 22 C362 4 Door 8W 80 22 C362 4 Door 8W 80 23 C363 2 Door 8W 80 23 C3...

Page 887: ...3 In PDC 8W 80 44 Joint Connector No 4 8W 80 45 Junction Block C1 8W 80 45 Junction Block C2 8W 80 45 Junction Block C3 8W 80 46 Component Page Junction Block C4 8W 80 46 Junction Block C5 8W 80 46 J...

Page 888: ...65 Right Front Door Tweeter Midlevel Premium 8W 80 65 Component Page Right Front Door Woofer Midlevel Premium 8W 80 66 Right Front Park Turn Signal Lamp No 1 8W 80 66 Right Front Park Turn Signal Lam...

Page 889: ...8 E2 20OR PANEL LAMPS FEED 9 C62 20DB PK DUAL ZONE A C ACTUATOR 10 C35 20DG YL MODE DOOR DRIVER 11 C34 20DB WT COMMON DOOR DRIVER 12 C32 20GY DB RECIRCULATION DOOR DRIVER 13 G31 20VT LG AMBIENT TEMPE...

Page 890: ...CAV CIRCUIT FUNCTION 1 2 3 4 Z6 18BK PK GROUND 5 R45 18DG LB AIRBAG LINE 2 6 R43 18BK LB AIRBAG LINE 1 7 R42 18BK YL PASSENGER AIRBAG LINE 1 8 R44 18DG YL PASSENGER AIRBAG LINE 2 9 R54 18LB YL PASSENG...

Page 891: ...LB GROUND 8 Z47 18BK LB GROUND 9 D25 20VT YL PCI BUS 10 X80 18LB BK AMPLIFIED RIGHT DOOR SPEAKER 11 X82 18LB VT AMPLIFIED RIGHT DOOR SPEAKER 12 X85 18LG DG AMPLIFIED LEFT DOOR SPEAKER 13 X92 18TN BK...

Page 892: ...18BR LG 3 9L 5 9L TRS REVERSE SENSE B L10 18BR LG EXCEPT 3 9L 5 9L FUSED IGNITION SWITCH OUTPUT RUN BASE OVERHEAD CONSOLE 3 WAY CAV CIRCUIT FUNCTION 1 Y158 20YL VT INTERIOR LAMP DRIVER 2 M1 20PK FUSED...

Page 893: ...BLACK 6 WAY CAV CIRCUIT FUNCTION 1 F32 14PK DB FUSED B 2 L50 14WT TN BRAKE LAMP SWITCH OUTPUT 3 V30 20DB RD BRAKE LAMP SWITCH OUTPUT 4 V32 20YL RD SPEED CONTROL SUPPLY 5 Z2 18BK LG GROUND 6 V40 20WT...

Page 894: ...18YL BR EXCEPT 2 5L 3 Y124 16DG VT EXCEPT 2 5L 4 Y125 16DG WT EXCEPT 2 5L 5 Y115 18YL WT EXCEPT 2 5L 6 Y117 18YL DB EXCEPT 2 5L 7 Y119 18YL TN EXCEPT 2 5L 8 Y114 18YL VT EXCEPT 2 5L 9 L1 18VT BK 10 A...

Page 895: ...9L 5 9L 12 A14 16RD WT 13 L10 18BR LG 14 G7 18WT OR 15 Y113 18YL OR 16 K200 18VT OR 17 K100 18VT WT 18 F18 20LG BK 19 K125 18WT DB 20 D25 18VT YL 4 7L 20 C24 18DB PK EXCEPT 4 7L 21 K4 18BK LB EXCEPT...

Page 896: ...DE CAV CIRCUIT 1 F142 18OR DG 2 K200 18VT OR 3 K4 18BK LB 4 K141 18TN WT C108 2 5L OXYGEN SENSOR JUMPER CAV CIRCUIT 1 F142 18OR DG 2 K200 18VT OR 3 K4 18BK LB 4 K141 18TN WT C126 ELECTRIC BRAKE SIDE C...

Page 897: ...L39 12LB 19 20 D21 18PK 21 22 D20 18LG 23 24 25 V23 16BR PK 26 D22 20PK BK 4 7L 27 Y113 18YL OR 28 29 K4 18BK LB EXCEPT 2 5L 30 31 32 33 V30 20DB RD SPEED CONTROL 34 L63 16DG RD 35 36 37 L62 16BR RD 3...

Page 898: ...DB WT 68 F18 20LG BK 69 G29 18BK TN 70 C43 18OR LB 71 V32 18YL RD EXCEPT 2 5L 72 F32 14PK DB 73 V37 18RD LG EXCEPT 2 5L 74 V20 18BK WT C200 BLACK INSTRUMENT PANEL SIDE CAV CIRCUIT 1 V40 20WT PK 2 3 4...

Page 899: ...YL 47 Y112 18YL BR 48 Y119 18YL TN 49 50 T41 18BK WT 51 Y115 18YL WT 52 Y114 18YL VT 53 V45 18VT 54 Y128 20DG GY 55 Y117 18YL DB 56 Z2 20BK LG 57 D25 20VT YL 58 Y193 20ST LG 59 A34 16LB RD 60 V48 16R...

Page 900: ...K DB C202 NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 2 3 4 5 C35 20DG YL 6 C57 20DB GY 7 C5 14LG 8 C6 14LB 9 C62 20DB GY 10 C4 16TN 11 C21 20DB OR 12 C32 20GY DB 13 C1 12DG 14 C7 12BK TN 15 16 C34 20...

Page 901: ...X93 18WT RD 6 X91 18WT BK 7 C15 12BK WT 8 F91 12GY RD 9 X94 18TN VT 10 X92 18TN BK 11 D25 20VT YL 12 C63 20LB 13 14 C70 12DG 15 G13 20BR RD 16 C246 BLACK BODY SIDE CAV CIRCUIT 1 X87 18LG VT 2 X85 18L...

Page 902: ...BK 2 A4 12BK PK C301 BLACK BASE CONSOLE SIDE CAV CIRCUIT 1 A12 16RD TN 2 M1 20PK 3 Z1 16BK 4 Y158 20YL VT C301 BLACK BODY SIDE CAV CIRCUIT 1 A12 16RD TN 2 M1 20PK 3 Z1 16BK 4 DOOR 3 Z1 18BK 2 DOOR 4 Y...

Page 903: ...0BK 3 L632 16DG RD 4 L1 20VT BK C325 BLACK CHASSIS SIDE CAV CIRCUIT 1 L7 20BK YL 2 Z1 20BK 3 L63 16DG RD 4 L1 20VT BK C329 BLACK BODY SIDE CAV CIRCUIT 1 M1 20PK 2 M3 20PK DB 3 L50 14WT TN 4 Z1 18BK 5...

Page 904: ...L62 18BK PK 3 L1 20VT BK 4 Y203 16RD WT 5 L207 18BK OR 6 7 B40 14LB 8 Z1 14BK 9 Z1 14BK 10 L63 18DG RD C352 BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 L1 18VT BK 2 L62 16BR RD 3 L63 16DG RD 4 Y203 16...

Page 905: ...B114 20WT VT 11 K4 18BK LB 12 K226 18DB WT 13 A61 16DG BK 14 Z1 16BK C360 BLACK TAIL LAMPS SIDE CAV CIRCUIT 1 L7 20BK YL 2 Z1 20BK 3 L632 16DG BR 4 L1 20VT BK C360 BLACK CHASSIS SIDE CAV CIRCUIT 1 L7...

Page 906: ...Q26 14VT WT 7 Q16 14BR WT 8 G73 20LG OR VTSS 9 P96 20WT LG 10 C361 4 DOOR WHITE BODY SIDE CAV CIRCUIT 1 2 3 4 P34 16PK BK 5 P33 16OR BK 6 Q26 14VT WT 7 Q16 14BR WT 8 G73 20LG OR VTSS 9 L10 18BR LG 10...

Page 907: ...TN BK 12 L10 18BR LG C362 2 DOOR NATURAL RIGHT FRONT DOOR SIDE CAV CIRCUIT 1 P76 22OR YL 2 P74 22DB 3 P72 22YL BK 4 X82 18LB VT 5 X80 18LB BK 6 7 G74 20TN RD 8 Z2 20BK LG 9 10 Z1 20BK 11 F121 20TN BK...

Page 908: ...BODY SIDE PREMI UM CAV CIRCUIT 1 P76 22OR YL 2 P74 22DB 3 P72 22YL BK 4 X87 18LG VT 5 X85 18LG DG 6 M1 20PK 7 G75 20TN 8 Z2 20BK LG 9 F21 12TN POWER WINDOWS LOCKS 10 Z1 14BK POWER WINDOWS LOCKS 11 F12...

Page 909: ...RRORS 9 M1 20PK 10 Z2 20BK LG C363 4 DOOR BLACK LEFT FRONT DOOR SIDE PREMIUM CAV CIRCUIT 1 P76 22OR YL 2 P74 22DB POWER MIRRORS 3 P72 22YL BK POWER MIRRORS 4 X87 18LG VT 5 X85 18LG DG 6 G75 20TN 7 Z1...

Page 910: ...5 P33 16OR BK 6 Q26 14VT WT 7 Q1 14YL 8 F21 12TN 9 Q28 14DG WT 10 G73 20LG OR 11 Q18 14GY BK 12 Q16 14BR WT 13 Q27 14RD BK 14 Q17 14DB WT C364 4 DOOR BLACK LEFT FRONT DOOR SIDE CAV CIRCUIT 1 P114 20YL...

Page 911: ...REAR DOOR SIDE LEFT CAV CIRCUIT 1 Z2 20BK LG 2 G74 18TN RD 3 P33 16OR BK POWER WINDOWS LOCKS 4 P34 16PK BK POWER WINDOWS LOCKS 5 Q1 14YL 6 Q17 14DB WT 7 Q27 14RD BK 8 X93 18WT RD 9 X91 18WT BK 10 C366...

Page 912: ...5L CAMSHAFT POSITION SENSOR SIGNAL 2 K4 18BK LB 3 9L 5 9L SENSOR GROUND 2 K4 16BK LB 2 5L SENSOR GROUND 3 K7 16OR 3 9L 5 9L 5V SUPPLY 3 K7 18OR 2 5L 5V SUPPLY CAPACITOR BLACK 2 WAY CAV CIRCUIT FUNCTIO...

Page 913: ...L308 20LG RD PARK LAMP SWITCH SENSE 8 V52 18DG RD INTERMITTENT FRONT WIPER MODE SENSE 9 M4 18GY BK INTERIOR LAMP DEFEAT 10 D25 18VT YL PCI BUS 11 L4 18VT WT LOW BEAM SWITCH OUTPUT 12 X20 20GY WT RADI...

Page 914: ...OR AJAR SWITCH SENSE 16 Y158 20YL VT STANDARD INTERIOR LAMP DRIVER 16 Y158 18YL VT EXCEPT STANDARD INTERIOR LIGHTS CONTROL CENTRAL TIMER MODULE C3 GRAY 12 WAY CAV CIRCUIT FUNCTION 1 A302 16RD TN FUSED...

Page 915: ...NG C3 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 V37 22RD LG SPEED CONTROL SPEED CONTROL SWITCH SIGNAL 3 K4 22BK LB SPEED CONTROL SENSOR GROUND 4 X3 22BK RD HORN RELAY CONTROL CLOCKSPRING C4 PREMIUM RADIO B...

Page 916: ...MATIC SHUT DOWN RELAY OUTPUT 3 COIL ON PLUG NO 2 4 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K92 16TN PK COIL DRIVER NO 2 2 A142 16DG OR AUTMATIC SHUT DOWN RELAY OUTPUT 3 COIL ON PLUG NO 3 4 7L BLACK 3 WA...

Page 917: ...HUT DOWN RELAY OUTPUT 3 COIL ON PLUG NO 8 4 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K98 16LB RD COIL DRIVER NO 8 2 A142 16DG OR AUTMATIC SHUT DOWN RELAY OUTPUT 3 COMBINATION FLASHER BLACK 14 WAY CAV CIR...

Page 918: ...7 18WT OR VEHICLE SPEED SENSOR SIGNAL 13 Z19 12BK PK GROUND 14 A10 12RD DG FUSED B CONTROLLER ANTILOCK BRAKE C2 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 B9 20RD LEFT FRONT WHEEL SPEED SENSOR 2 B8 20RD GY LE...

Page 919: ...VT YL PCI BUS DLC 6 D25 18VT YL PCI BUS PCM 7 D25 18VT YL PCI BUS TCM 8 D25 20VT YL PCI BUS CAB 9 10 11 D25 20VT YL PCI BUS AMP 12 D25 20VT YL PCI BUS RADIO 13 D25 20VT YL PCI BUS HVAC 14 15 D25 18VT...

Page 920: ...UTPUT 4 P33 18OR BK 2 DOOR DOOR LOCK RELAY OUTPUT 4 P33 16OR BK 4 DOOR DOOR LOCK RELAY OUTPUT DRIVER DOOR MODULE C1 BLUE 12 WAY CAV CIRCUIT FUNCTION 1 Q28 14DG WT MASTER WINDOW SWITCH RIGHT REAR DOWN...

Page 921: ...OR WHITE 8 WAY CAV CIRCUIT FUNCTION 1 P71 22YL DRIVER MIRROR UP MOVEMENT 2 P75 22DB WT DRIVER MIRROR LEFT MOVEMENT 3 P76 22OR YL MIRROR COMMON DRIVER 4 F121 20TN BK FUSED REAR WINDOW DEFOGGER RELAY OU...

Page 922: ...NGINE COOLANT TEMPERATURE SENSOR 4 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND 2 K2 18TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL ENGINE OIL PRESSURE SENSOR BLACK 2 WAY CAV CIRCU...

Page 923: ...V48 18RD GY FRONT WIPER HIGH SPEED FUEL INJECTOR NO 1 2 5L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K11 18WT DB FUEL INJECTOR NO 1 DRIVER 2 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 1 3...

Page 924: ...UT FUEL INJECTOR NO 3 3 9L 4 7L 5 9L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K13 18YL WT FUEL INJECTOR NO 3 DRIVER 2 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 4 2 5L BLACK 2 WAY CAV CI...

Page 925: ...FUEL INJECTOR NO 7 4 7L 5 9L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K26 18VT FUEL INJECTOR NO 7 DRIVER 2 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 8 4 7L 5 9L BLACK 2 WAY CAV CIRCUIT...

Page 926: ...ROUND 10 M11 20PK LB COURTESY LAMP SWITCH SENSE 11 M3 20PK DB CARGO LAMP SWITCH SENSE 12 M4 18GY BK INTERIOR LAMP DEFEAT 13 14 E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL HIGH NOTE HORN BLACK 2 WAY CAV C...

Page 927: ...16RD YL FUSED B 5 G26 18LB KEY IN IGNITION SWITCH SENSE 6 Z1 20BK GROUND 7 A22 12BK OR FUSED IGNITION SWITCH OUTPUT RUN 8 C1 12DG BLOWER MOTOR FEED 9 A31 12BK WT FUSED IGNITION SWITCH OUTPUT RUN ACC...

Page 928: ...AIR TEMPERATURE SIGNAL JOINT CONNECTOR NO 1 IN PDC GRAY 28 WAY CAV CIRCUIT FUNCTION 1 L1 18VT BK BACK UP LAMP FEED 2 L1 18VT BK BACK UP LAMP FEED 3 L1 18VT BK BACK UP LAMP FEED 4 F142 16OR DG FUSED AU...

Page 929: ...OR AUTOMATIC SHUT DOWN RELAY OUTPUT 14 A142 14DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 15 A142 14DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 16 V40 20WT PK BRAKE LAMP SWITCH SENSE 17 V40 18WT PK BRAKE LAMP S...

Page 930: ...14 L107 20WT HEADLAMP SWITCH OUTPUT 15 L107 20WT HEADLAMP SWITCH OUTPUT 16 17 18 F75 18VT FUSED B 19 F75 18VT PREMIUM RADIO FUSED B 20 21 22 JUNCTION BLOCK C1 ORANGE 4 WAY CAV CIRCUIT FUNCTION 1 A7 1...

Page 931: ...USED IGNITION SWITCH OUTPUT START 13 L61 16LG LEFT TURN SIGNAL JUNCTION BLOCK C4 BROWN 14 WAY CAV CIRCUIT FUNCTION 1 M120PK FUSED B 2 M1 20PK HIGHLINE BASE FUSED B 2 M1 18PK MIDLINE PREMIUM FUSED B 3...

Page 932: ...1 M1 20PK FUSED B 2 M1 20PK FUSED B 3 M1 20PK FUSED B 4 L79 20RD YL PARK LAMP RELAY CONTROL 5 F75 18VT FUSED B 6 V6 18DB FUSED IGNITION SWITCH OUTPUT RUN ACC 7 X3 20BK RD HORN RELAY CONTROL 8 X3 20BK...

Page 933: ...6TN RIGHT TURN SIGNAL 13 C15 14BK WT REAR WINDOW DEFOGGER RELAY OUTPUT 14 A41 16YL FUSED IGNITION SWITCH OUTPUT START 15 L50 14WT TN BRAKE LAMP SWITCH OUTPUT 16 L61 16LG LEFT TURN SIGNAL JUNCTION BLOC...

Page 934: ...FUNCTION 1 X87 18LG VT AMPLIFIED LEFT DOOR SPEAKER 2 3 X85 18LG DG AMPLIFIED LEFT DOOR SPEAKER LEFT FRONT DOOR TWEETER MIDLEVEL PREMIUM NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 X87 18LG VT AMPLIFIED LEFT...

Page 935: ...DE MARKER LAMP 2 WAY CAV CIRCUIT FUNCTION 1 L7 20BK YL PARK LAMP RELAY OUTPUT 2 Z1 20BK GROUND LEFT FRONT WHEEL SPEED SENSOR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B8 20RD GY LEFT FRONT WHEEL SPEED SENS...

Page 936: ...OR POWER WINDOW MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q23 14RD WT LEFT REAR WINDOW DRIVER DOWN 2 Q13 14DB LEFT REAR WINDOW DRIVER UP LEFT REAR DOOR POWER WINDOW SWITCH BLUE 6 WAY CAV CIRCUIT FUNCTI...

Page 937: ...22BK LB SENSOR GROUND LEFT TAIL STOP TURN SIGNAL LAMP BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 L7 20BK YL HEADLAMP SWITCH OUTPUT 3 L632 16DG BR LEFT REAR TURN SIGNAL LICENSE LAMP NATURAL 2...

Page 938: ...GROUND 2 K1 18DG RD MAP SENSOR SIGNAL 3 K7 18OR 5V SUPPLY MODE DOOR ACTUATOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C35 20DG YL MODE DOOR DRIVER 2 C34 20DB WT COMMON DOOR DRIVER MULTI FUNCTION SWITCH GRAY...

Page 939: ...PER PUMP MOTOR CONTROL 20 OUTPUT SPEED SENSOR 4 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T13 18DB BK SPEED SENSOR GROUND 2 T14 18LG WT OUTPUT SPEED SENSOR SIGNAL OUTPUT SPEED SENSOR 3 9L 5 9L GRAY 2 WAY...

Page 940: ...ELAY OUTPUT 3 K41 18BK DG OXYGEN SENSOR 1 1 SIGNAL 4 K4 18BK LB SENSOR GROUND OXYGEN SENSOR 1 1 UPSTREAM EXCEPT 3 9L 5 9L BLACK 4 WAY CAV CIRCUIT FUNCTION 1 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELA...

Page 941: ...K WT 4 7L A T GROUND 3 K141 18TN WT 4 7L M T OXYGEN SENSOR 1 2 SIGNAL 3 K4 18BK LB 4 7L A T SENSOR GROUND 4 K141 18TN WT 4 7L M T OXYGEN SENSOR 1 2 SIGNAL 4 K4 18BK LB 4 7L A T SENSOR GROUND OXYGEN SE...

Page 942: ...WT OXYGEN SENSOR 2 2 SIGNAL PASSENGER AIRBAG YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 2 3 R44 18DG YL PASSENGER AIRBAG LINE 2 4 R42 18BK YL PASSENGER AIRBAG LINE 1 PASSENGER AIRBAG ON OFF SWITCH 6 WAY CAV...

Page 943: ...20WT LG PASSENGER DOOR SWITCH MUX 2 L10 20BR LG 4 DOOR FUSED IGNITION SWITCH OUTPUT RUN 2 L10 18BR LG 2 DOOR FUSED IGNITION SWITCH OUTPUT RUN 3 4 5 Z2 20BK TN 4 DOOR GROUND 5 Z2 20BK LG 2 DOOR GROUND...

Page 944: ...FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 5 6 7 8 Z1 20BK GROUND PASSENGER SEATBELT TENSIONER YELLOW 2 WAY CAV CIRCUIT FUNCTION A R56 18LB DG PASSENGER SEATBELT TENSIONER LINE 1 B R54 18LB YL PASSENGER...

Page 945: ...SWITCH SENSE POWERTRAIN CONTROL MODULE C1 2 5L BLACK 32 WAY CAV CIRCUIT FUNCTION 1 2 F18 18LG BK FUSED IGNITION SWITCH OUTPUT RUN START 3 4 K4 18BK LB SENSOR GROUND 5 6 7 K19 16BK GY IGNITION COIL NO...

Page 946: ...9L IDLE AIR CONTROL NO 2 DRIVER 11 K40 16BR WT 4 7L IDLE AIR CONTROL NO 3 DRIVER 11 K40 18BR WT 3 9L 5 9L IDLE AIR CONTROL NO 3 DRIVER 12 K10 18DB OR 4 7L STEERING PRESSURE SWITCH SENSE 13 14 15 K21 1...

Page 947: ...IT FUNCTION 1 T34 18GY BK 3 9L 5 9L TRANSMISSION TEMPERATURE SENSOR SIGNAL 2 K26 18VT 4 7L 5 9L FUEL INJECTOR NO 7 DRIVER 3 4 K11 18WT DB FUEL INJECTOR NO 1 DRIVER 5 K13 18YL WT FUEL INJECTOR NO 3 DRI...

Page 948: ...18TN RD SPEED CONTROL VACUUM SOLENOID CONTROL 5 V35 18LG RD SPEED CONTROL VENT SOLENOID CONTROL 6 7 8 K100 18VT WT OXYGEN SENSOR 1 1 HEATER CONTROL 9 K512 18DG BK OXYGEN SENSOR DOWNSTREAM HEATER RELA...

Page 949: ...X60 20DG RD RADIO 12V OUTPUT 2 X93 18WT RD BASE RADIO AMPLIFIED LEFT REAR SPEAKER 2 X51 20BR YL PREMIUM RADIO LEFT REAR SPEAKER 3 X94 18TN VT BASE RADIO AMPLIFIED RIGHT REAR SPEAKER 3 X52 20DB WT PREM...

Page 950: ...T FUNCTION 1 Z1 20BK GROUND 2 3 L1 20VT BK BACK UP LAMP FEED RIGHT FOG LAMP BLACK 2 WAY A Z1 18BK GROUND CAV CIRCUIT FUNCTION B L39 18LB FOG LAMP RELAY OUTPUT RIGHT FRONT DOOR SPEAKER BASE BLACK 3 WAY...

Page 951: ...ACK 3 WAY CAV CIRCUIT FUNCTION 1 L60 16TN RIGHT TURN SIGNAL 2 L7 20BK YL PARK LAMP RELAY OUTPUT 3 Z1 20BK GROUND RIGHT FRONT SIDE MARKER LAMP 2 WAY CAV CIRCUIT FUNCTION 1 L7 20BK YL PARK LAMP RELAY OU...

Page 952: ...AY CAV CIRCUIT FUNCTION 1 G74 18TN RD PASSENGER DOOR AJAR SWITCH SENSE 2 Z2 20BK LG GROUND 3 P34 16PK BK DOOR UNLOCK RELAY OUTPUT 4 P33 16OR BK DOOR LOCK RELAY OUTPUT RIGHT REAR POWER WINDOW MOTOR BLA...

Page 953: ...PREMIUM 2 WAY CAV CIRCUIT FUNCTION 1 X20 22RD BK RADIO CONTROL MUX 2 Z2 22BK LG GROUND RIGHT SPEED CONTROL SWITCH WHITE 2 WAY CAV CIRCUIT FUNCTION 1 V37 22RD LG SPEED CONTROL SWITCH SIGNAL 2 K4 22BK...

Page 954: ...TROL VENT SOLENOID CONTROL 3 V30 20DB RD BRAKE LAMP SWITCH OUTPUT 4 Z1 18BK GROUND THROTTLE POSITION SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K4 18BK LB 2 5L SENSOR GROUND 1 K7 18OR 3 9L 4 7L 5 9L 5V...

Page 955: ...LG GROUND TRANSFER CASE CONTROL MODULE C2 GRAY 16 WAY CAV CIRCUIT FUNCTION A1 Y114 18YL VT 5 VOLT SELECTOR SWITCH SUPPLY A2 Y113 18YL OR MODE SENSOR A A3 A4 A5 A6 T41 18BK WT PARK NEUTRAL POSITION SWI...

Page 956: ...CIRCUIT FUNCTION 1 Y118 20YL LB 5 VOLT SELECTOR SWITCH SUPPLY 2 Y187 20PK GY DEFAULT INDICATOR 3 4 Y121 20YL LG NEUTRAL INDICATOR 5 Y120 20YL DG MODE SELECT 6 E2 20OR PANEL LAMPS FEED 7 F12 20DB WT FU...

Page 957: ...YL DB PRESSURE CONTROL SOLENOID CONTROL 19 T119 18WT DB 2C SOLENOID CONTROL 20 T120 18LG LR CC SOLENOID CONTROL 21 22 23 24 25 26 27 28 G7 18WT OR VEHICLE SPEED SENSOR SIGNAL 29 T29 18GY UNDERDRIVE PR...

Page 958: ...R CC SOLENOID CONTROL 3 T41 18BK WT PARK NEUTRAL POSITION SWITCH SENSE T41 4 T41 16YL TRS T41 SENSE 5 T42 18VT WT TRS T42 SENSE 6 L1 18VT BK BACK UP LAMP FEED 7 T60 18BR 3 4 SHIFT SOLENOID CONTROL 8 T...

Page 959: ...LG RD GOVERNOR PRESSURE SIGNAL 5 K88 18VT WT GOVERNOR PRESSURE SOLENOID CONTROL 6 T60 18BR OVERDRIVE SOLENOID CONTROL 7 K54 18OR BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T34 18GY BK TRANSMISSION...

Page 960: ...Instrument Panel 31 32 33 Ambient Temperature Sensor BK Radiator Top Support 1 Amplifier C1 WT Right Side of Instrument Panel 30 32 Amplifier C2 WT Right Side of Instrument Panel 30 32 Automatic Day...

Page 961: ...enter of Console N S Center High Mounted Stop Lamp BK Headliner N S Center Power Outlet In Center of Console N S Central Timer Module C1 Right Side of Instrument Panel 32 Central Timer Module C2 Right...

Page 962: ...2 BL Driver Door 36 Driver Door Power Lock Motor Ajar Switch Premium BK Driver Door 36 Driver Door Power Window Motor BK Driver Door 36 Driver Power Mirror Driver Door 36 Driver Seatbelt Tensioner Pil...

Page 963: ...At HVAC Control N S High Note Horn BK Left Front Inner Fender 1 Idle Air Control Motor 3 9L 5 9L BK At Throttle Body 11 14 Idle Air Control Motor 2 5L 4 7L GY At Throttle Body 9 16 Ignition Coil LT GY...

Page 964: ...Side Marker Lamp At Lamp N S Left Front Wheel Speed Sensor LT GY Near Brake Controller 2 8 Left Headlamp BL At Lamp N S Left License Lamp BK At Lamp N S Left Rear Door Ajar Switch Base BK Rear Door N...

Page 965: ...ower Lock Motor Ajar Switch Premium BK Passenger Door N S Passenger Door Power Lock Switch NAT Passenger Door N S Passenger Door Power Window Motor BK Passenger Door N S Passenger Door Power Window Sw...

Page 966: ...1 Right Headlamp BL At Lamp 3 Right License Lamp BK At Lamp N S Right Rear Door Ajar Switch Base BK Right Rear Door N S Right Rear Door Power Lock Motor Ajar Switch Premium BK Right Rear Door N S Rig...

Page 967: ...BK Side of Transmission 23 26 28 Transfer Case Selector Switch BK Center of Instrument Panel at Switch 30 Transfer Case Shift Motor BK Side of Transmission 23 26 28 Transmission Control Module BK Rig...

Page 968: ...Fig 1 RIGHT FRONT ENGINE COMPARTMENT AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 CONNECTOR GROUND LOCATIONS Continued...

Page 969: ...Fig 2 LEFT FRONT ENGINE COMPARTMENT 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 970: ...Fig 3 RIGHT FENDER AREA Fig 4 LEFT FENDER AREA AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 CONNECTOR GROUND LOCATIONS Continued...

Page 971: ...Fig 5 KICK PANEL AREAS Fig 6 ENGINE COMPARTMENT TO DASH 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 972: ...Fig 7 RIGHT REAR ENGINE COMPARTMENT AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 CONNECTOR GROUND LOCATIONS Continued...

Page 973: ...Fig 8 RIGHT FENDER AREA 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 974: ...Fig 9 ENGINE LEFT SIDE 2 5L Fig 10 ENGINE RIGHT SIDE 2 5L AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 CONNECTOR GROUND LOCATIONS Continued...

Page 975: ...Fig 11 ENGINE LEFT SIDE 3 9L Fig 12 ENGINE RIGHT SIDE 3 9L 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 976: ...Fig 13 ENGINE REAR 3 9L Fig 14 ENGINE LEFT SIDE 5 9L AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 CONNECTOR GROUND LOCATIONS Continued...

Page 977: ...Fig 15 ENGINE RIGHT SIDE 5 9L 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 978: ...Fig 16 ENGINE LEFT SIDE 4 7L AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 CONNECTOR GROUND LOCATIONS Continued...

Page 979: ...Fig 17 ENGINE RIGHT SIDE 4 7L 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 980: ...Fig 18 ENGINE CONNECTORS FRONT 4 7L AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 CONNECTOR GROUND LOCATIONS Continued...

Page 981: ...Fig 19 RIGHT REAR ENGINE COMPARTMENT CONNECTORS 8W 90 22 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 982: ...Fig 20 MANUAL TRANSMISSION CONNECTORS 2 5L AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 23 CONNECTOR GROUND LOCATIONS Continued...

Page 983: ...Fig 21 MANUAL TRANSMISSION CONNECTORS 3 9L 8W 90 24 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 984: ...Fig 22 MANUAL TRANSMISSION 4 7L 4X2 AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 25 CONNECTOR GROUND LOCATIONS Continued...

Page 985: ...Fig 23 MANUAL TRANSMISSION 4 7L 4X4 8W 90 26 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 986: ...Fig 24 MANUAL TRANSMISSION 4 7 4X4 AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 27 CONNECTOR GROUND LOCATIONS Continued...

Page 987: ...Fig 25 AUTOMATIC TRANSMISSION CONNECTORS 3 9 5 9L 4X2 8W 90 28 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 988: ...Fig 26 AUTOMATIC TRANSMISSION CONNECTORS 3 9L 5 9L 4X4 AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 29 CONNECTOR GROUND LOCATIONS Continued...

Page 989: ...Fig 27 AUTOMATIC TRANSMISSION 4 7L 4X2 8W 90 30 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 990: ...Fig 28 AUTOMATIC TRANSMISSION 4 7L 4X4 AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 31 CONNECTOR GROUND LOCATIONS Continued...

Page 991: ...Fig 29 AUTOMATIC TRANSMISSION 4 7 4X4 8W 90 32 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 992: ...Fig 30 RIGHT SIDE CENTER INSTRUMENT PANEL CONNECTORS AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 33 CONNECTOR GROUND LOCATIONS Continued...

Page 993: ...Fig 31 LEFT SIDE INSTRUMENT PANEL CONNECTORS 8W 90 34 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 994: ...Fig 32 INSTRUMENT PANEL CONNECTORS AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 35 CONNECTOR GROUND LOCATIONS Continued...

Page 995: ...Fig 33 AIRBAG CONTROL MODULE 8W 90 36 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 996: ...Fig 34 MULTI FUNCTION SWITCH CONNECTORS AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 37 CONNECTOR GROUND LOCATIONS Continued...

Page 997: ...Fig 35 JUNCTION BLOCK CONNECTORS 8W 90 38 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 998: ...Fig 36 FRONT DOOR CONNECTORS AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 39 CONNECTOR GROUND LOCATIONS Continued...

Page 999: ...Fig 37 REAR DOOR CONNECTORS Fig 38 LEFT FRONT BODY WIRING 8W 90 40 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 1000: ...Fig 39 CAB WIRING AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 41 CONNECTOR GROUND LOCATIONS Continued...

Page 1001: ...Fig 40 BODY WIRING 8W 90 42 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 1002: ...Fig 41 CHASSIS WIRING AN 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 43 CONNECTOR GROUND LOCATIONS Continued...

Page 1003: ...Fig 42 TAIL LAMPS 8W 90 44 8W 90 CONNECTOR GROUND LOCATIONS AN CONNECTOR GROUND LOCATIONS Continued...

Page 1004: ...ear of Engine 1 S103 3 9L 4 7L 5 9L Rear of Engine 3 6 S106 2 5L Rear of Engine 2 S106 3 9L 5 9L Near Inj 4 4 S107 2 5L Rear of Engine N S S107 3 9L 5 2L Rear of Engine N S S107 4 7L Right Rear of Eng...

Page 1005: ...r T O for Tail Lamps 11 S316 Left Rear Frame Rail 11 S317 Near T O for Tail Lamps 11 S318 Left Rear Frame Rail 11 S319 Near T O for CTM 10 S322 Left A Post 9 S323 Left A Pillar 9 S324 Left A Post 9 S3...

Page 1006: ...Fig 1 LEFT SIDE ENGINE HARNESS SPLICES 2 5L Fig 2 RIGHT SIDE ENGINE HARNESS SPLICES 2 5L AN 8W 95 SPLICE LOCATIONS 8W 95 3 SPLICE LOCATIONS Continued...

Page 1007: ...Fig 3 LEFT SIDE ENGINE HARNESS SPLICES 3 9L Fig 4 RIGHT SIDE ENGINE HARNESS SPLICES 3 9L 8W 95 4 8W 95 SPLICE LOCATIONS AN SPLICE LOCATIONS Continued...

Page 1008: ...Fig 5 LEFT SIDE ENGINE HARNESS SPLICES 5 9L Fig 6 LEFT SIDE ENGINE HARNESS SPLICES 4 7L AN 8W 95 SPLICE LOCATIONS 8W 95 5 SPLICE LOCATIONS Continued...

Page 1009: ...Fig 7 RIGHT SIDE ENGINE HARNESS SPLICES 4 7L 8W 95 6 8W 95 SPLICE LOCATIONS AN SPLICE LOCATIONS Continued...

Page 1010: ...Fig 8 INSTRUMENT PANEL AN 8W 95 SPLICE LOCATIONS 8W 95 7 SPLICE LOCATIONS Continued...

Page 1011: ...Fig 9 A PILLAR SPLICES Fig 10 CAB SPLICES 8W 95 8 8W 95 SPLICE LOCATIONS AN SPLICE LOCATIONS Continued...

Page 1012: ...Fig 11 CHASSIS SPLICES AN 8W 95 SPLICE LOCATIONS 8W 95 9 SPLICE LOCATIONS Continued...

Page 1013: ...Fig 12 RIGHT FENDER AREA 8W 95 10 8W 95 SPLICE LOCATIONS AN SPLICE LOCATIONS Continued...

Page 1014: ...Fig 13 FRONT DOOR SPLICES AN 8W 95 SPLICE LOCATIONS 8W 95 11 SPLICE LOCATIONS Continued...

Page 1015: ......

Page 1016: ...ntrol and protection fea tures including Automatic resetting circuit breakers Blade type fuses Cartridge fuses Circuit splice blocks Flashers Relays Following are general descriptions of the major com...

Page 1017: ...cess heat radiates 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 hea...

Page 1018: ...ove the lower bezel from the instrument panel Refer to Instrument Panel Lower Bezel in Body for the procedure 3 Pull the cigar lighter knob and element out of the cigar lighter receptacle base or unsn...

Page 1019: ...be certain that the circuit breaker terminals still con tact the terminals in the junction block cavities 2 Connect the negative lead of a 12 volt DC volt meter to a good ground 3 With the voltmeter p...

Page 1020: ...he screws to 3 4 N m 30 in lbs Be certain that both screws are tightened to the proper torque value 3 Install and latch the cover onto the PDC 4 Reconnect the battery negative cable IOD FUSE DESCRIPTI...

Page 1021: ...e is being prepared for delivery in order to restore full electrical system operation NOTE When removing or installing the IOD fuse it is important that the ignition switch be in the Off position Fail...

Page 1022: ...s Refer to Junction Block in the index of this service manual for the location of complete JB circuit dia grams REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTE...

Page 1023: ...crew that secures the JB to the left instrument panel end bracket Tighten the screw to 2 2 N m 20 in lbs 3 Reach through the outboard side of the instru ment panel steering column opening to access an...

Page 1024: ...r to Connector Locations in the Wiring Section of this service manual for the location of more information on the headlamp and dash wire harness connector locations 3 Remove all of the fasteners that...

Page 1025: ...x of this service manual for the loca tion of more information on the headlamp and dash wire harness connector locations 14 Reconnect the battery negative cable POWER OUTLET DESCRIPTION An accessory p...

Page 1026: ...ery negative cable 2 Remove the lower bezel from the instrument panel Refer to Instrument Panel Lower Bezel in Body for the procedure 3 Pull the cigar lighter knob and element out of the cigar lighter...

Page 1027: ...bution Center PDC The relay and fuse block has cavities for up to four additional blade type mini fuses the electronic combination flasher and three additional International Standards Organization rel...

Page 1028: ...Junction Block JB Fig 13 7 Remove the relay and fuse block and the instrument panel wire harness from the instrument panel as a unit INSTALLATION The relay and fuse block is serviced as a unit with t...

Page 1029: ...t receptacle base and note the position of the rectangu lar retaining bosses of the mount that secures the receptacle base to the instrument panel lower bezel Fig 11 5 Insert a pair of external snap r...

Page 1030: ...REMOVAL 19 INSTALLATION 20 CYLINDER HEAD DESCRIPTION 20 OPERATION 20 DIAGNOSIS AND TESTING 20 CYLINDER HEAD GASKET 20 STANDARD PROCEDURE 21 VALVE GUIDE WEAR MEASURING 21 VALVE GUIDE SERVICE 21 REMOVAL...

Page 1031: ...FRONT MOUNT REMOVAL 49 INSTALLATION 49 REAR MOUNT REMOVAL 50 INSTALLATION 50 LUBRICATION DESCRIPTION 50 OPERATION 50 DIAGNOSIS AND TESTING 51 REAR SEAL AREA LEAKS 51 ENGINE OIL LEAKS 51 ENGINE OIL PR...

Page 1032: ...AND TESTING ENGINE DIAGNOSIS INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance These malfunctions may be classified a...

Page 1033: ...LECTRICAL IGNITION CONTROL DESCRIPTION 2 No fuel 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...

Page 1034: ...5 Spark plug cables defective or crossed 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 Tes...

Page 1035: ...s and replace as necessary 9 Excessive runout of valve seats or valve faces 9 Grind valves and seats CONNECTING ROD NOISE 1 Insufficient oil supply 1 Check engine oil level 2 Low oil pressure 2 Check...

Page 1036: ...logged 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 fasten...

Page 1037: ...loose or damaged 9 Replace as necessary OIL PUMPING AT RINGS SPARK PLUGS FOULING 1 Worn or damaged rings 1 Hone cylinder bores and replace rings 2 Carbon in oil ring slots 2 Replace rings 3 Incorrect...

Page 1038: ...rnt or not seated properly Inspect valve and valve seat Reface or replace as necessary AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent burnt or not seated properly Inspect valve and valve seat Reface...

Page 1039: ...lied in a continuous bead approximately 3 mm 0 120 in in diameter All mounting holes must be circled For corner sealing a 3 17 or 6 35 mm 1 8 or 1 4 in drop is placed in the center of the gasket conta...

Page 1040: ...e Using honing oil C 3501 3880 or a light honing oil available from major oil distributors CAUTION DO NOT use engine or transmission oil mineral spirits or kerosene 3 Honing should be done by moving t...

Page 1041: ...Excessive pressure or high RPM beyond the recommended speed can damage the sealing surfaces The mild white 120 grit bristle disc is recommended If necessary the medium yellow 80 grit bristle disc may...

Page 1042: ...ngs at the steering gear b Drain the pump reservoir c Cap the fittings on the hoses and steering gear to prevent foreign material from entering the system 21 Identify tag and disconnect all necessary...

Page 1043: ...he injector rail Refer to 14 FUEL SYSTEM FUEL DELIVERY QUICK CONNECT FITTING STANDARD PROCE DURE 25 Connect all the vacuum hoses and wire con nectors 26 Connect suction discharge hose to compressor if...

Page 1044: ...in ValveFace Angle Intake 46 5 DESCRIPTION SPECIFICATION Exhaust 46 5 Valve Head Diameter Intake 48 387 48 641 mm 1 905 1 915 in Exhaust 37 973 38 227 mm 1 495 1 505 in Tip Refinishing Max Alowable 0...

Page 1045: ...RODS Total Weight Less Bearing 663 to 671 grams 23 39 to 23 67 oz Length Center to Center 155 52 to 155 62 mm DESCRIPTION SPECIFICATION 6 123 to 6 127 in Piston Pin Bore Diameter 23 59 to 23 62 mm 0...

Page 1046: ...12 to 0 9315 in Piston Pin Diameter 23 637 to 23 640 mm 0 9306 to 0 9307 in Piston to Pin Clearance 0 0102 to 0 0208 mm 0 0005 to 0 0009 in DESCRIPTION SPECIFICATION PISTON RINGS Ring Gap Clearance To...

Page 1047: ...port Adaptor 75 55 Bracket Bolts Exhaust Manifold Pipe Nuts 27 20 Exhaust Manifold Bolt 1 41 30 DESCRIPTION N m Ft Lbs In Lbs Bolts 2 5 31 23 Nuts 6 and 7 14 126 Flywheel Converter Housing Bolts 38 28...

Page 1048: ...and remove cover 3 Remove air cleaner element filter from hous ing 4 Clean inside of housing before replacing ele ment Valve Spring Compressor Tool MD 998772A Hydraulic Valve Tappet Removal Tool C 41...

Page 1049: ...leaking between adjacent cylinders follow the proce dures in Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING An engine cylinder head gasket leaking between adja cent cylinde...

Page 1050: ...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 inch REMOVAL This procedure can be done with the engine in or out of the vehicle 1 Disconnect negative c...

Page 1051: ...gasket Fig 13 17 If this was the first time the bolts were removed put a paint dab on the top of the bolt If the bolts have a paint dab on the top of the bolt or it isn t known if they were used befo...

Page 1052: ...No 8 and No 10 head bolts CAUTION During the final tightening sequence bolt No 7 will be tightened to a lower torque than the rest of the bolts DO NOT overtighten bolt No 7 10 Tighten the engine cyli...

Page 1053: ...DIRECT LINE WITH THE FAN DO NOT PUT HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 27 Operate the engine with the radiator cap off Inspect for leaks and continue operating the engine u...

Page 1054: ...airs of rocker arms Fig 18 Place them on a bench in the same order as removed 5 Remove the push rods and place them on a bench in the same order as removed 6 Clean all the components with cleaning sol...

Page 1055: ...n the end of the No 1 cylinder intake valve push rod Use rubber tubing to secure the indicator stem on the push rod Set the dial indicator pointer at zero Set the dial indicator pointer at zero Rotate...

Page 1056: ...ners valve stem seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent damage to the valve guides Identify valves to ensure installation in original...

Page 1057: ...screws bridge and pivot assem blies and rocker arms for access to each valve spring to be removed 3 Remove push rods Retain the push rods bridges pivots and rocker arms in the same order and position...

Page 1058: ...e at their original location 8 Tighten the bridge cap screws alternately one at a time to avoid damaging the bridge Tighten the cap screws to 28 N m 21 ft lbs torque 9 Install the engine cylinder head...

Page 1059: ...gine cylinder head 13 Remove the vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 14 Remove the timing case cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOV...

Page 1060: ...ssure relief holes must be free of debris 6 Lubricate the camshaft with Mopart Engine Oil Supplement or equivalent 7 Carefully install the camshaft to prevent dam age to the camshaft bearings Fig 27 8...

Page 1061: ...es The oil squirt holes in the rods must face the camshaft The arrow on the piston crown should point to the front of the engine Fig 33 Verify that the oil squirt holes in the rods face the camshaft a...

Page 1062: ...ts installed This will determine if two 0 0254 mm 0 001 inch undersize inserts or another combination is needed to provide the correct clearance Refer to CONNECTING ROD BEARING FITTING CHART CONNECTIN...

Page 1063: ...REMOVAL 1 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 2 Remove the oil pump from the rear main bear ing cap 3 Remove the vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION...

Page 1064: ...SEAL FRONT INSTALLATION 14 Immediately install the oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLA TION CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings Fig 39 are located in the cylinder blo...

Page 1065: ...ER STANDARD STANDARD LOWER 0 025 mm U S 0 051 mm U S 0 001 in 0 002 in NOTE When replacing inserts the odd size inserts must be either all on the top in cylinder block or all on the bottom in main bea...

Page 1066: ...ize Red 63 2333 Red Red 63 2206 mm Undersize Undersize 2 4895 0 254 mm 0 254 mm 2 4890 in 0 010 in 0 010 in 0 254 mm 0 010 in MEASURING BEARING TO JOURNAL CLEARANCE CRANKSHAFT INSTALLED When using Pla...

Page 1067: ...e origi nal clearance an additional 0 0127 mm 0 0005 inch The clearance would then be 0 0381 mm 0 0015 inch CAUTION Never use a pair of inserts that differ more than one bearing size as a pair FOR EXA...

Page 1068: ...of each insert with engine oil 2 Loosen all the main bearing caps Install the main bearing upper inserts 3 Install the lower bearing inserts into the main bearing caps 4 Install the main bearing cap s...

Page 1069: ...torque 16 Install new rear main seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION 17 Lower the vehicle 18 Install the spark plugs Tighten the plugs to 37 N m 27 ft lbs torque...

Page 1070: ...ct the negative cable to the battery CRANKSHAFT OIL SEAL REAR REMOVAL 1 Remove the flywheel or converter drive plate Discard the old bolts 2 Pry out the seal from around the crankshaft flange making s...

Page 1071: ...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 do...

Page 1072: ...with engine oil They will charge themselves within a very short period of engine operation 1 Dip each tappet in Mopart Engine Oil Supple ment or equivalent 2 Use Hydraulic Valve Tappet Removal Install...

Page 1073: ...lts Fig 50 Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003...

Page 1074: ...for excessive wear taper and scoring Refer to Connecting Rod Bearings in the Service Procedures portion of this Section Check the connecting rod for signs of twist or bend ing Check the piston for tap...

Page 1075: ...0 0005 inch CAUTION DO NOT intermix bearing caps Each connecting rod and bearing cap are stamped with the cylinder number The stamp is located on a machined surface adjacent to the oil squirt hole tha...

Page 1076: ...talled with either side up It is not necessary to use a tool to install the upper and lower rails Insert oil rail spacer first then side rails 6 The two compression rings are different and cannot be i...

Page 1077: ...Identification 1 SECOND COMPRESSION RING 2 CHAMFER 3 ONE DOT Fig 60 Compression Ring Chamfer Location 1 TOP COMPRESSION RING 2 SECOND COMPRESSION RING 3 PISTON 4 CHAMFER Fig 61 Compression Ring 1 COMP...

Page 1078: ...mounts support the engine at each side These supports are made of resilient rubber 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Support the engine 4 Remove through bolt and nut 5 Rai...

Page 1079: ...le 6 Connect the negative cable to the battery LUBRICATION DESCRIPTION A gear type positive displacement pump is mounted at the underside of the block opposite the No 4 main bearing OPERATION The pump...

Page 1080: ...a leak is detected between the crankshaft and seal while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged The seal area on the crankshaft could have minor nicks or s...

Page 1081: ...Fig 67 Oil Lubrication System 2 5L Engine 9 52 ENGINE 2 5L AN LUBRICATION Continued...

Page 1082: ...of an engine the engine oil must be maintained at an acceptable level The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick 1 Position vehicle on level surface...

Page 1083: ...E OIL PAN REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Remove the oil pan drain plug and drain the engine oil 4 Disconnect the exhaust pipe at the engine exhaust manifold 5 D...

Page 1084: ...lock and timing case cover 6 Position the oil pan over the dowels and onto the gasket 7 Install the 1 4 inch oil pan bolts Tighten these bolts to 9 5 N m 84 in lbs torque Install the 5 16 inch oil pan...

Page 1085: ...MOVAL The positive displacement gear type oil pump is driven by the distributor shaft which is driven by a gear on the camshaft Oil is siphoned into the pump through an inlet tube and strainer assembl...

Page 1086: ...ery negative cable 2 Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 3 Remove the air inlet hose and resonator from the throttle body and air cleaner Fig 76 4 Loosen the accessory driv...

Page 1087: ...No 1 Tighten to 41 N m 30 ft lbs torque Fasteners Nos 2 through 5 Tighten to 31 N m 23 ft lbs torque Fasteners Nos 6 and 7 Tighten to 23 N m 17 ft lbs torque 5 Connect fuel supply tube to the fuel rai...

Page 1088: ...head and mani fold wash with solvent and blow dry with com pressed air INSPECTION Inspect manifold for cracks Inspect mating sur faces of manifold for flatness with a straight edge Seal surfaces must...

Page 1089: ...roud 5 Remove the A C compressor if equipped Refer to 24 HEATING AIR CONDITIONING PLUMB ING A C COMPRESSOR REMOVAL and generator bracket assembly from the engine cylinder head and move to one side 6 R...

Page 1090: ...ner which reduces noise and prolongs timing chain life In addition it compensates for wear and temperature changes on the valve train for proper engine operation 1 Disconnect negative cable from batte...

Page 1091: ...ect installation of the timing chain turn the crankshaft to position the camshaft sprocket timing mark as shown in Fig 85 Count the number of chain pins between the timing marks of both sprockets Ther...

Page 1092: ...N 85 INTAKE EXHAUST VALVES SEATS DESCRIPTION 85 STANDARD PROCEDURE 85 VALVES GUIDES AND SPRINGS 85 REMOVAL 87 CLEANING 87 INSPECTION 88 INSTALLATION 88 ENGINE BLOCK CLEANING 89 INSPECTION 89 CAMSHAFT...

Page 1093: ...N 119 REMOVAL 119 CLEANING 119 INSPECTION 119 INSTALLATION 119 TIMING BELT CHAIN COVER S REMOVAL 120 INSTALLATION 120 TIMING BELT CHAIN TENSIONER AND PULLEY DESCRIPTION 120 OPERATION 120 TIMING BELT C...

Page 1094: ...age Diagnosis Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD DIAGNOSIS AND TESTING Lash Adjuster Tappet Noise Diagnosis Refer to 9 ENGINE ENGINE BLOCK HYDRAULIC LIFT ERS CAM IN BLOCK DIAGNOSIS AND TEST I...

Page 1095: ...or water in fuel system 4 Clean system and replace fuel filter 5 Faulty fuel pump 5 Install new fuel pump 6 Incorrect valve timing 6 Correct valve timing 7 Blown cylinder head gasket 7 Install new cyl...

Page 1096: ...L REMOVAL 7 Intake manifold vacuum leak 7 Inspect intake manifold gasket and vacuum hoses Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD DIAGNOSIS AND TESTING ENGINE MISSES ON ACCELERATION 1 Worn or inco...

Page 1097: ...s and replace as necessary 9 Excessive runout of valve seats or valve faces 9 Grind valves and seats CONNECTING ROD NOISE 1 Insufficient oil supply 1 Check engine oil level 2 Low oil pressure 2 Check...

Page 1098: ...logged 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 fasten...

Page 1099: ...OIL PUMPING AT RINGS SPARK PLUGS FOULING 1 Worn or damaged rings 1 Hone cylinder bores and replace rings 2 Carbon in oil ring slots 2 Replace rings 3 Incorrect ring size installed 3 Replace rings 4 W...

Page 1100: ...nspect valve and valve seat Reface or replace as necessary AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent burnt or not seated properly Inspect valve and valve seat Reface or replace as necessary AIR...

Page 1101: ...r Plastic or wood scraper Fig 4 Drill motor with 3M Roloc Bristle Disc white or yellow Fig 4 CAUTION Excessive pressure or high RPM beyond the recommended speed can damage the sealing surfaces The mil...

Page 1102: ...he 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 hole with a special Heli...

Page 1103: ...alant is still wet to the touch within 10 minutes The usage of a locating dowel is recommended during assembly to prevent smearing material off the location Mopart Gasket Sealant in an aerosol can sho...

Page 1104: ...RD PROCEDURE 14 Using a new gasket install throttle body Refer to 14 FUEL SYSTEM FUEL INJECTION THROTTLE BODY INSTALLATION 15 Connect the accelerator linkage Refer to 14 FUEL SYSTEM FUEL INJECTION THR...

Page 1105: ...0 Torque Converter Drive Plate 31 270 Bolts Transfer Case to Insulator 204 150 Mounting Plate Nuts DESCRIPTION N m In Ft Transmission Support Bracket 68 50 Bolts 2WD Vibration Damper Bolt 183 135 Wate...

Page 1106: ...2 5005 in Main Journal Out of Round Max 0 0254 mm 0 001 in DESCRIPTION SPECIFICATION Main Journal Taper Max 0 0254 mm 0 001 in Main Journal Beraing Clearance No 1 0 013 0 038 mm 0 0005 0 0015 in No 2...

Page 1107: ...h 49 962 mm 1 967 in Spring Tension Valve Closed 378 N 41 66 mm 85 lbs 1 64 in Valve Open 890 N 30 89 mm 200 lbs 1 212 in DESCRIPTION SPECIFICATION Number of Coils 6 8 Installed Height 41 66 mm 1 64 i...

Page 1108: ...25 0 00075 in Clearance in Rod Interference 0 0178 0 0356 mm 0 0007 0 0014 in DESCRIPTION SPECIFICATION Diameter 24 996 25 001 mm 0 9841 0 9843 in End Play None Length 75 946 76 454 mm 2 990 3 010 in...

Page 1109: ...ng No 1 4 connecting rod journal O S Tappets L 3 89 2032 mm diamound 008 in shaped stamp Top pad Front of engine and flat ground on outside surface of each O S tappet bore O S Valve Stems X Milled pad...

Page 1110: ...ont Oil Seal Installer 6635 Camshaft Holder C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cyl...

Page 1111: ...linder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition The valves located in the cylinder head open and close to either allow...

Page 1112: ...nder heads Fig 8 are held in place by eight bolts The spark plugs are located at the peak of the wedge between the valves 1 Disconnect the battery negative cable from the battery 2 Drain cooling syste...

Page 1113: ...cations Install the plugs and tighten to 41 N m 30 ft lbs torque 8 Install coil wires 9 Connect coolant temperature sending unit wire 10 Connect the fuel injector harness 11 Connect the vacuum supply...

Page 1114: ...ANDARD PROCEDURE VALVES GUIDES AND SPRINGS VALVE CLEANING Clean valves thoroughly Discard burned warped or cracked valves Remove carbon and varnish deposits from inside of valve guides with a reliable...

Page 1115: ...Ream to 0 0763 mm 0 003 inch Step 2 Ream to 0 381 mm 0 015 inch REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 43 1 4 to 43 3 4 face angle and a 44 1 4 to 44 3 4 seat angle Fig...

Page 1116: ...example 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 th...

Page 1117: ...ith 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 Instal...

Page 1118: ...oo 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 Mount Adhesive Plug should be 54 0 to 57 7 mm 2...

Page 1119: ...bearing in the tool Install horse shoe lock and by reversing removal procedure care fully drive bearing shell into place 3 Install remaining bearings in the same man ner Bearings must be carefully al...

Page 1120: ...the camshaft bolt cup washer Tighten bolt to 68 N m 50 ft lbs torque 12 Measure camshaft end play Fig 25 Refer to 9 ENGINE SPECIFICATIONS for proper clear ance If not within limits install a new timin...

Page 1121: ...re removal Remove bearing caps and bearings one at a time 4 Lift the crankshaft out of the block 5 Remove and discard the crankshaft rear oil seals 6 Remove and discard the front crankshaft oil seal I...

Page 1122: ...d be marked at removal to ensure correct assembly Upper and lower bearing halves are NOT inter changeable Lower main bearing halves of No 1 and 3 are interchangeable Upper and lower No 2 bearing halve...

Page 1123: ...capbolts to 115 N m 85 ft lbs torque 4 Install the oil pump Refer to 9 ENGINE LU BRICATION OIL PUMP INSTALLATION 5 Install the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION CRANKSHAFT OI...

Page 1124: ...her from the rear of the engine or from the engine front cover DIAGNOSIS AND TESTING REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area o...

Page 1125: ...E LUBRICATION OIL PUMP REMOVAL 3 Remove the rear main bearing cap Remove and discard the old lower oil seal 4 Carefully remove and discard the old upper oil seal LOWER SEAL 1 Remove the oil pan Refer...

Page 1126: ...n ment dowel and cap bolts DO NOT remove excess material after assembly DO NOT strike rear cap more than two times for proper engagement 7 Install the rear main bearing cap with cleaned and oiled cap...

Page 1127: ...take manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 3 Insert Distributor Drive Shaft Bushing Puller Tool C 3052 into old bushing and thread down until a tight fit is obtained Fig 37 4 Ho...

Page 1128: ...on NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case noise may be dampened by applying side thrust on the valve spring If noise is not apprecia bly...

Page 1129: ...l tappets are to be removed identify tappets to ensure installation in original location 8 If the tappet or bore in cylinder block is scored scuffed or shows signs of sticking ream the bore to next ov...

Page 1130: ...0 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 9...

Page 1131: ...ng 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 connecting rod bore must be installed toward cranksh...

Page 1132: ...6 mm 0 0097 in side clear ance e Pistons with insufficient or excessive side clearance should be replaced 3 Orient the rings a Arrange top compression ring 90 counter clockwise from the oil ring rail...

Page 1133: ...7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 7 Install the fan shroud 8 Connect the negative cable to the battery FRONT MOUNT REMOVAL 2WD 1 Disconnect the negative cable from the battery 2...

Page 1134: ...10 If engine support bracket is to be removed re placed remove support bracket to transmission bell housing bolt s and three 3 support bracket to engine block bolts Remove support bracket Fig 52 Fig...

Page 1135: ...65 ft lbs 2 Install Engine mount insulator and tighten insulator to support bracket nut to 41 N m 30 ft lbs Tighten insulator to support bracket through bolt nut to 102 N m 75 ft lbs 3 Lower engine a...

Page 1136: ...om the battery 2 Raise the vehicle on a hoist 3 Support the transmission with a transmission jack NOTE AUTOMATIC TRANSMISSION Remove stud nuts holding the insulator to the crossmember Fig 57 Raise rea...

Page 1137: ...the stud nuts to 41 N m 30 ft lbs torque 2 Remove transmission jack 3 Lower the vehicle 4 Connect the negative cable to the battery 4WD NOTE AUTOMATIC TRANSMISSION If the insulator bracket was remove...

Page 1138: ...s 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 the hole when the rods rotate and th...

Page 1139: ...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 2...

Page 1140: ...adually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provide the best bubbles which will...

Page 1141: ...r 3 Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss Fig 62 4 When filter separates from adapter nipple tip gasket end upward to minimize oil spill Remove fi...

Page 1142: ...Tighten these bolts to 24 N m 215 in lbs torque 9 Lower the engine into the support cushion brackets and tighten the through bolt nut to the proper torque 10 Install the drain plug Tighten drain plug...

Page 1143: ...re thickness and diameter of outer rotor If outer rotor thickness measures 20 9 mm 0 825 in or less or if the diameter is 62 7 mm 2 469 in or less replace outer rotor Fig 69 Fig 66 Oil Pressure Relief...

Page 1144: ...n its bore Small marks may be removed with 400 grit wet or dry sandpaper The relief valve spring has a free length of approx imately 49 5 mm 1 95 in The spring should test between 19 5 and 20 5 pounds...

Page 1145: ...llowing the fuel delivered by the fuel injectors to ignite thus producing power DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold...

Page 1146: ...The plenum pan rail must be clean and dry free of all foreign material INSPECTION Inspect manifold for cracks Inspect mating surfaces of manifold for flatness with a straightedge INSTALLATION 1 If the...

Page 1147: ...unit wire 11 Connect the heater hoses and bypass hose 12 Install distributor cap and wires 13 Hook up the return spring 14 Connect the accelerator linkage Refer to 14 FUEL SYSTEM FUEL INJECTION THROT...

Page 1148: ...oot INSTALLATION CAUTION If the studs came out with the nuts when removing the engine exhaust manifold install new studs Apply sealer on the coarse thread ends Water leaks may develop at the studs if...

Page 1149: ...cial Tool 6635 must be used to align cover and seal with crankshaft 3 Position the special tool 6635 onto the crank shaft Fig 82 4 Tighten chain case cover bolts to 41 N m 30 ft lbs torque Tighten oil...

Page 1150: ...ensioner must be removed for this operation 1 Place a scale next to the timing chain so that any movement of the chain can be measured 2 Place a torque wrench and socket over cam shaft sprocket attach...

Page 1151: ...respec tive shafts and verify alignment of timing marks Fig 86 with a straight edge if necessary 6 Install the camshaft bolt Tighten the bolt to 68 N m 50 ft lbs torque 7 Remove tensioner pin Again ve...

Page 1152: ...59 REFACING 159 ROCKER ARM ADJUSTER ASSEMBLY DESCRIPTION 160 DIAGNOSIS AND TESTING 160 HYDRAULIC LASH ADJUSTER 160 REMOVAL 160 INSTALLATION 160 VALVE SPRINGS DESCRIPTION 161 REMOVAL 161 INSTALLATION 1...

Page 1153: ...SPECTION 207 INSTALLATION 207 ENGINE 4 7L DIAGNOSIS AND TESTING ENGINE DIAGNOSIS INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine...

Page 1154: ...to low 1 Refer to 14 FUEL SYSTEM FUEL INJECTION IDLE AIR CONTROL MOTOR REMOVAL 2 Idle mixture to lean or to rich 2 Refer to Powertrain Diagnosis Information 3 Vacuum leak 3 Inspect intake manifold an...

Page 1155: ...UG CLEANING 2 Dirt in fuel system 2 Clean fuel system 3 Burned warped or pitted valves 3 Replcae as necessary 4 Faulty coil 4 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 1 ENGINE MISS...

Page 1156: ...NG ROD NOISE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE FLUID TYPES SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or...

Page 1157: ...LOCK CRANKSHAFT OIL SEAL FRONT REMOVAL 6 Scratched or damaged vibration damper hub 6 Polish or replace damper OIL PRESSURE DROP 1 Low oil level 1 Check and correct oil level 2 Faulty oil pressure send...

Page 1158: ...ution Continue the test for the remaining cylin ders 8 Refer to 9 ENGINE SPECIFICATIONS for the correct engine compression pressures DIAGNOSIS AND TESTING CYLINDER COMBUSTION PRESSURE LEAKAGE The comb...

Page 1159: ...f great importance Too thin a bead can result in leakage while too much can result in spill over which can break off and obstruct fluid feed lines A continuous bead of the proper width is essential to...

Page 1160: ...ating dowel is recommended during assembly to prevent smearing material off the location Mopart Gasket Sealant in an aerosol can should be applied using a thin even coat sprayed completely over both s...

Page 1161: ...nnect the engine block heater power cable from the block heater if equipped 17 Lower vehicle 18 Remove throttle body resonator assembly and air inlet hose 19 Disconnect throttle and speed control cabl...

Page 1162: ...CT Sensor Manifold absolute pressure MAP Sensor Camshaft Position CMP Sensor Coil Over Plugs 31 Disconnect the vacuum lines at the throttle body and intake manifold 32 Release fuel rail pressure Refer...

Page 1163: ...isconnect body ground strap at the left side cowl Fig 10 NOTE It will be necessary to support the transmis sion in order to remove the engine 38 Position a suitable jack under the transmis sion 39 Rem...

Page 1164: ...wer hoses 17 Connect the transmission oil cooler lines to the radiator 18 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION fan assembly and shroud Refer to 7 CO...

Page 1165: ...in PISTON RINGS Ring Gap Top Compression Ring 0 37 0 63 mm DESCRIPTION SPECIFICATION 0 0146 0 0249 in Second Compression Ring 0 37 0 63 mm 0 0146 0 0249 in Oil Control Steel Rails 0 25 0 76 mm 0 0099...

Page 1166: ...7 6 VALVES Face Angle 45 45 5 Head Diameter Intake 48 52 48 78 mm 1 9103 1 9205 in Exhaust 36 87 37 13 mm 1 4516 1 4618 in DESCRIPTION SPECIFICATION Length Overall Intake 113 45 114 21 mm 4 4666 4 496...

Page 1167: ...Rotor Diameter MIN 85 925 mm 0 400 in Tip Clearance Between Rotors MAX 150 mm 0 006 in DESCRIPTION SPECIFICATION OIL PRESSURE At Curb Idle Speed MIN 25 kPa 4 psi 3000 rpm 170 758 kPa 25 110 psi CAUTI...

Page 1168: ...ing Chain Tensioner Arm Special Pin Bolt 17 150 Hydraulic Tensioner Bolts 28 250 Timing Chain Primary Tensioner Bolts 28 250 Timing Drive Idler Sprocket Bolt 34 25 Thermostat Housing Bolts 13 115 Wate...

Page 1169: ...al Installer 8349 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 Crankshaft Damper Installer 8512 Puller 1026 Crankshaft Damper Removal Insert 8513 Chain Tensioner Wedge 8350 9 140 ENGIN...

Page 1170: ...ndary Chain Holder 8515 Remover Rocker Arm 8516 Valve Spring Compressor 8387 Idler Shaft Remover 8517 Valve Spring Compressor Adapters 8519 Valve Spring Tester C 647 Dial Indicator C 3339 AN ENGINE 4...

Page 1171: ...hous ing 4 Clean inside of housing before replacing ele ment INSTALLATION 1 Install element into housing 2 Position housing cover into housing locating tabs 3 Pry up spring clips and lock cover to hou...

Page 1172: ...hroud and fan blade assembly Refer to 7 COOLING ENGINE FAN DRIVE VIS COUS CLUTCH REMOVAL 9 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 10 Remove the power steeri...

Page 1173: ...out removing these four bolts NOTE The cylinder head is attached to the cylinder block with fourteen bolts 21 Remove the cylinder head retaining bolts 22 Remove the cylinder head and gasket Discard th...

Page 1174: ...ight side secondary chain ten sioner Refer to 9 ENGINE VALVE TIMING TIM ING BELT CHAIN AND SPROCKETS REMOVAL 18 Remove the cylinder head access plug Fig 19 19 Remove the right side secondary chain gui...

Page 1175: ...s necessary Fig 17 Camshaft Sprocket V8 Marks 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD Fig 18 Using Special Tool 8515 to Hold Chains to Idler Sprocket 1 LOCK ARM 2 RIGHT CAMSHAFT CHAIN 3 SECONDARY C...

Page 1176: ...over the locating dowels NOTE The four smaller cylinder head mounting bolts require sealant to be added to them before installing Failure to do so may cause leaks 4 Lubricate the cylinder head bolt th...

Page 1177: ...HEAD NOTE The cylinder head bolts are tightened using a torque plus angle procedure The bolts must be examined BEFORE reuse If the threads are necked down the bolts should be replaced Necking can be c...

Page 1178: ...ner 12 Remove Special Tool 8515 13 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 14 Install the crankshaft damper Refer to 9 ENGINE ENGINE BLOCK...

Page 1179: ...t DO NOT remove the camshaft sprocket retaining bolt Leave the bolt snug against the sprocket NOTE The timing chain tensioners must be secured prior to removing the camshaft sprockets Failure to secur...

Page 1180: ...bolts to 11 N m 100 in lbs 6 Position the camshaft drive gear into the tim ing chain aligning the V8 mark between the two marked chain links Two links marked during removal Fig 31 Fig 28 Securing Timi...

Page 1181: ...ilure to do so can cause bolt over torque resulting in bolt failure 8 Remove excess oil from bolt then install the camshaft sprocket retaining bolt and hand tighten 9 Remove Special Tool 8350 timing c...

Page 1182: ...ket Installation 1 ADJUSTABLE PLIERS 2 CAMSHAFT DOWEL Fig 33 SPECIAL TOOL 8350 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD 3 SPECIAL TOOL 8350 WEDGE 4 SPECIAL TOOL 8350 WEDGE AN ENGINE 4 7L 9 153 CAMSH...

Page 1183: ...tar get wheel for any reason Severe damage will occur to the target wheel A damaged target wheel could cause a vehicle no start condition 4 Loosen but DO NOT remove the camshaft sprocket retaining bol...

Page 1184: ...EDGE 4 SPECIAL TOOL 8350 WEDGE Fig 36 Camshaft Position Sensor 1 CRANKSHAFT POSITION SENSOR 2 CYLINDER HEAD COVER 3 CAMSHAFT POSITION SENSOR 4 RIGHT SIDE CYLINDER BLOCK Fig 37 Camshaft Sprocket and Ch...

Page 1185: ...he tim ing chain aligning the V8 mark between the two marked chain links Two links marked during removal Fig 39 NOTE When gripping the camshaft place the pliers on the tube portion of the camshaft onl...

Page 1186: ...g 40 Camshaft Sprocket Installation 1 ADJUSTABLE PLIERS 2 CAMSHAFT DOWEL Fig 41 Tightening Right Side Cam Sprocket Retaining Bolt 1 TORQUE WRENCH 2 SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 LEFT CAMS...

Page 1187: ...ylinder head cover 5 Disconnect the left side breather tube and remove the breather tube 6 Remove the cylinder head cover mounting bolts 7 Remove cylinder head cover and gasket NOTE The gasket may be...

Page 1188: ...ROCEDURE REFACING NOTE Valve seats that are worn or burned can be reworked provided that correct angle and seat width are maintained Otherwise the cylinder head must be replaced NOTE When refacing val...

Page 1189: ...ver adjuster Normal adjusters should feel very firm Spongy adjusters can be bottomed out easily Remove suspected lash adjusters and replace Before installation make sure adjusters are at least partial...

Page 1190: ...ol lubrication REMOVAL 1 Remove the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 2 Using Special Tool 8516 Rocker Arm Remover remove the rocker arms and the hydrau...

Page 1191: ...hite bedplate is bolted to the block The block design allows coolant flow between the cylinders bores and an internal coolant bypass to a single poppet inlet thermostat is included in the cast aluminu...

Page 1192: ...e proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in INCRE MENTS is required If a bore gauge is not available do not use an inside micrometer Fig 49 2 Measure the inside d...

Page 1193: ...ace strip of Plas tigage across full width of the lower insert at the cen ter of bearing cap Plastigage must not crumble in use If brittle obtain fresh stock 5 Install bearing cap and connecting rod o...

Page 1194: ...insert install the insert and cap Tighten the connecting rod bolts to 27 N m 20 ft lbs plus a 90 turn Slide snug fitting feeler gauge between the con necting rod and crankshaft journal flange Fig 55 R...

Page 1195: ...e select fit main bearing markings are located on the rear side of the target wheel The crankshaft oil seals are one piece design The front oil seal is retained in the timing chain cover and the rear...

Page 1196: ...ove all oil and sealant residue 3 Inspect the bedplate main bearing bores for cracks scoring or severe blueing If either condition exists the engine must be replaced 4 Inspect the crankshaft thrust wa...

Page 1197: ...bedplate retaining bolts making sure to place the stud bolts in the correct location Torque the bolts in the sequence shown Fig 61 Tighten bolts A L to 54 N m 40 ft lbs Tighten bolts 1 10 to 2 8 N m...

Page 1198: ...rt Select inserts required to obtain the specified bearing to journal clearance CRANKSHAFT MAIN BEARING SELECTION The main bearings are select fit to achieve proper oil clearances For main bearing sel...

Page 1199: ...ttery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Remove A C compressor mouning fasteners and set aside 4 Drain cooling system Refer to 7 COOLING STANDARD PR...

Page 1200: ...TOR FAN INSTALLATION 4 Install upper radiator hose 5 Install A C compressor and tighten fasteners to 54 N m 40 ft lbs 6 Install accessory drive belt refer Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELT...

Page 1201: ...es The crankshaft seal flange is specially machined to complement the function of the rear oil seal 6 For bubbles that remain steady with shaft rotation no further inspection can be done until dis ass...

Page 1202: ...th a solid lubricant Molykote to reduce friction and provide scuff resis tance The connecting rods are made of forged pow dered metal with a fractured cap design A pressed fit piston pin is used to at...

Page 1203: ...Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL and Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL Timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVE...

Page 1204: ...rod for signs of twist or bend ing Check the piston for taper and elliptical shape before it is fitted into the cylinder bore Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECT ING ROD STANDARD PROCEDURE...

Page 1205: ...LATION Oil pan and gasket windage tray Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLA TION 11 Fill crankcase with proper engine oil to cor rect level 12 Connect negative cable to battery PISTON RINGS...

Page 1206: ...oil ring side rail No 2 Intermediate piston ring No 1 Upper piston ring 8 Install the oil ring expander 9 Install upper side rail Fig 79 by placing one end between the piston ring groove and the expan...

Page 1207: ...orner 9 Remove crankshaft damper bolt 10 Remove damper using Special Tools 8513 Insert and 1026 Three Jaw Puller Fig 83 Fig 80 Upper and Intermediate Rings Installation Fig 81 Piston Ring End Gap Posi...

Page 1208: ...N DRIVE VISCOUS CLUTCH INSTALLATION 6 Install radiator upper shroud and tighten fas teners to 11 N m 95 in lbs 7 Connect electrical connector for shroud fan 8 Install radiator upper hose 9 Install acc...

Page 1209: ...e retaining bolts to 20 26 N m 15 20 ft lbs FRONT MOUNT REMOVAL 1 Disconnect the negative cable from the battery CAUTION Remove the fan blade fan clutch and fan shroud before raising engine Failure to...

Page 1210: ...from the insulator mount through bolt Manual transmission and 4x2 auto matic transmission only Fig 92 Fig 93 4 Remove the four bolts and washers retaining the mount to the transmission 4x4 automatic t...

Page 1211: ...mount bracket to transmission retaining bolts 4x4 automatic transmission only to 68 N m 50 ft lbs 5 Tighten the isolator mount to crossmember retaining nuts Manual transmission and 4x2 auto matic tran...

Page 1212: ...alve mounted inside the oil pump housing For lubrication flow refer to Fig 95 Fig 95 Engine Oil Lubrication System 1 LEFT CYLINDER HEAD OIL GALLERY 2 OIL PRESSURE SENSOR LOCATION 3 TO LEFT CYLINDER HE...

Page 1213: ...il Port in bolt hole Diagonal Cross Drilling to Main Oil Gallery Main Oil Gallery drilled through head from rear to front 1 Base of Camshaft Towers 2 Lash Adjuster Towers Base of Camshaft Towers Verti...

Page 1214: ...by using a black light INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is nece...

Page 1215: ...ple viscosities such as 5W 30 or 10W 30 in the 4 7L engines These are specified with a dual SAE viscos ity grade which indicates the cold to hot temperature viscosity range Select an engine oil that i...

Page 1216: ...o pan Inspect drain plug threads for stretching or other damage Replace drain plug if damaged 6 Install drain plug in crankcase 7 Lower vehicle and fill crankcase with specified type and amount of eng...

Page 1217: ...both left and right side engine mount through bolts Fig 103 11 Raise engine to provide clearance to remove oil pan 12 Place blocks of wood between engine brackets and lower mounts to provide stability...

Page 1218: ...e and install both the left and right side engine mount through bolts Fig 103 Tighten the nuts to 68 N m 50 ft lbs 6 Remove jack and install oil filter 7 Install structural dust cover Refer to 9 ENGIN...

Page 1219: ...OVER S REMOVAL 3 Remove the timing chains and tensioners Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 4 Remove the four bolts primary timing chain tensioner and the oil pump...

Page 1220: ...a straight edge across the body of the oil pump between the bolt holes if a feeler gauge of 095 mm 0 0038 in or greater can be inserted between the straightedge and the rotors the pump must be replac...

Page 1221: ...NE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 5 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 6 Install the pick up tube and oil p...

Page 1222: ...hose and positive crankcase ventilation PCV hose 6 Disconnect generator electrical connections 7 Disconnect air conditioning compressor electri cal connections 8 Disconnect left and right radio suppr...

Page 1223: ...on TPS Sensor Coolant Temperature CTS Sensor Idle Air Control IAC Motor Ignition coil towers Fuel injectors 13 Install top oil dipstick tube retaining bolt and ground strap 14 Connect generator electr...

Page 1224: ...as teners 11 Raise vehicle on hoist 12 Disconnect exhaust pipe from manifold 13 Remove fasteners attaching starter Move starter aside 14 Remove lower exhaust manifold attaching fas teners 15 Remove ex...

Page 1225: ...partment CLEANING 1 Clean the exhaust manifold using a suitable cleaning solvent then allow to air dry 2 Clean all gasket residue from the manifold mating surface INSPECTION 1 Inspect the exhaust mani...

Page 1226: ...shield to distort and or crack 4 Install exhaust manifold heat shield Tighten fasteners to 8 N m 72 in lbs then loosen 45 degrees 5 Install starter and fasteners 6 Connect exhaust pipe to manifold 7 C...

Page 1227: ...ld bolts starting at center and working outward to 25 N m 18 ft lbs CAUTION Over tightening heat shield fasteners may cause shield to distort and or crack 4 Install exhaust manifold heat shield Fig 12...

Page 1228: ...cond ary chain drives The idler sprocket assembly con sists of two integral thirty tooth sprockets and a fifty tooth sprocket that is splined to the assembly The spline joint is a non serviceable pres...

Page 1229: ...15mm 0 5906 inches 3 If the measurement exceeds the specification the secondary timing chains are worn and require replacement Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL N...

Page 1230: ...ers SINGLE CAMSHAFT TIMING NOTE to adjust the timing on one camshaft pre form the following procedure 1 Using Chain Tensioner Wedge special tool 8350 stabilize the secondary chain drive Fig 126 For re...

Page 1231: ...t remove oil from bolt then install the retaining bolt Using Special Tools Spanner Wrench 6958 with Adapter Pins 8346 and a suitable torque wrench Tighten retaining bolt to 122N m 90 ft Lbs Fig 128 Fi...

Page 1232: ...Remove the generator Refer to 8 ELECTRI CAL CHARGING GENERATOR REMOVAL 9 Remove A C compressor Refer to 24 HEAT ING AIR CONDITIONING PLUMBING A C COM PRESSOR REMOVAL 10 Remove cover and gasket Fig 131...

Page 1233: ...ING STANDARD PROCEDURE 3 Remove right and left cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 4 Remove radiator fan shroud 5 Rotate engine until timing mark on cra...

Page 1234: ...magnetized tar get wheel could cause a vehicle no start condition Fig 133 Engine Top Dead Center TDC Indicator Mark 1 TIMING CHAIN COVER 2 CRANKSHAFT TIMING MARKS Fig 134 Camshaft Sprocket V8 Marks 1...

Page 1235: ...g 138 remove the left camshaft sprocket Slowly rotate the camshaft approximately 15 degrees clockwise to a neutral posi tion Fig 136 Collapsing And Pinning Primary Chain Tensioner 1 PRIMARY CHAIN TENS...

Page 1236: ...y chain tensioner piston and ratcheting device Inspect for evidence of heavy contact between tensioner piston and tensioner arm If this condition exist the tensioner and tensioner arm should be replac...

Page 1237: ...secondary chains to be visible through the two lower openings on the idler sprocket 4 o clock and 8 o clock Once the secondary timing chains are installed position special tool 8515 to hold chains in...

Page 1238: ...ue of bolt resulting in bolt failure 13 Remove Special Tool 8515 then attach both sprockets to camshafts Remove excess oil from bolts then Install sprocket bolts but do not tighten at this time 14 Ver...

Page 1239: ...Tool 6958 Spanner with Adaptor Pins 8346 tighten left Fig 144 and right Fig 145 camshaft sprocket bolts to 122 N m 90 ft lbs 19 Rotate engine two full revolutions Verify tim ing marks are at the follo...

Page 1240: ...E Before installing threaded plug in right cylin der head the plug must be coated with sealant to prevent leaks 24 Coat the large threaded access plug with Mopart Thread Sealant with Teflon then insta...

Page 1241: ...CEDURE 233 VALVES GUIDES AND SPRINGS 233 REMOVAL 236 CLEANING 236 INSPECTION 236 INSTALLATION 236 ROCKER ARM ADJUSTER ASSEMBLY REMOVAL 237 INSTALLATION 237 ENGINE BLOCK CLEANING 237 INSPECTION 237 CAM...

Page 1242: ...ic roller tappets This engine is designed for unleaded fuel The engine lubrication system consists of a rotor type oil pump and a full flow oil filter The cylinders are numbered from front to rear 1 3...

Page 1243: ...DIAGNOSIS CHART 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 PROCE...

Page 1244: ...r water in fuel system 4 Clean system and replace fuel filter 5 Faulty fuel pump 5 Install new fuel pump 6 Incorrect valve timing 6 Correct valve timing 7 Blown cylinder head gasket 7 Install new cyli...

Page 1245: ...CCELERATION 1 Worn or incorrectly gapped spark plugs 1 Replace spark plugs or clean and set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Spark plug cables defective or crossed 2 Re...

Page 1246: ...AND TESTING engine oil pressure test specifications 3 Thin or diluted oil 3 Change oil to correct viscosity Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE for correct procedure engine oil specif...

Page 1247: ...Misaligned or deteriorated gaskets 1 Replace gasket 2 Loose fastener broken or porous metal part 2 Tighten repair or replace the part 3 Front or rear crankshaft oil seal leaking 3 Replace seal 4 Leaki...

Page 1248: ...ean or replace relief valve 9 Oil pump suction tube loose or damaged 9 Replace as necessary OIL PUMPING AT RINGS SPARK PLUGS FOULING 1 Worn or damaged rings 1 Hone cylinder bores and replace rings 2 C...

Page 1249: ...en for pressurized air escaping through the throttle body tailpipe or oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than...

Page 1250: ...of 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 ven...

Page 1251: ...und as well 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 gl...

Page 1252: ...tomatic transmission vehicles discon nect the engine from the torque converter drive plate On manual transmission vehicles move engine for ward until drive pinion shaft clears the clutch disc Remove e...

Page 1253: ...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 1 966 1 968...

Page 1254: ...h Finish Intake 1 016 1 524 mm 0 040 0 060 in Exhaust 1 524 2 032 mm 0 060 0 080 in Valves Face Angle 43 25 43 75 DESCRIPTION SPECIFICATION Head Diameter Intake 47 752 mm 1 88 in Exhaust 41 072 1 617...

Page 1255: ...Max 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 Pist...

Page 1256: ...und on outside surface OS US Item Identification Location of Identification of each O S tappet bore O S Valve Stems X Milled pad 127 mm adjacent to two 005 in 3 89 tapped holes on each end of cylinder...

Page 1257: ...68 50 4WD Automatic Rear Support Bracket to 41 30 Crossmember Flange Nuts Rear Support Plate to Transfer 41 30 Case Bolts Rocker Arm Bolts 28 21 Spark Plugs 41 30 Starter Motor Mounting Bolts 68 50 Th...

Page 1258: ...Puller 1026 Crankshaft Damper Removal Insert 8513 Front Oil Seal Installer 6635 Cam Bearing Remover Installer C3132 A Camshaft Holder C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Drive...

Page 1259: ...l element into housing 2 Position housing cover into housing locating tabs 3 Pry up spring clips and lock cover to housing CYLINDER HEAD DESCRIPTION The cast iron cylinder heads Fig 5 are mounted to t...

Page 1260: ...re cap Start the engine and allow it to warm up until thermostat opens If a large combustion compression pressure leak exists bubbles will be visible in the coolant COOLING SYSTEM TESTER METHOD WARNIN...

Page 1261: ...der heads 2 Clean cylinder block front and rear gasket sur faces using a suitable solvent 3 Position new cylinder head gaskets onto the cylinder block 4 Position cylinder heads onto head gaskets and c...

Page 1262: ...tallation If damaged use a new gasket INSTALLATION 1 The cylinder head cover gasket can be used again Install the gasket onto the head rail 2 Position the cylinder head cover onto the gas ket Tighten...

Page 1263: ...0 316 0 317 in 0 381 mm 8 331 8 357 mm 0 015 in 0 328 0 329 in 1 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Ream the valve guides from standard to 0 381 mm 0 015...

Page 1264: ...seat with a 15 stone If the blue is transferred to bottom edge of valve face raise valve seat with a 60 stone 4 When seat is properly positioned the width of intake seats should be 1 016 1 524 mm 0 04...

Page 1265: ...the indicator The total dial 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...

Page 1266: ...s for evidence 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 port...

Page 1267: ...being careful not to damage cam bearings with the cam lobes INSTALLATION CAMSHAFT BEARINGS 1 Install new camshaft bearings with Camshaft Bearing Remover Installer Tool C 3132 A by sliding the new cams...

Page 1268: ...s 10 Install rocker arms 11 Install timing case cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 12 Install cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEA...

Page 1269: ...aging 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 bl...

Page 1270: ...in bearings Number three main bearing is flanged this flange controls crankshaft thrust OPERATION The main bearings encircle the crankshaft main bearing journals this aligns the crankshaft to the cent...

Page 1271: ...shaft Main Bearing Remover Installer Tool C 3059 into oil hole of crankshaft Fig 28 2 Slowly rotate crankshaft counterclockwise slid ing the bearing into position Remove Tool C 3059 3 Install the bear...

Page 1272: ...Fig 31 4 Remove the vibration damper bolt and seal installation tool 5 Inspect the seal flange on the vibration damper 6 Install the vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER I...

Page 1273: ...opriate corrective action have been identified Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR REMOVAL for proper replacement procedures REMOVAL The service seal is a two piece Viton seal The...

Page 1274: ...r sur face of the seal To ensure proper installation use the installation tool provided with the kit Install the new seal with the white paint facing toward the rear of the engine 4 Install the new lo...

Page 1275: ...t is squeezed out 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 INSTALLA TION DISTRIBUTOR BUSHING REMOVA...

Page 1276: ...Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case noise may be dampened by applying side thrust on the valve spring If noise is not apprecia bly reduced...

Page 1277: ...8 If the tappet or bore in cylinder block is scored scuffed or shows signs of sticking ream the bore to next oversize Replace with oversize tappet CLEANING Clean tappet with a suitable solvent Rinse i...

Page 1278: ...015 mm 9845 9848 in RING GROOVE HEIGHT OIL RAIL 4 033 4 058 mm 1588 1598 in COMPRESSION RAIL 1 529 1 554 mm 0602 0612 in TOTAL FINISHED 470 8 2 grams WEIGHT 16 607 0706 ounces REMOVAL 1 Remove the en...

Page 1279: ...leaned and oiled rod bolts and tighten nuts to 61 N m 45 ft lbs torque 9 Install the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN INSTALLATION 10 Install the cylinder head Refer to 9 ENGINE CYLINDER...

Page 1280: ...oling system fan Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove vibration damper bolt and...

Page 1281: ...ll the bolts Tighten the retainer bolts to 11 N m 95 in lbs torque 6 Install the cooling fan Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 7 Connect the battery negative cable FRONT...

Page 1282: ...and three 3 support bracket to engine block bolts Remove support bracket Fig 49 Fig 50 INSTALLATION 2WD 1 With the engine raised SLIGHTLY position insulator assembly onto the engine block and install...

Page 1283: ...o cross member Fig 52 Remove insulator 4WD 1 Disconnect the negative cable from the battery 2 Raise the vehicle on a hoist 3 Support the transmission with a transmission jack 4 Remove stud nuts holdin...

Page 1284: ...nd screen assembly to gather engine oil from the oil pan OPERATION The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan The oil is driven between the drive and...

Page 1285: ...the area of the suspected leak If an oil leak source is not readily identifiable the following steps should be followed 1 Do not clean or degrease the engine at this time because some solvents may ca...

Page 1286: ...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 2...

Page 1287: ...verfill crankcase with engine oil oil foaming and oil pressure loss can result To ensure proper lubrication of an engine the engine oil must be maintained at an acceptable level The acceptable levels...

Page 1288: ...NE LUBRICATION OIL STANDARD PROCEDURE OIL PAN REMOVAL 2WD 1 Disconnect the negative cable from the battery 2 Remove engine oil dipstick 3 Disconnect distributor cap and position away from cowl 4 Raise...

Page 1289: ...il pan bolts Tighten the bolts to 24 N m 215 in lbs torque 7 Remove the dowels Install the remaining oil pan bolts Tighten these bolts to 24 N m 215 in lbs torque 8 Install the drain plug Tighten drai...

Page 1290: ...spring and relief valve Fig 61 2 Remove oil pump cover Fig 62 3 Remove pump outer rotor and inner rotor with shaft Fig 62 4 Wash all parts in a suitable solvent and inspect carefully for damage or wea...

Page 1291: ...hecking Oil Pump Cover Flatness 1 COVER 2 STRAIGHT EDGE 3 FEELER GAUGE Fig 64 Measuring Outer Rotor Thickness Fig 65 Measuring Inner Rotor Thickness Fig 66 Measuring Outer Rotor Clearance in Housing 1...

Page 1292: ...sert the cotter pin 4 Tap on a new retainer cap 5 Prime oil pump before installation by filling rotor cavity with engine oil INSTALLATION 1 Install oil pump During installation slowly rotate pump body...

Page 1293: ...N If the studs came out with the nuts when removing the exhaust manifold install new studs 1 Position the exhaust manifolds on the two studs located on the cylinder head Install conical washers and nu...

Page 1294: ...Ms occurs the area of the suspected leak has been found 4 Repair as required REMOVAL 1 Disconnect the negative cable from the battery 2 Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE...

Page 1295: ...o ensure a leak proof seal However an excessive amount of sealant may reduce the effectiveness of the flange gas ket The sealant should be approximately 5 mm 0 2 in in diameter and 15mm 0 6in long 5 I...

Page 1296: ...all the accessory drive bracket and A C compressor Refer to 24 HEATING AIR CONDI TIONING PLUMBING A C COMPRESSOR INSTALLATION 18 Install the generator and drive belt Refer to 7 COOLING ACCESSORY DRIVE...

Page 1297: ...n and free from burrs 2 The water pump mounting surface must be cleaned 3 Using a new cover gasket carefully install chain case cover to avoid damaging oil pan gasket Use a small amount of Mopart GEN...

Page 1298: ...E VISCOUS CLUTCH INSTALLATION 16 Position the fan shroud and install the bolts Tighten the bolts to 11 N m 95 in lbs torque 17 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 18 Connect the...

Page 1299: ...lide both sprockets evenly over their respec tive shafts and use a straightedge to check alignment of timing marks Fig 85 6 Install the camshaft bolt Tighten the bolt to 68 N m 50 ft lbs torque 7 Chec...

Page 1300: ...2 5L ENGINE CAUTION Avoid application of rust prevention com pounds or undercoating materials to exhaust sys tem floor pan exhaust heat shields Light overspray near the edges is permitted Application...

Page 1301: ...25 4 mm 1 0 in If the system con tacts any body panel it may amplify objectionable noises from the engine or body Fig 2 Fig 1 Exhaust System 2 5L Engines Typical 1 TAILPIPE 2 MUFFLER 3 MUFFLER HANGER...

Page 1302: ...lange 4 Tighten connection attaching nuts Refer to 11 EXHAUST SYSTEM SPECIFICATIONS 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold Refer to 9 ENGINE MANIFOLDS EXHAUST MANIFOLD REMOVAL...

Page 1303: ...em components disconnect the oxygen sensor connector s Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and or sensor 1 Raise and support the vehicle 2 Saturate the bolt...

Page 1304: ...ainless steel designed to operate at extremely high temperatures OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion cham bers during the exhaust stro...

Page 1305: ...atures OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion cham bers during the exhaust stroke of the engine This process aids in reducing emissions o...

Page 1306: ...engine and inspect for exhaust leaks and exhaust system contact with the body panels Adjust the alignment if needed EXHAUST PIPE 2 5L REMOVAL CAUTION When servicing or replacing exhaust system compon...

Page 1307: ...9L REMOVAL CAUTION When servicing or replacing exhaust system components disconnect the oxygen sensor connector s Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and o...

Page 1308: ...AUTION When servicing or replacing exhaust system components disconnect the oxygen sensor connector s Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and or sensor 1 Ra...

Page 1309: ...h 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 Fig 14 15 16 17...

Page 1310: ...OOR PAN MIDDLE HEAT SHIELD 2 NUT AND WASHER 3 FLOOR PAN FRONT HEAT SHIELD Fig 18 Center Bearing Heat Shield Standard Cab and Extended Cab 1 SCREW AND WASHER SELF TAPPING 2 CENTER BEARING HEAT SHIELD F...

Page 1311: ...st system contact with the body panels Adjust the alignment if needed MUFFLER DESCRIPTION All engines use a stainless steel muffler to control exhaust noise levels and exhaust back pressure REMOVAL CA...

Page 1312: ...e engine inspect for exhaust leaks and exhaust system contact with the body panels Adjust the alignment if needed TAILPIPE 2 5L 3 9L 4 7L DESCRIPTION The tailpipe is made of stainless steel and attach...

Page 1313: ...oxygen sensor wires will damage the harness and or sensor 1 Raise and support the vehicle 2 Saturate the clamp nuts with Mopart Rust Penetrant Allow 5 minutes for penetration 3 Remove muffler to tail...

Page 1314: ...front and rear fascias They are mounted to the frame with brackets and may contain some lamp ele ments OPERATION Bumpers are designed to protect the exterior sheet metal in low impact situations The...

Page 1315: ...s to fog lamps if equipped 5 Install push in fasteners attaching air deflector to front bumper fascia 6 Remove lifting device 7 Close hood FRONT FASCIA REMOVAL 1 Remove the front bumper 2 Remove the b...

Page 1316: ...forward of the rear bumper This damper is used to address NVH issues The cab is isolated from the frame with rubber load cushions Fig 5 and Fig 6 with through bolts The cargo box or bed is attached t...

Page 1317: ...CAUTION Do not reuse damaged fasteners quality of repair would be suspect Do not drill holes in top or bottom frame rail flanges frame rail failure can result Do Not use softer than Grade 5 bolts to...

Page 1318: ...ed away from existing holes WELDING Use MIG TIG or arc welding equipment to repair welded frame components Frame components that have been damaged should be inspected for cracks before returning the v...

Page 1319: ...If necessary ream the hole out just enough to sufficiently receive the bolt Conical type washers are preferred over the split ring type lock washers Normally grade 5 bolts are adequate for frame repa...

Page 1320: ...Fig 7 Cargo Box 1 CARGO BOX 2 FRAME RAIL Fig 8 Frame Reinforcement 1 250 IN FROM EDGE 2 TOP FLANGE 3 BOTTOM FLANGE 4 FRAME RAIL 5 FRAME REPAIR REINFORCEMENT AN FRAME BUMPERS 13 7 FRAME Continued...

Page 1321: ...OP VIEW WHEELBASE 4X2 4X4 DIMN A DIMN B DIMN C DIMN D DIMN E DIMN F DIMN G 112 4X4 1674 8 1901 0 2159 3 3539 4 3738 5 2591 0 2081 7 124 4X4 1674 8 1901 0 2464 0 3844 2 4208 5 2591 0 2506 1 131 4X4 215...

Page 1322: ...4X4 FRAME SIDE VIEW AN FRAME BUMPERS 13 9 FRAME Continued...

Page 1323: ...DIMN D DIMN E DIMN F DIMN G 112 4X2 1674 8 1901 0 2176 9 3539 5 3738 5 2591 0 2081 7 124 4X2 1674 8 1901 0 2481 6 3844 2 4208 5 2591 0 2506 1 131 4X2 2156 7 2383 0 2659 5 4022 1 4220 3034 9 2081 7 4X...

Page 1324: ...ut 108 N m 80 ft lbs FRONT SKID PLATE REMOVAL 1 Position a support under the skid plate 2 Remove the bolts that attach the skid plate to the front crossmember Fig 9 3 Remove the bolts that attach the...

Page 1325: ...the screws with 23 N m 200 in lbs torque 4 Remove the support from under the skid plate TRAILER HITCH REMOVAL 1 Support trailer hitch on a suitable lifting device 2 Remove fasteners attaching trailer...

Page 1326: ...OVAL 1 Hoist and support vehicle on safety stands 2 Remove bolts attaching skid plate to crossmem bers Fig 14 3 Separate skid plate from vehicle INSTALLATION 1 Position skid plate on vehicle 2 Install...

Page 1327: ......

Page 1328: ...UEL PUMP AMPERAGE TEST 9 FUEL PUMP MODULE DESCRIPTION 11 OPERATION 11 REMOVAL 11 INSTALLATION 12 FUEL RAIL DESCRIPTION 13 OPERATION 13 REMOVAL 14 INSTALLATION 17 FUEL TANK DESCRIPTION 18 OPERATION 18...

Page 1329: ...emain in fuel supply line between the check valve and fuel injectors Fuel pressure that has dropped to 0 psi on a cooled down vehicle engine off is a normal condition When the elec tric fuel pump is a...

Page 1330: ...fuel pump relay from Power Distribu tion Center PDC For location of relay refer to label on underside of PDC cover 3 Start and run engine until it stalls 4 Attempt restarting engine until it will no l...

Page 1331: ...6856 Adapters Fuel Pressure Test 6539 and or 6631 Fitting Air Metering 6714 O2S Oxygen Sensor Remover Installer C 4907 Test Kit Fuel Test Kit Fuel Pressure C 4799 B Fuel Line Removal Tool 6782 14 4 F...

Page 1332: ...mal sched uled maintenance Filters should only be replaced if a diagnostic procedure indicates to do so FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION The fuel gauge sending unit fuel level sensor is atta...

Page 1333: ...20 ohms 6 ohms With float in down position resistance should be 220 ohms 6 ohms REMOVAL The fuel gauge sending unit fuel level sensor and float assembly is located on the side of fuel pump module Fig...

Page 1334: ...E RELEASE PROCEDURE IN THIS GROUP The lines tubes hoses used on fuel injected vehicles are of a special construction This is due to the higher fuel pressures and the possibility of contami nated fuel...

Page 1335: ...filter fuel pressure regulator The fuel pressure regulator is not con trolled by engine vacuum WARNING THE FUEL SYSTEM IS UNDER CON STANT FUEL PRESSURE EVEN WITH THE ENGINE OFF BEFORE DISCONNECTING FU...

Page 1336: ...S adapter Fig 8 and its test leads will be used to check fuel pump amperage specifica tions 1 Be sure fuel tank contains fuel before starting test If tank is empty or near empty amperage read ings wil...

Page 1337: ...mperage on DRB screen Amperage should be below 10 0 amps If amperage is below 10 0 amps and specifications for the Fuel Pump Pressure Fuel Pump Capacity and Fuel Pres sure Leak Down tests were met the...

Page 1338: ...er Fuel Pressure Reg ulator and Fuel Gauge Sending Unit REMOVAL WARNING THE FUEL SYSTEM IS UNDER A CON STANT PRESSURE EVEN WITH ENGINE OFF BEFORE SERVICING FUEL PUMP MODULE FUEL SYSTEM PRESSURE MUST B...

Page 1339: ...fuel tank 2 Position locknut over top of fuel pump module Tighten finger tight 3 Carefully rotate fuel filter fuel pressure regula tor until fuel fitting is pointed towards drivers side of vehicle Fi...

Page 1340: ...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 this connecting hose it does not use any clamps Nev...

Page 1341: ...entifying its correspond ing cylinder Fig 20 If not identify each connector before removal 6 Disconnect fuel supply line latch clip and fuel line at fuel rail Refer to Quick Connect Fittings in this g...

Page 1342: ...A C compressor to intake manifold support bracket three bolts Fig 22 6 Disconnect electrical connectors at all 8 fuel injectors To remove connector refer to Fig 23 Push red colored slider away from in...

Page 1343: ...will be necessary for fuel line disconnection Refer to Quick Connect Fittings 8 Remove vacuum lines at throttle body 9 Disconnect electrical connectors at all 8 fuel injectors To remove connector refe...

Page 1344: ...pped 9 Install cable routing bracket to intake mani fold 10 Connect throttle cable at throttle body 11 Connect speed control cable at throttle body if equipped 12 Connect automatic transmission cable...

Page 1345: ...ead shoulder 6 Install 4 fuel rail mounting bolts and tighten to 27 N m 20 ft lbs 7 Install ignition coils Refer to Ignition Coil Removal Installation 8 Connect electrical connectors to throttle body...

Page 1346: ...fuel tank As an alternative procedure the electric fuel pump may be activated Refer to DRB scan tool for fuel pump activation procedures Activate electric fuel pump or gasoline draining station and dr...

Page 1347: ...tank mounting straps to side of vehicle and lower tank just enough to allow access to connections at top of tank 13 Clean quick connect fittings of any dirt con taminants before removal 14 Disconnect...

Page 1348: ...tall fill and vent hoses to fill and vent tubes 10 Install splash shield in front of left rear wheelhouse 11 Connect negative cable to battery 12 Refill fuel tank and install fill cap 13 Inspect all h...

Page 1349: ...DURE CAUTION The interior components o rings spac ers of some types of quick connect fitting are not serviced separately If service parts are not avail able do not attempt to repair a damaged fitting...

Page 1350: ...it may be difficult to discon nect fitting Use an open end wrench on shoulder of plastic retainer ring to aid in dis connection b After disconnection plastic retainer ring will remain with quick conne...

Page 1351: ...serted pull fuel line from fuel rail f After disconnection locking fingers will remain within quick connect fitting at end of fuel line 8 Disconnect quick connect fitting from fuel sys tem component b...

Page 1352: ...om the fuel tank through this valve s The valve s cannot be serviced separately If replacement is necessary the fuel tank must be replaced Refer to Fuel Tank Removal Installation REMOVAL The rollover...

Page 1353: ...RIPTION 40 OPERATION 40 REMOVAL 40 INSTALLATION 40 IDLE AIR CONTROL MOTOR DESCRIPTION 40 OPERATION 40 REMOVAL 41 INSTALLATION 42 INTAKE AIR TEMPERATURE SENSOR DESCRIPTION 42 OPERATION 42 REMOVAL 42 IN...

Page 1354: ...ns Verify coil sec ondary cable is firmly connected to coil Fig 3 5 Verify distributor cap is correctly attached to distributor Be sure spark plug cables are firmly con nected to the distributor cap a...

Page 1355: ...Also check connection to brake vac uum booster 13 Inspect air cleaner inlet and air cleaner ele ment for dirt or restrictions 14 Inspect radiator grille area radiator fins and air conditioning condens...

Page 1356: ...lant temperature sensor Fig 8 20 Raise and support vehicle 21 All 3 9L V 6 and 5 2L V 8 All 5 9L V 8 With Four Wheel Drive 4WD Verify both upstream and downstream oxygen sensor wire con nectors are fi...

Page 1357: ...air gap Refer to 5 Brakes for information 27 If equipped with 4 wheel antilock brake sys tem verify electrical harness is firmly connected to each front wheel speed sensor Verify both front wheel spe...

Page 1358: ...firmly connected to coil Fig 15 5 Verify distributor cap is correctly attached to distributor Be sure spark plug cables are firmly con nected to distributor cap and the spark plugs are in their correc...

Page 1359: ...sensor wire connector is firmly connected to harness connec tor Fig 17 16 Verify MAP sensor electrical connector is firmly connected to MAP sensor Fig 18 Also verify rubber L shaped fitting from MAP s...

Page 1360: ...pped with 4 wheel antilock brake sys tem verify electrical harness is firmly connected to each front wheel speed sensor Verify both front wheel speed sensors are firmly attached Refer to 5 Brakes for...

Page 1361: ...ile servicing accelerator pedal or cables 1 From inside the vehicle hold up accelerator pedal Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm Fig 22 Plastic cabl...

Page 1362: ...m it The flywheel drive plate has groups of four notches at its outer edge On 2 5L 4 cylinder engines there are two sets of notches Fig 25 The notches cause a pulse to be generated when they pass unde...

Page 1363: ...l effect device combined with an internal magnet It is also sensitive to steel within a certain distance from it On 5 2 5 9L V 8 engines the flywheel drive plate has 8 single notches spaced every 45 d...

Page 1364: ...Remove air tube between throttle body and air cleaner housing 2 Near rear of intake manifold disconnect pigtail harness on the sensor from main electrical harness 3 Remove 2 sensor mounting bolts 4 Re...

Page 1365: ...rottle body and air cleaner housing INSTALLATION 3 9 5 2 5 9L 1 Position crankshaft position sensor to engine 2 Install mounting bolts and tighten to 8 N m 70 in lbs torque 3 Connect main harness elec...

Page 1366: ...used to identify each fuel injector with its respective cylinder number The injectors are energized individually in a sequen tial order by the Powertrain Control Module PCM The PCM will adjust injecto...

Page 1367: ...1 Remove PDC cover 2 Remove relay from PDC 3 Check condition of relay terminals and PDC connector terminals for damage or corrosion Repair if necessary before installing relay 4 Check for pin height...

Page 1368: ...value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions the PCM recalls that 125 steps were required to maintain the target This program allows for...

Page 1369: ...i fold temperature increases resistance voltage in the sensor decreases As temperature decreases resis tance voltage in the sensor increases OPERATION The IAT sensor provides an input voltage to the P...

Page 1370: ...4 7L 1 Install sensor into intake manifold Tighten sensor to 28 N m 20 ft lbs torque 2 Connect electrical connector to sensor INSTALLATION 2 5L The intake manifold air temperature sensor is located in...

Page 1371: ...oring a known good sensor As the altitude increases the air becomes thinner less oxygen If a vehicle is started and driven to a very different altitude than where it was at key on the barometric press...

Page 1372: ...he MAP sensor is located on the front of the intake manifold Fig 41 An o ring seals the sensor to the intake manifold 1 Disconnect electrical connector at sensor 2 Clean area around MAP sensor 3 Remov...

Page 1373: ...ifold Fig 41 An o ring seals the sensor to the intake manifold 1 Clean MAP sensor mounting hole at intake manifold 2 Check MAP sensor o ring seal for cuts or tears 3 Position sensor into manifold 4 In...

Page 1374: ...1 volt inversely proportional to the amount of oxygen in the exhaust In other words if the oxygen content is low the volt age output is high if the oxygen content is high the output voltage is low The...

Page 1375: ...upstream sensors are used 1 1 and 2 1 The 1 1 sensor is the first sensor to receive exhaust gases from the 1 cylinder They provide an input voltage to the PCM The input tells the PCM the oxygen conte...

Page 1376: ...D CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR Fig 44 Upstream Oxygen Sensor Locations Except 4 7L V 8 Engine 1 EXHAUST PIPE 2 UPSTREA...

Page 1377: ...ensor CAUTION When disconnecting the sensor electrical connector do not pull directly on wire going into sensor 3 Remove the O2S sensor with an oxygen sensor removal and installation tool Fig 48 Oxyge...

Page 1378: ...torque 2 Connect the O2S sensor wire connector 3 Lower the vehicle INSTALLATION 2 5L Threads of new oxygen sensors are factory coated with anti seize compound to aid in removal DO NOT add any addition...

Page 1379: ...additional information 5 Remove four throttle body mounting bolts Fig 52 6 Remove throttle body from intake manifold 7 Discard old throttle body to intake manifold gasket REMOVAL 2 5L A factory adjus...

Page 1380: ...trol cables 6 Install vacuum line to throttle body 7 Install electrical connectors 8 Install air duct at throttle body INSTALLATION 2 5L A factory adjusted set screw is used to mechani cally limit the...

Page 1381: ...ever Fig 55 b Remove cable housing at throttle body mounting bracket by pressing forward on release tab with a small screwdriver Fig 56 To prevent cable housing breakage press on tab only enough to re...

Page 1382: ...ccelerator pedal or cables 1 3 9 5 2 5 9L Engines a Snap cable end onto lever pin Fig 55 On models with V 8 engines be sure cable is routed under plastic cam Fig 55 b Connect cable to throttle body mo...

Page 1383: ...le opening idle to 4 49 volts at wide open throttle Along with inputs from other sensors the PCM uses the TPS input to determine current engine operating conditions In response to engine operating con...

Page 1384: ...will not rotate install the sensor with the throttle shaft on the other side of the socket tangs The TPS will be under slight tension when rotated 1 Install the TPS and two retaining bolts 2 Tighten...

Page 1385: ...aft end of the throttle body slides into a socket in the TPS Fig 65 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...

Page 1386: ...s attached to the gear pinion The rotation of the pinion moves the gear rack from side to side This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels...

Page 1387: ...s loose 1 Tighten bolts to specification 2 Loose or damaged suspension components 2 Inspect and repair suspension 3 Internal gear noise 3 Replace steering gear 4 Pressure hose in contact with other co...

Page 1388: ...5 Internal gear leak 5 Replace gear STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Tire pressure 1 Adjust tire pressure 2 Wheel alignment 2 Align front end 3 Lack of lubrication 3 Inspec...

Page 1389: ...ect the high pressure hose from the power steering pump 5 Connect the tube to the pump hose fitting 6 Connect the power steering hose from the steering gear to the adapter 7 Open the test valve comple...

Page 1390: ...ut below specifications replace pump 13 Open the test valve and turn the steering wheel to the extreme left and right positions three times against the stops Record the highest pressure reading at eac...

Page 1391: ...NENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS CHARGE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE...

Page 1392: ...quipped from col umn 7 Remove the lower and upper shrouds 8 Disconnect the shift cable by unsnapping the shift cable clip from the shift lever and remove from the cable bracket Fig 3 9 Remove the turn...

Page 1393: ...assemble the mounting nuts 3 Firmly slide steering column upward against the studs in dash panel and hand tighten the nuts 4 Install steering shaft coupler on the steering shaft and install a new bolt...

Page 1394: ...tic trans mission and a steering column mounted shifter an interlock device is located within the steering col umn This interlock device is used to lock the trans mission shifter in the PARK position...

Page 1395: ...cket to gain access to the ignition switch mounting screws Fig 7 9 Disconnect the electrical connector at rear of ignition switch Fig 8 10 Remove ignition switch mounting screw 11 Using a small screwd...

Page 1396: ...pped with a manual transmis sion and a floor mounted shifter on certain mod els a lever is located on the steering column behind the ignition key lock cylinder The lever must be manually operated to a...

Page 1397: ...lever from the steering column assembly INSTALLATION 1 Install the gear shift lever onto the steering column assembly Fig 10 2 Install the shift lever screws Tighten the screws to 12 N m 105 In Lbs 3...

Page 1398: ...replace the boot seal OPERATION The steering column shaft is attached to the gear pinion The rotation of the pinion moves the gear rack from side to side This lateral action of the rack pushes and pul...

Page 1399: ...ccess to the gear 3 Remove the nuts from the tie rod ends 4 Separate tie rod ends from the knuckles with Puller C 3894 A Refer to 19 STEERING LINKAGE TIE ROD END REMOVAL Fig 5 5 Remove the power steer...

Page 1400: ...RD PROCEDURE 8 Adjust the toe position Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE INSTALLATION 4WD NOTE Before installing gear inspect bushings and replace if worn or damaged 1 Install...

Page 1401: ...ing Gear Gear to Frame Bolts 258 190 Rack and Pinion Steering Gear Intermediate Shaft Bolt 49 36 Tie Rod End Knuckle Nut 108 80 Tie Rod End Jam Nut 75 55 Power Steering Line Pressure Line 35 25 Power...

Page 1402: ...outer tie rod end nut at the steer ing knuckle 3 Separate the tie rod ball stud from the knuckle with Remover MB 991113 Fig 2 4 Unthread the outer tie rod end from the inner tie rod INSTALLATION INNER...

Page 1403: ...G LINKAGE TIE ROD END REMOVAL 2 Remove the jam nut 3 Remove the outer clamp from the rubber boot Fig 4 4 Remove the boot inner clamp 5 On 4x2 vehicles mark the breather tube loca tion on steering gear...

Page 1404: ...ing pump oil cooler On the 5 2L and 5 9L the oil cooler is mounted to the engine block On the 4 7L the oil cooler is mounted to the power steering pump NOTE Power steering pumps are not interchange ab...

Page 1405: ...n the fluid level 6 Lower the front wheels and let the engine idle for two minutes 7 Turn the steering wheel in both direction and verify power assist and quiet operation of the pump If the fluid is e...

Page 1406: ...e and return hose to the pump Tighten the pressure line to 35 N m 25 ft lbs 5 Install power steering pressure switch connec tor 6 Install the serpentine drive belt Refer to 7 COOLING ACCESSORY DRIVE D...

Page 1407: ...Flow Control Valve 75 55 5 2L 5 9L Power Steering Pump Pressure Line 35 25 4 7L Power Steering Pump Pump Mounting Bolts 28 21 4 7L Power Steering Pump Flow Control Valve 81 60 4 7L Power Steering Pump...

Page 1408: ...ANDARD PROCEDURE INSTALLATION PRESSURE HOSE 1 Install the pressure hose to the vehicle 2 Reconnect the pressure hose at the gear Tighten the hose to 34 N m 25 ft lbs 3 Reconnect the pressure hose at t...

Page 1409: ...pump assembly Refer to 19 STEER ING PUMP 4 7L REMOVAL OR Refer to 19 STEERING PUMP 5 2 L 5 9L REMOVAL 2 Remove pulley from pump with Puller C 4333 Fig 7 INSTALLATION CAUTION On vehicles equipped with...

Page 1410: ...wo alumi num gear housings and a detachable clutch housing The mainshaft is supported by two sealed ball bearings and the countershaft is supported by two tapered roller bearings The transmission gear...

Page 1411: ...nizer begins to speed up or slow down the selected gear depending on whether we are up shifting or down shifting The synchronizer does this by having the synchronizer hub splined to the mainshaft or t...

Page 1412: ...ake some noise dur ing normal operation Rotating gears generate a mild whine that is audible but generally only at extreme speeds Severe highly audible transmission noise is gener ally the initial ind...

Page 1413: ...t plunger and spring with a pencil magnet Fig 5 Fig 2 BACKUP LIGHT SWITCH 1 BACKUP LAMP SWITCH Fig 3 SHIFT TOWER 1 SHIFT TOWER AND LEVER ASSEMBLY 2 SHIFT SOCKET 3 SEAL Fig 4 SHIFT SHAFT BUSHING LOCK B...

Page 1414: ...ady to be removed from case Three bolts at the rear of housing are for the output shaft bearing retainer Fig 6 INPUT SHAFT BEARING RETAINER BOLTS 1 BOLTS 5 2 BEARING RETAINER Fig 7 INPUT SHAFT BEARING...

Page 1415: ...ift socket off to the side so roll pin removal does not interfere with gears Fig 10 FRONT HOUSING 1 FRONT HOUSING 2 REAR HOUSING 3 DOWELS 2 4 PLASTIC MALLET Fig 11 INPUT SHAFT AND COUNTERSHAFT BEARING...

Page 1416: ...bushing Fig 16 7 Rotate 3 4 fork around synchro sleeve until fork clears shift arms on 1 2 and fifth reverse forks then remove 3 4 fork Fig 17 Fig 14 SHIFT SHAFT 1 SHIFT SHAFT 2 3 4 FORK 3 SHAFT DETE...

Page 1417: ...ner bolts Fig 20 Bolts are rear of shift tower opening 2 Grab hold of mainshaft and countershaft and remove geartrain from rear housing Fig 21 Fig 18 REVERSE IDLER SHAFT SUPPORT BOLT 1 SUPPORT BOLT 2...

Page 1418: ...t Remove synchronizer unit as an assembly to avoid intermixing parts Mark each synchro hub and sleeve for assembly reference 1 Remove snap ring that secures 3 4 synchro hub on output shaft 2 Remove 3...

Page 1419: ...ove fifth gear Fig 28 15 Remove fifth gear needle bearing Spread bearing apart just enough to clear shoulder on output shaft Fig 29 16 Remove fifth reverse synchro hub snap ring Fig 30 Fig 25 1 2 SYNC...

Page 1420: ...e any fork exhibiting wear or damage in these areas Do not attempt to salvage shift forks Check condition of the shift shaft detent plunger and spring The plunger should be smooth and free of nicks or...

Page 1421: ...Helicoil inserts NOTE The front housing contains the countershaft front bearing race The rear housing contains the countershaft rear bearing race If a countershaft bearing failure results the bearing...

Page 1422: ...d or severely scored Inspect shaft splines and bearings surfaces Minor nicks on the bearing surfaces can be smoothed with 320 420 grit emery and final polished with crocus cloth Replace the shaft if t...

Page 1423: ...chro onto shaft with shop press and Remover 6310 1 Fig 39 CAUTION Fifth reverse synchro hub and sleeve can be installed backwards One side of the sleeve has double grooves and offset teeth This side m...

Page 1424: ...ifth gear on shaft and onto bearing Fig 43 9 Install output shaft bearing 10 Install output shaft bearing snap ring spread snap ring only enough to install it Fig 44 Verify snap ring is seated in shaf...

Page 1425: ...ng Fig 47 16 Start 1 2 synchro assembly on shaft by hand Fig 48 Be sure synchro sleeve is properly posi tioned CAUTION The 1 2 synchro hub and sleeve can be installed backwards One side of the sleeve...

Page 1426: ...ted in sleeve 20 Install synchro cone into synchro ring 21 Install second gear needle bearing on shaft Fig 52 22 Install second gear onto shaft and bearing Fig 53 Verify second gear is seated on synch...

Page 1427: ...TOOL 6310 1 Fig 52 SECOND GEAR BEARING 1 SECOND GEAR BEARING 2 SPECIAL TOOL 6310 1 Fig 53 SECOND GEAR 1 SPECIAL TOOL 6310 1 2 1 2 SYNCHRO ASSEMBLY 3 BEARING 4 SECOND GEAR Fig 54 TWO PIECE THRUST WASH...

Page 1428: ...by hand Fig 58 CAUTION The 3 4 synchro hub and sleeve can be installed backwards One side of the sleeve has two grooves and offset teeth This side must be installed towards 3rd gear away from 4th gea...

Page 1429: ...ng the shaft splines 30 Install 3 4 synchro hub new snap ring Fig 60 with thickest snap ring that will fit in shaft groove Verify snap ring is seated in groove 31 Verify position of synchro sleeves be...

Page 1430: ...put shaft gears are fully meshed with the mainshaft gears Fig 65 6 Thread one Pilot Stud 8120 in center or pas senger side hole of output shaft bearing retainer Then position retainer on fifth gear 7...

Page 1431: ...GEAR SYNCHRO RING 2 INPUT SHAFT 3 STAND 8355 Fig 64 MAINSHAFT ON SUPPORT STAND 1 MAIN SHAFT 2 SUPPORT STAND 8355 Fig 65 COUNTERSHAFT ON SUPPORT STAND 1 COUNTER SHAFT 2 MAIN SHAFT 3 SUPPORT STAND 8355...

Page 1432: ...move Pilot Stud 8120 and install last retainer bolt Fig 70 7 Tighten all three retainer bolts to 22 N m 16 ft lbs NOTE All bolts except the reverse idler shaft bolts have o rings to seal the bolts to...

Page 1433: ...ft out of position SHIFT SHAFT SHAFT LEVER AND BUSHING AND SHIFT SOCKET 1 Verify all synchro sleeves are in Neutral posi tion centered on hub CAUTION Synchros must all be in Neutral position to preven...

Page 1434: ...shaft lever Fig 78 Shaft lever roll pin is approximately 22 mm 7 8 in long Shift socket roll pin is approximately 33 mm 1 1 4 in long 10 Align roll pin holes in shift shaft lever and bushing then sta...

Page 1435: ...es in shift fork arms are aligned Fig 77 SHIFT SOCKET AND SHAFT 1 SHIFT SOCKET 2 SHIFT SHAFT Fig 78 SHAFT LEVER AND SOCKET ROLL PINS 1 SHAFT LEVER ROLL PIN 2 SHIFT SOCKET ROLL PIN Fig 79 STARTING ROLL...

Page 1436: ...t in Neu tral or one or more components are misaligned Do not force the front housing into place 6 Place transmission in horizontal position 7 Apply Mopar Gasket Maker or equivalent to housing attachi...

Page 1437: ...shaft cannot be rotated by hand or is not smooth through several rotations re check the coun tershaft pre load 12 Lubricate then install shift shaft detent plunger in housing bore Fig 87 Lubricate pl...

Page 1438: ...mission case or bearing retainer 20 Install and tighten bearing retainer bolts to 29 N m 21 4 ft lbs Fig 92 Fig 88 BACKUP LIGHT SWITCH 1 BACKUP LAMP SWITCH Fig 89 INPUT SHAFT SNAP RING 1 INPUT SHAFT S...

Page 1439: ...ission on jack and position trans mission under vehicle 4 Raise transmission until input shaft is centered in clutch disc hub 5 Move transmission forward and start input shaft in clutch disc and pilot...

Page 1440: ...41 30 Bearing Retainer Rear 34 25 Drain Fill Plug 34 25 Shift Shaft Lock Bolt 27 20 Idler Shaft Bolts M8 27 20 Idler Shaft Bolts M10 52 40 Shift Tower Bolts 14 10 120 SPECIAL TOOLS MANUAL NV1500 Inst...

Page 1441: ...mover 8117 Support Stand 8355 Remover Bearing 8356 Remover Bearing Race L 4454 Splitter Bearing 1130 Tube 6310 1 Remover Installer 8119 Stud Alignment 8120 21 32 MANUAL NV1500 AN MANUAL NV1500 Continu...

Page 1442: ...h fully synchronized manual transmission Fifth gear is an overdrive range with a ratio of 0 73 1 The NV3500 is available in two and four wheel drive con figurations The transmission gear case consists...

Page 1443: ...Fig 1 NV3500 Manual Transmission 21 34 MANUAL NV3500 AN MANUAL NV3500 Continued...

Page 1444: ...1 1 FIFTH 0 73 1 REVERSE 3 55 1 OPERATION The manual transmission receives power through the clutch assembly from the engine The clutch disc is splined to the transmission input shaft and is turned at...

Page 1445: ...ll or overfill condition 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 l...

Page 1446: ...ack Secure transmission to jack with safety chains 11 Remove transmission harness from retaining clips on transmission shift cover 12 Remove clutch slave cylinder splash shield if equipped 13 Remove c...

Page 1447: ...tach front housing to rear housing Fig 12 Three bolts at extreme rear of housing are actually for the output shaft bearing retainer It is not necessary to remove all three bolts at this time Leave at...

Page 1448: ...te position of input shaft shift shaft and forks and geartrain components in housing Fig 16 Fig 10 INPUT SHAFT BEARING RETAINER 1 SHAFT BEARING 2 BEARING RETAINER 3 INPUT SHAFT Fig 11 INPUT SHAFT SNAP...

Page 1449: ...press the roll pin down ward and out of the shift socket Fig 17 NOTE Press the roll pin just enough to clear the shift shaft Be careful not to push the pin into the geartrain Fig 14 INPUT SHAFT AND C...

Page 1450: ...on 1 2 and fifth reverse forks then remove 3 4 fork Fig 22 7 Remove the reverse idler shaft support bolt front bolt Fig 23 Fig 18 SHIFT SHAFT LEVER AND BUSHING ROLL PIN 1 PIN PUNCH 2 BUSHING AND LEVE...

Page 1451: ...g 25 d Stand geartrain and rear housing upright on fixture Fig 26 Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position 11 Remove rear bolt holding...

Page 1452: ...put shaft bearing as shown Fig 28 3 Lift rear housing up and off geartrain Fig 29 4 Remove countershaft rear bearing from coun tershaft Fig 30 5 Examine condition of bearing bore and idler shaft notch...

Page 1453: ...ndition of bearing bore counter shaft rear bearing race and idler shaft notch in rear housing Replace housing if race bore or notch are worn or damaged GEARTRAIN FROM FIXTURE 1 Remove reverse idler ge...

Page 1454: ...rrect assembly 1 Remove snap ring that secures 3 4 synchro hub on output shaft 2 Remove 3 4 synchro assembly third gear syn chro ring and third gear with shop press and Bearing Splitter 1130 Position...

Page 1455: ...g synchro fric tion cone and synchro cone Fig 40 8 Remove interm ring 9 Remove 1 2 synchro hub snap ring Fig 37 THRUST WASHER 1 PRY TOOL 2 THRUST WASHER RETAINING RING Fig 38 TWO PIECE THRUST WASHER 1...

Page 1456: ...ove fifth gear needle bearing Spread bearing apart just enough to clear shoulder on output shaft Fig 45 Fig 41 HUB SLEEVE AND 1 2 SYNCHRO 1 1 2 SYNCHRO HUB AND SLEEVE 2 SPECIAL TOOL 1130 Fig 42 FIRST...

Page 1457: ...d or corrosive base sol vents Dry all parts except bearings with compressed air Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent Gunk or similar sol vents Do not dry the b...

Page 1458: ...Inspect the housings carefully Look for cracks stripped threads scored mating surfaces damaged bearing bores or worn dowel pin holes Minor nicks on mating surfaces can be dressed off with a fine file...

Page 1459: ...ing shaft thrust washer wave washer and thrust plate Replace the bearing if any of the needle bearing rollers are worn chipped cracked flat spotted or brinnelled Also replace the bearing if the plasti...

Page 1460: ...stall the springs struts and detent balls one at a time as follows 1 Slide the sleeve part way onto the hub Leave enough room to install the spring in the hub and the strut in the hub groove 2 Install...

Page 1461: ...eated NOTE Snap rings are available in thicknesses from 2 00 mm to 2 20 mm 0 078 to 0 086 in Install thickest snap ring that will fit in shaft groove Fig 53 REVERSE GEAR BEARING 1 REVERSE GEAR BEARING...

Page 1462: ...g 61 Verify bearing is seated on shaft shoulder and is properly joined 12 Install first gear on shaft and over bearing with bearing synchro cone facing up Fig 62 13 Install first gear synchro ring Fig...

Page 1463: ...shop press Fig 65 CAUTION Align the synchro ring and sleeve as hub the is being pressed onto the shaft The synchro ring can crack if not aligned Fig 62 FIRST GEAR 1 FIRST GEAR 2 SPECIAL TOOL 3 BEARIN...

Page 1464: ...Install second gear onto shaft and bearing Fig 69 Verify second gear is fully seated on syn chro components 23 Install two piece thrust washer Fig 70 Ensure washer halves are seated in shaft groove an...

Page 1465: ...nstall third gear needle bearing on shaft Fig 73 Fig 70 TWO PIECE THRUST WASH 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS 4 LUG BORE 5 LUG 6 WASHER HALF Fig 71 RETAINING RING 1 THRUST WAS...

Page 1466: ...e 3 4 synchro hub and sleeve can be installed backwards One side of the sleeve has grooves in it This side of sleeve faces the front of the shaft Fig 73 THIRD GEAR BEARING 1 THIRD GEAR BEARING Fig 74...

Page 1467: ...eeve should be facing forward First gear side of 1 2 sleeve should be facing first gear Tapered side of fifth reverse sleeve should be facing forward REVERSE IDLER ASSEMBLY 1 Lubricate idler component...

Page 1468: ...AR 4 TAPER FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 81 IDLER GEAR AND BEARING 1 IDLER GEAR 2 BEARING 3 LOCK BALL 4 REAR OF SHAFT Fig 82 IDLER GEA...

Page 1469: ...s for damage and replace if necessary NOTE The detent plunger bushings are installed to a specific depth The space between the two bush ings when correctly installed contain an oil feed hole Do not at...

Page 1470: ...ain in input shaft Fig 88 Carefully rotate output shaft until the 3 4 synchro ring seats in synchro hub and sleeve Fig 84 ASSEMBLY FIXTURE FOR GEARTRAIN 1 SPECIAL TOOL 6747 2A 2 SPECIAL TOOL 8115 3 SP...

Page 1471: ...ed with shaft gear teeth and that bolt holes are facing out and not toward geartrain Adjust pedestal up or down if necessary Also be sure that short end of idler shaft is facing up as shown 11 On 2 wh...

Page 1472: ...ht coat of petroleum jelly to shift shaft bushing bearing in rear housing Fig 96 6 Reach into countershaft rear bearing with fin ger and push each bearing roller outward against race Then apply extra...

Page 1473: ...gages to the countershaft before the rear output shaft bearing engages the housing Fig 94 REAR HOUSING DOWELS 1 HOUSING ALIGNMENT DOWELS 2 REAR HOUSING 3 DOWEL FLUSH WITH SURFACE Fig 95 COUNTERSHAFT R...

Page 1474: ...jelly to countershaft rear bearing and bearing race 5 Install countershaft rear bearing in bearing race Fig 96 CAUTION Be sure the large diameter side of the roller retainer faces the countershaft an...

Page 1475: ...everse fork arms as shown 3 Slide the end of shift shaft with shaft detent notches through 3 4 shift fork 4 Assemble shift shaft shift lever and bushing Fig 104 Be sure slot in bushing is facing up an...

Page 1476: ...into shaft lever by hand Fig 109 11 Seat shaft lever roll pin with pin punch Fig 110 CAUTION The shaft lever roll pin must be flush with the surface of the lever The lever bushing will bind on the rol...

Page 1477: ...4 Small diameter side goes toward bearing race in housing 4 Reach into countershaft front bearing with fin ger and push each bearing roller outward against race Then apply extra petroleum jelly to hol...

Page 1478: ...re tapped back into place 10 Place transmission in horizontal position 11 Apply Mopar Gasket Maker or equivalent to housing attaching bolts Apply sealer material sealer to underside of bolt heads and...

Page 1479: ...etent plug into transmission case until plug seats 17 Install backup light switch Fig 119 18 Install input shaft snap ring Fig 120 Fig 116 HOUSING BOLTS 1 HOUSING ATTACHING BOLTS APPLY SEALER BEFOREHA...

Page 1480: ...FT TOWER AND LEVER 1 Apply petroleum jelly to ball end of shift lever and interior of shift socket 2 Shift the transmission into third gear 3 Align and install shift tower and lever assem bly Fig 125...

Page 1481: ...ove transmission forward and start input shaft in clutch disc 6 Work transmission forward until seated against engine Do not allow transmission to remain unsup ported after input shaft has entered clu...

Page 1482: ...bricant Check lubricant level in transfer case and add lubri cant if necessary 15 Install transfer case skid plate if equipped and crossmember Tighten attaching bolts nuts to 41 N m 30 ft lbs 16 Insta...

Page 1483: ...NUAL NV3550 Remover Seal C 3985 B Installer Seal C 3972 A Remover Bushing 6957 Installer Bushing 6951 Handle C 4171 Remover Plug 8117 Remover Installer 6858 Fixture 6747 21 74 MANUAL NV3500 AN MANUAL...

Page 1484: ...7 2B Cup Adapter 8115 Splitter Bearing 1130 Tube 6310 1 Installer Bushing 8118 Remover Installer 8119 Pin Alignment 8120 Installer Seal C 3860 A Installer 8123 Installer Cone 6448 AN MANUAL NV3500 21...

Page 1485: ...3972 A and Handle C 4171 Fig 129 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines 4 Install propeller shaft with reference marks aligned 5 Remove support and lowe...

Page 1486: ...ransmission must be level to obtain an accu rate lubricant level check A drive on type of hoist is recommended for this purpose The lubricant capacity is approximately 2 28 liters 4 8 pints This is th...

Page 1487: ...FILTER DIAGNOSIS AND TESTING 144 EFFECTS OF INCORRECT FLUID LEVEL 144 CAUSES OF BURNT FLUID 144 FLUID CONTAMINATION 144 STANDARD PROCEDURE 144 FLUID LEVEL CHECK 144 FLUID AND FILTER REPLACEMENT 145 T...

Page 1488: ...ASSEMBLY 245 INSTALLATION 253 ADJUSTMENTS 254 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...

Page 1489: ...Fig 1 42RE Transmission 21 80 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1490: ...switch 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 P...

Page 1491: ...ub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the park ing...

Page 1492: ...transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear out put The entir...

Page 1493: ...in a clockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direction The rear planet ca...

Page 1494: ...y 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...

Page 1495: ...ive 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 t...

Page 1496: ...AND 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 DR...

Page 1497: ...n fourth gear the overdrive clutch is slipping Simi larly if the direct clutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the t...

Page 1498: ...e 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 posi...

Page 1499: ...n to vehicle speed Or approximately 6 89 kPa 1 psi for every 1 mph 6 Governor pressure rise should be smooth and drop back to no more than 20 6 kPa 3 psi after engine returns to curb idle and brakes a...

Page 1500: ...hten around the drum Spring pressure should release the servo when air pressure is removed Rear Servo Air Test Apply air pressure to the rear servo apply passage The servo rod should extend and cause...

Page 1501: ...down lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with...

Page 1502: ...LAYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Fluid Level Low 1 Correct level and check for leaks 2 Filter Clogged 2 Change filter 3 Gearshift Linkage Mis adjusted 3 Adjust linkage and repair li...

Page 1503: ...d reassemble linkage as needed Replace worn damaged parts 3 U Joint Axle Transfer Case Broken 3 Perform preliminary inspection procedure for vehicle that will not move Refer to procedure in diagnosis...

Page 1504: ...fective gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Mis adjusted Damaged 1 Repair or replace linkage parts as needed 2 Park Sprag Sticking 2 Replace overdri...

Page 1505: ...nction 5 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 PC...

Page 1506: ...rmine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level...

Page 1507: ...ages in case 5 Servo Band or Linkage Malfunction 5 Air pressure check servo operation and repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears...

Page 1508: ...URS IMMEDIATELY AFTER 2 3 SHIFT 1 Overdrive Solenoid Connector or Wiring Shorted 1 Test connector and wiring for loose connections shorts or ground and repair as needed 2 TPS Malfunction 2 Test TPS an...

Page 1509: ...ine no start 7 PCM Malfunction 7 Check with DRB scan tool and replace if necessary 8 Overdrive Solenoid Shorted Open 8 Replace solenoid if shorted or open and repair loose or damaged wires DRB scan to...

Page 1510: ...shaft 7 O D Check Valve Bleed Orifice Failure 7 Check for function secure orifice insert in O D piston retainer DELAYED 3 4 UPSHIFT SLOW TO ENGAGE 1 Fluid Level Low 1 Add fluid and check for leaks 2 T...

Page 1511: ...air 5 Valve Body Manual Lever Assembly Bent Worn Broken 5 Inspect lever assembly and replace if damaged NO REVERSE OR SLIPS IN REVERSE 1 Direct Clutch Pack front clutch Worn 1 Disassemble unit and reb...

Page 1512: ...out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn Damaged 11 Replace seal 12 Torque Converter Weld Leak Cracked Hub 12 Replace converter 13 Case Porosity Leak...

Page 1513: ...rain fluid and reinstall pan 19 Remove fill tube bracket bolts and pull tube out of transmission Retain fill tube seal On 4x4 models it will also be necessary to remove bolt attaching transfer case ve...

Page 1514: ...ve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 18 11 Remove accumulator piston and inner and outer springs Fig 19 12 Remove pump oil s...

Page 1515: ...ody Bolt Locations 1 VALVE BODY BOLTS 2 VALVE BODY BOLTS Fig 18 Valve Body Removal 1 GOVERNOR PRESSURE SENSOR 2 VALVE BODY 3 PARK ROD 4 ACCUMULATOR PISTON 5 GOVERNOR PRESSURE SOLENOID Fig 19 Accumulat...

Page 1516: ...haft or from rear clutch hub Fig 25 25 Remove output shaft thrust plate from inter mediate shaft hub Fig 26 Fig 21 Removing Front Band Strut 1 BAND LEVER 2 BAND STRUT 3 FRONT BAND Fig 22 Removing Fron...

Page 1517: ...hes dur ing service of main transmission components 29 Loosen rear band adjusting screw 4 5 turns 30 Remove low reverse drum snap ring Fig 29 Fig 25 Removing Intermediate Shaft Thrust Washer 1 INTERME...

Page 1518: ...oughly 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 passages are clear NOTE Do not use shop towels or rags to dr...

Page 1519: ...ansmission case and compo nents clean Also make sure the tools and workbench area used for assembly operations are equally clean Shop towels used for wiping off tools and hands must be made from lint...

Page 1520: ...on drum hub into overrunning clutch rollers d Press drum rearward and turn it in clock wise direction until drum seats in overrunning clutch Fig 37 Fig 33 Rear Servo Components 1 SERVO PISTON 2 PISTON...

Page 1521: ...seal ring on rear clutch retainer hub and seal rings on input shaft Fig 42 Also verify that shaft seal rings are installed in sequence shown 12 Install rear clutch thrust washer Fig 43 Use additional...

Page 1522: ...possible and support case with wood blocks Front rear clutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible 17 Slide front band into case 18...

Page 1523: ...lutch retainer Verify that front rear clutches are still seated before continuing Fig 45 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT THRUST WASHER 2 INPUT SHAFT 3 REAR CLUTCH RETAI...

Page 1524: ...rmediate shaft thrust 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 assem...

Page 1525: ...35 in lbs 34 Adjust front and rear bands 35 Install new valve body manual shaft seal in case Fig 54 Lubricate seal lip and manual shaft with petroleum jelly Start seal over shaft and into case Seat s...

Page 1526: ...rear of the crankshaft with a light coating of Mopar High Temp Grease 4 Align and install converter in oil pump 5 Carefully insert converter in oil pump Then rotate converter back and forth until full...

Page 1527: ...s be used to attach the converter to the driveplate Bolts that are too long will damage the clutch surface inside the converter 19 Install torque converter to driveplate bolts Tighten bolts to 31 N m...

Page 1528: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK AN AUTOMATIC TRANSMISSION 42RE 21 119 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1529: ...HYDRAULIC FLOW IN NEUTRAL 21 120 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1530: ...HYDRAULIC FLOW IN REVERSE AN AUTOMATIC TRANSMISSION 42RE 21 121 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1531: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 122 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1532: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR AN AUTOMATIC TRANSMISSION 42RE 21 123 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1533: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED 21 124 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1534: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED AN AUTOMATIC TRANSMISSION 42RE 21 125 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1535: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 126 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1536: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED AN AUTOMATIC TRANSMISSION 42RE 21 127 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1537: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 128 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1538: ...HYDRAULIC FLOW IN MANUAL SECOND 2 AN AUTOMATIC TRANSMISSION 42RE 21 129 AUTOMATIC TRANSMISSION 42RE Continued...

Page 1539: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING 21 130 AUTOMATIC TRANSMISSION 42RE AN AUTOMATIC TRANSMISSION 42RE Continued...

Page 1540: ...1 REVERSE 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 m...

Page 1541: ...ransmission 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 b...

Page 1542: ...lot 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 1543: ...staller 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...

Page 1544: ...ller Bushing SP 5325 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 AN AUTOMATIC TRANSMI...

Page 1545: ...down servo As the line pressure reaches the accumulator the com bination of spring pressure and line pressure forces the piston away from the accumulator plate This causes a balanced pressure situatio...

Page 1546: ...band is a single wrap design the band does not completely encompass wrap the drum that it holds LOW REVERSE REAR BAND The low reverse band or rear band Fig 64 is similar in appearance and operation to...

Page 1547: ...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 with Inch Pound Torque Wrench C 3380 A a 3 in extens...

Page 1548: ...vernor pressure sensor measures output pres sure of the governor pressure solenoid valve Fig 68 GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to supply transmis sion line pressure to...

Page 1549: ...GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body It also channels governor pressure from the solenoid valve to the governor c...

Page 1550: ...essure solenoid retainer to governor body 5 Separate solenoid retainer from governor Fig 70 6 Pull solenoid from governor body Fig 71 7 Pull pressure sensor from governor body 8 Remove bolts holding g...

Page 1551: ...position on governor Fig 75 11 Install screws to hold pressure solenoid retainer to governor body 12 Engage wire connectors into pressure sensor and solenoid Fig 76 13 Install transmission fluid pan a...

Page 1552: ...cle 2 Mark propeller shaft and axle yoke or compan ion flange for alignment reference 3 Disconnect and remove propeller shaft 4 Remove old seal with Seal Remover C 3985 B Fig 79 from overdrive extensi...

Page 1553: ...ion 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 g...

Page 1554: ...EUTRAL 6 Clean top of filler tube and dipstick to keep dirt from entering tube 7 Remove dipstick Fig 81 and check fluid level as follows a Correct acceptable level is in crosshatch area b Correct maxi...

Page 1555: ...d pour fluid in filter into drain pan 11 Dispose of used trans fluid and filter properly Fig 82 42 44RE Fluid Fill Graph Fig 83 Transmission Pan 1 TRANSMISSION 2 GASKET 3 PAN Fig 84 Transmission Filte...

Page 1556: ...dipstick in fill tube FRONT CLUTCH DESCRIPTION The front clutch assembly Fig 85 is composed of the front clutch retainer pressure plate clutch plates driving discs piston piston return spring return...

Page 1557: ...ner before compress ing spring 3 Remove retainer snap ring and remove com pressor tool 4 Remove spring retainer and clutch spring Note position of retainer on spring for assembly reference Fig 85 Fron...

Page 1558: ...ainer piston bore and clutch retainer hub Discard both seals as they are not reusable Fig 86 42RE Front Clutch Components 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLU...

Page 1559: ...the piston and or retainer if the seal surfaces are seriously scored ASSEMBLY NOTE The 42RE transmission uses four plates and discs for the front clutch 1 Soak clutch discs in transmission fluid whil...

Page 1560: ...en the two lands of the pis ton The pressure acts against the larger lower land to push the piston downward allowing the piston rod to extend though its guide against the apply lever Release of the se...

Page 1561: ...warped Check the servo piston bore for wear If the bore is severely scored or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse...

Page 1562: ...tion Normal position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift lever Transmission shall not be able to shift from neutr...

Page 1563: ...ounting at Dash Panel 4X4 1 DASH PANEL 2 GEARSHIFT CABLE MOUNTING BRACKET 3 GEARSHIFT CABLE Fig 99 Gearshift Cable at Steering Column 1 STEERING COLUMN 2 GEARSHIFT CABLE 3 GEARSHIFT CABLE LOCK TAB Fig...

Page 1564: ...transmission range sensor 10 Adjust the gearshift cable as necessary ADJUSTMENTS GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL Adjustment is CORRECT if the engine starts...

Page 1565: ...over that also serves as the reaction shaft support OPERATION As the torque converter rotates the converter hub rotates the inner and outer gears As the gears rotate the clearance between the gear tee...

Page 1566: ...ther diagnosis 4 Re connect the To cooler line to the transmis sion cooler inlet 5 Refill the transmission to proper level DISASSEMBLY 1 Remove seal ring from housing and reaction shaft support Fig 10...

Page 1567: ...rench 3 Turn remover 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 remove...

Page 1568: ...ow ing the instructions supplied with it Clearance between inner gear tooth and outer gear should be 0 08 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge Clearance be...

Page 1569: ...e b Secure pump assembly in case with 2 or 3 bolts or with pilot studs c Tighten support to pump bolts to 20 N m 15 ft lbs d Remove pump assembly from transmission case 12 Install new oil seal in pump...

Page 1570: ...t in the transmission overdrive unit and is considered a holding component The overdrive piston retainer piston and piston spacer are located on the rear of the main transmission case NOTE The number...

Page 1571: ...off The overdrive OFF mode defaults to ON after the ignition 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...

Page 1572: ...ansfer 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 rem...

Page 1573: ...nit over drain pan Tilt unit to drain residual fluid from case 15 Examine fluid for clutch material or metal fragments If fluid contains these items overhaul will be necessary 16 If overdrive unit doe...

Page 1574: ...ce Fig 136 Fig 131 Overdrive Piston Thrust Plate Removal 1 OVERDRIVE PISTON 2 OVERDRIVE PISTON SPACER SELECT FIT Fig 132 Intermediate Shaft Spacer Location 1 INTERMEDIATE SHAFT 2 INTERMEDIATE SHAFT SP...

Page 1575: ...Fig 140 Fig 136 42RE Overdrive Clutch Component Position 1 PRESSURE PLATE TO FRONT 2 OVERDRIVE CLUTCH PACK 3 CLUTCH DISC 3 4 CLUTCH PLATE 2 5 REACTION PLATE TO REAR Fig 137 Overdrive Clutch Wave 1 WA...

Page 1576: ...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 shop press...

Page 1577: ...Shop 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 145 Direct Clutch Pack Snap Ring Removal 1 CLUTCH HUB 2 SPECIAL TOOL 6227 1 3...

Page 1578: ...from hub 6 Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 151 Use small center punch or scriber to make alignment marks Fig 147 Direct Clutch Pack Removal 1...

Page 1579: ...t GEAR CASE AND PARK LOCK 1 Remove locating ring from gear case 2 Remove park pawl shaft retaining bolt and remove shaft pawl and spring 3 Remove reaction plug snap ring and remove reaction plug 4 Rem...

Page 1580: ...if collapsed distorted or cracked Be sure the splines and lugs on the gear drum and hub are in good condition The clutch plates and discs should slide freely in these components Inspect the thrust be...

Page 1581: ...Fig 159 Be sure drum is engaged in annulus gear lugs 5 Install clutch drum outer retaining ring Fig 159 6 Slide clutch drum forward and install inner retaining ring Fig 160 7 Install rear bearing and...

Page 1582: ...ar in annulus gear Fig 164 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 generous amoun...

Page 1583: ...planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 167 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proceeding 17 Install...

Page 1584: ...h hub and clutch pack on direct clutch spring Fig 172 Be sure hub is started on sun gear splines before proceeding WARNING THE NEXT STEP IN GEARTRAIN ASSEM BLY INVOLVES COMPRESSING THE DIRECT CLUTCH H...

Page 1585: ...ted in clutch drum ring groove 25 Install clutch hub retaining ring Fig 174 Be very sure retaining ring is fully seated in sun gear ring groove 26 Slowly release press ram remove compressor tools and...

Page 1586: ...r bearing locating ring extend into access hole in gear case Fig 177 7 Support geartrain on Tool 6227 1 Fig 178 Be sure tool is securely seated in clutch hub 8 Install overdrive gear case on geartrain...

Page 1587: ...stall overdrive clutch reaction plate first NOTE The reaction plate is thinner than the pres sure plate in a 42RE transmission Fig 177 Correct Rear Bearing Locating Ring Position 1 CASE ACCESS HOLE 2...

Page 1588: ...nal components are moved rearward for accurate measurement 2 Determine correct thickness intermediate shaft spacer as follows a Insert Special Tool 6312 through sun gear planetary gear and into pilot...

Page 1589: ...ial Caliper C 4962 over gauge tool Fig 187 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and dividing by 4 c Select and install...

Page 1590: ...nd piston retainer with razor knife Fig 189 4 Use old gasket as template and trim new gas ket to fit 5 Position new gasket over piston retainer and on transmission case Use petroleum jelly to hold gas...

Page 1591: ...lockwise the action causes the rollers to roll in the same direction as the race aided by the pushing of the springs As the rollers try to move in the same direction as the inner race they are wedged...

Page 1592: ...talled Bolt holes in cam are slightly countersunk on one side Be sure this side of cam faces rearward toward piston retainer 4 Verify that non threaded hole in clutch cam is properly aligned Check ali...

Page 1593: ...to the two mating holes in retainer b Lubricate overdrive piston seals with Mopar Door Ease or equivalent c Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 d Push overdrive piston...

Page 1594: ...is not confined It will simply leak past the piston There must be a resistance to flow in order to create pressure Piston sealing is extremely important in hydraulic operation Several kinds of seals...

Page 1595: ...to move ten times the distance required to move the larger piston one inch There fore for every inch the larger piston moves the smaller piston moves ten inches This principle is true in other instan...

Page 1596: ...netary gears Fig 206 6 Remove front planetary gear front thrust washer from annulus gear hub 7 Separate and remove driving shell rear plane tary and rear annulus from output shaft Fig 207 8 Remove fro...

Page 1597: ...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 Assemble...

Page 1598: ...ng Rear Planetary Front Thrust Washer 1 FRONT TABBED THRUST WASHER 2 REAR PLANETARY GEAR Fig 211 Installing Spacer On Sun Gear 1 SUN GEAR 2 SUN GEAR SPACER Fig 212 Installing Driving Shell Front Thrus...

Page 1599: ...washer on front planetary gear Fig 217 Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 14 Install front planetary gear on output shaft and in driving she...

Page 1600: ...r forward end of output shaft This allows geartrain compo nents to move forward for accurate end play check 23 Check planetary geartrain end play with feeler gauge Fig 223 Gauge goes between shoulder...

Page 1601: ...1 Installing Front Annulus Snap Ring 1 SNAP RING PLIERS 2 FRONT ANNULUS SNAP RING Fig 222 Installing Planetary Selective Snap Ring 1 SELECTIVE SNAP RING 2 SNAP RING PLIERS Fig 223 Checking Planetary G...

Page 1602: ...ays 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 c...

Page 1603: ...piston seals 7 Remove input shaft snap ring Fig 226 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 1604: ...ed 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 229 Use a suitably sized press tool to suppo...

Page 1605: ...C REAR SEAL RING 2 TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT Fig 229 Pressing Input Shaft Into Rear Clutch Retainer 1 INPUT SHAFT 2 REAR CLUTCH RETAINER...

Page 1606: ...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 pressure applied the piston is held up in its bore by the pi...

Page 1607: ...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...

Page 1608: ...e that can completely fill the available space within the solenoid housing The strength of the spring and the length of the plunger also contribute to the response speed possi ble by a particular sole...

Page 1609: ...tle valve cable to lock in the adjustment ADJUSTMENTS TRANSMISSION THROTTLE VALVE CABLE A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneou...

Page 1610: ...hment stud Carefully slide cable off stud Do not pry or pull cable off 4 Verify that transmission throttle lever is in fully closed position Then be sure lever on throttle body is at curb idle positio...

Page 1611: ...ll with an internal turbine a stator an overrunning clutch an impeller and an electronically applied con verter clutch The converter clutch provides reduced engine speed and greater fuel economy when...

Page 1612: ...the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 243 Impeller 1 ENGINE FLEXPLATE 4 EN...

Page 1613: ...through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 244 Turbi...

Page 1614: ...gs to slip If the impeller and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to t...

Page 1615: ...tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine begins to match the speed of the impeller the fl...

Page 1616: ...d 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 transmission 3 Align torque converter to o...

Page 1617: ...ion occurs that gener ates significant amounts of sludge and or clutch par ticles and metal shavings the valve must be replaced The valve must be removed whenever the cooler and lines are reverse flus...

Page 1618: ...in PARK or NEUTRAL providing a ground for the sig nal from the starter relay and the JTEC engine con troller OPERATION As the switch moves through its linear motion Fig 252 contacts slide across a cir...

Page 1619: ...suitable hoist 2 Disconnect the vehicle s shift cable from the manual lever 3 With the manual lever in the PARK position the PARK position is with the manual lever moved to the full rearward position...

Page 1620: ...ance is not correct replace the TRS 11 With the manual lever in the SECOND posi tion the SECOND position is with the manual lever moved one detent rearward of the full forward posi tion measure the re...

Page 1621: ...operation Fig 258 6 Move the transmission manual shaft lever to the PARK position 7 Connect TRS wiring connector to the TRS and lower vehicle 8 Refill the transmission fluid to the correct level Fig 2...

Page 1622: ...ow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and transfer plat...

Page 1623: ...TOR 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...

Page 1624: ...NER 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...

Page 1625: ...RING 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 THRO...

Page 1626: ...14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 C...

Page 1627: ...Directs 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 fron...

Page 1628: ...increase Oil pressure on the opposite end of the valve pushes the valve to the right opening the dump and lowering oil pressure The result is spring pressure working against oil pressure to maintain...

Page 1629: ...spring decreases the size of the metering passage When the size of the metering passage is reduced the pressure rises again and the size of the land is increased again Pressure is regulated by this co...

Page 1630: ...Fig 266 Regulator Valve in DRIVE Position Fig 267 Regulator Valve in REVERSE Position AN AUTOMATIC TRANSMISSION 42RE 21 221 VALVE BODY Continued...

Page 1631: ...ight 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...

Page 1632: ...ottom 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...

Page 1633: ...d build 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...

Page 1634: ...Thus the 1 2 shift point is cushioned and the quality is improved During a WOT kickdown kickdown pres sure is applied between the kickdown valve and the 1 2 shift control valve This additional pressu...

Page 1635: ...ng line pres sure from the 2 3 shift valve to act directly on the 3 4 upshift valve Line pressure on the 3 4 shift valve overcomes valve spring pressure moving the valve to the upshift position Fig 27...

Page 1636: ...Fig 275 2 3 Shift Valve After Shift Fig 276 3 4 Shift Valve Before Shift Fig 277 3 4 Shift Valve After Shift AN AUTOMATIC TRANSMISSION 42RE 21 227 VALVE BODY Continued...

Page 1637: ...pressure 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 a...

Page 1638: ...ansmis sion Once the TCC control valve has moved to the right Fig 280 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 fr...

Page 1639: ...mechanism 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...

Page 1640: ...huttle 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...

Page 1641: ...levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 284 5 Remove the transmission range sensor 6 Position drain pan under transmission oil pan 7 Remove tran...

Page 1642: ...ight 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 286...

Page 1643: ...lever out of valve body Fig 288 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 289 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLENOID 3 SOLE...

Page 1644: ...te Fig 297 Hold bracket firmly against spring tension while removing last screw Fig 292 Detent Ball And Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 293 Park Rod 1 MANUAL LEVER 2 E CLIP...

Page 1645: ...taching screws Fig 300 22 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 301 23 Remove left side screw and remove 3 4...

Page 1646: ...ERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 300 Accumulator Housi...

Page 1647: ...in in diameter 30 Remove transfer plate from upper housing Fig 307 31 Turn transfer plate over so upper housing sep arator plate is facing upward 32 Remove upper housing separator plate from transfer...

Page 1648: ...FER PLATE Fig 308 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PLATE 3 FILTER SCREEN 4 BRACE Fig 309 Rear Clutch And Rear Servo Check Ball 1 REAR CLUTCH CHECK BALL 2 REAR S...

Page 1649: ...r housing around and remove limit valve and shift valve covers Fig 313 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 313 9 Rem...

Page 1650: ...INER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING...

Page 1651: ...RING 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 THRO...

Page 1652: ...rings 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...

Page 1653: ...his will damage the valve housing INSPECTION Inspect the throttle and manual valve levers and shafts Do not attempt to straighten a bent shaft or correct a loose lever Replace these components if worn...

Page 1654: ...enoid governor pressure sensor and retaining clip park lock rod and E clip ASSEMBLY CAUTION Do not force valves or plugs into place during reassembly If the valve body bores valves and plugs are free...

Page 1655: ...r 4 Position lower housing separator plate on transfer plate Fig 321 5 Install lower housing on assembled transfer plate and upper housing Fig 322 6 Install and start all valve body screws by hand exc...

Page 1656: ...econd ary spring and install spring on end of valve b Install shuttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E clip in groove at end of shuttle valve...

Page 1657: ...INER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING...

Page 1658: ...TOR 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...

Page 1659: ...to valve body housings Fig 327 7 Bend tube brace tabs up and against tube to hold it in position Fig 328 8 Tighten all valve body housing screws to 4 N m 35 in lbs torque after tube and brace are ins...

Page 1660: ...tor housing upward over valve springs and plug 7 Hold accumulator housing firmly in place and install remaining two attaching screws Be sure springs and clutch valve plug are properly seated Fig 330 T...

Page 1661: ...ve springs and bracket are properly aligned Then tighten all three bracket screws to 4 N m 35 in lbs torque 17 Perform Line Pressure and Throttle Pressure adjustments Refer to 21 TRANSMISSION TRAN SAX...

Page 1662: ...ing shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly 7 Position valve body in case and work end of park lock rod into and through pawl sprag Turn...

Page 1663: ...e performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting...

Page 1664: ...screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed...

Page 1665: ...AGNOSIS AND TESTING 325 EFFECTS OF INCORRECT FLUID LEVEL 325 CAUSES OF BURNT FLUID 325 FLUID CONTAMINATION 325 STANDARD PROCEDURE 326 FLUID LEVEL CHECK 326 FLUID AND FILTER REPLACEMENT 327 TRANSMISSIO...

Page 1666: ...STALLATION 437 ADJUSTMENTS 438 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 clut...

Page 1667: ...Fig 1 46RE Transmission 21 258 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1668: ...ue 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 1669: ...b 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 s...

Page 1670: ...ransferred 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 1671: ...n 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 car...

Page 1672: ...y 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...

Page 1673: ...ive 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 t...

Page 1674: ...AND 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 DRI...

Page 1675: ...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 1676: ...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 posit...

Page 1677: ...n to vehicle speed Or approximately 6 89 kPa 1 psi for every 1 mph 6 Governor pressure rise should be smooth and drop back to no more than 20 6 kPa 3 psi after engine returns to curb idle and brakes a...

Page 1678: ...lease the servo when air pressure is removed Rear Servo Air Test Apply air pressure to the rear servo apply passage The servo rod should extend and cause the band to tighten around the drum Spring pre...

Page 1679: ...ns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jell...

Page 1680: ...AYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Fluid Level Low 1 Correct level and check for leaks 2 Filter Clogged 2 Change filter 3 Gearshift Linkage Mis adjusted 3 Adjust linkage and repair lin...

Page 1681: ...d reassemble linkage as needed Replace worn damaged parts 3 U Joint Axle Transfer Case Broken 3 Perform preliminary inspection procedure for vehicle that will not move Refer to procedure in diagnosis...

Page 1682: ...ective gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Mis adjusted Damaged 1 Repair or replace linkage parts as needed 2 Park Sprag Sticking 2 Replace overdriv...

Page 1683: ...nction 5 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 PC...

Page 1684: ...ure Too Low 6 Perform hydraulic pressure tests to determine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as...

Page 1685: ...Faulty 7 Perform air pressure check and repair as required 8 Front and Rear Bands Mis adjusted 8 Adjust bands DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 2 Clutch Dragging Failed 2 A...

Page 1686: ...eized or shorted 3 PCM Malfunction 3 Test with DRB scan tool Replace PCM if faulty 4 Valve Body Stuck Valves 4 Repair stuck 3 4 lockup or lockup timing valve CLUNK NOISE FROM DRIVELINE ON CLOSED THROT...

Page 1687: ...Wire Shorted Cut 6 Test switch sensor as described in service section and replace if necessary Engine no start 7 PCM Malfunction 7 Check with DRB scan tool and replace if necessary 8 Overdrive Soleno...

Page 1688: ...ve piston and clutch hub NO 2 thrust bearing is between the planetary gear and the direct clutch spring plate NO 3 thrust bearing is between overrunning clutch hub and output shaft 7 O D Check Valve B...

Page 1689: ...e Sensor Faulty 3 Refer to service section for test and replacement procedure 4 Park Neutral Switch or Transmission Range Sensor Connection Faulty 4 Connectors spread open Repair 5 Valve Body Manual L...

Page 1690: ...s 10 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pum...

Page 1691: ...mounts 11 Remove bolts holding the engine to transmis sion brackets to the front axle if equipped 12 Loosen bolts attaching engine to transmission brackets to each side of the engine block 13 Raise en...

Page 1692: ...dial indicator plunger against a flat spot on the oil pump and zero the dial indica tor e Move input shaft in and out and record read ing Record the maximum travel for assembly ref erence 4 Remove thr...

Page 1693: ...for assembly reference Remove and discard piston seals if worn or cut 11 Remove pump oil seal with suitable pry tool or slide hammer mounted screw 12 Remove front band lever pin access plug Fig 20 Use...

Page 1694: ...case Fig 23 14 Remove oil pump gasket Fig 24 Note gas ket position in case for assembly reference 15 Loosen front band adjusting screw until band is completely loose 16 Remove front band strut and anc...

Page 1695: ...e intermediate shaft thrust washer Tri angular shaped washer will either be on shaft pilot hub or in rear clutch retainer Fig 29 Fig 23 Oil Pump Removal 1 OIL PUMP AND REACTION SHAFT SUPPORT Fig 24 Oi...

Page 1696: ...verse drum and thrust washer off piston retainer hub and out of rear band Fig 33 27 Note that overrunning clutch race will remain on splines of low reverse drum after removal Fig 34 The race is a perm...

Page 1697: ...servo rod guide with large C clamp and Tool C 4470 or Compressor Tool C 3422 B Fig 38 Compress guide only enough to permit snap ring removal about 1 8 in Fig 31 Intermediate Shaft And Planetary Geartr...

Page 1698: ...tart one end of ring out of bore Then carefully work 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 c...

Page 1699: ...rocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital as they pre vent forei...

Page 1700: ...piston 4 Compress rear servo piston with C clamp or Valve Spring Compressor C 3422 B and install servo piston snap ring Fig 42 5 Lubricate front servo piston components and servo bore in case with tr...

Page 1701: ...g 45 3 Install low reverse drum Fig 46 Slide drum through rear band onto piston retainer hub and into engagement with overrunning clutch and race 4 Install thrust washer in low reverse drum spot face...

Page 1702: ...46 Low Reverse Drum 1 LOW REVERSE DRUM 2 REAR BAND LINK 3 HUB OF OVERDRIVE PISTON RETAINER Fig 47 Low Reverse Drum Snap Ring 1 LOW REVERSE DRUM 2 TABBED WASHER 3 SNAP RING Fig 48 Rear Band Reaction Pi...

Page 1703: ...quare cut ends of front seal rings are firmly seated against each other Lubricate seal rings with petroleum jelly after checking them 5 Assemble front and rear clutches Fig 53 Align lugs on front clut...

Page 1704: ...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 front clutch retainer...

Page 1705: ...mp seals with petroleum Mopar ATF 4 type 9602 6 Mount oil pump on pilot studs and slide pump into case opening Fig 60 Work pump into case by hand Do not use a mallet or similar tools to seat pump 7 Re...

Page 1706: ...nsmission and tighten the retaining screw on Adapter 8266 5 to secure it to the input shaft d Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indica tor e Mov...

Page 1707: ...nd transmis sion failure can result if not done 6 Install torque converter Use C clamp or metal strap to hold converter in place for installation BAND ADJUSTMENT AND FINAL 1 Adjust front and rear band...

Page 1708: ...onnector and oxygen sensor Be sure that all transmission harnesses are properly routed CAUTION It is essential that correct length bolts be used to attach the converter to the driveplate Bolts that ar...

Page 1709: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK 21 300 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1710: ...HYDRAULIC FLOW IN NEUTRAL AN AUTOMATIC TRANSMISSION 46RE 21 301 AUTOMATIC TRANSMISSION 46RE Continued...

Page 1711: ...HYDRAULIC FLOW IN REVERSE 21 302 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1712: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR AN AUTOMATIC TRANSMISSION 46RE 21 303 AUTOMATIC TRANSMISSION 46RE Continued...

Page 1713: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 304 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1714: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED AN AUTOMATIC TRANSMISSION 46RE 21 305 AUTOMATIC TRANSMISSION 46RE Continued...

Page 1715: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED 21 306 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1716: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED AN AUTOMATIC TRANSMISSION 46RE 21 307 AUTOMATIC TRANSMISSION 46RE Continued...

Page 1717: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED 21 308 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1718: ...HYDRAULIC FLOW IN MANUAL LOW 1 AN AUTOMATIC TRANSMISSION 46RE 21 309 AUTOMATIC TRANSMISSION 46RE Continued...

Page 1719: ...HYDRAULIC FLOW IN MANUAL SECOND 2 21 310 AUTOMATIC TRANSMISSION 46RE AN AUTOMATIC TRANSMISSION 46RE Continued...

Page 1720: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING AN AUTOMATIC TRANSMISSION 46RE 21 311 AUTOMATIC TRANSMISSION 46RE Continued...

Page 1721: ...DIMENSIONS Component Metric Inch Front clutch thrust washer reaction shaft support hub 1 55 mm 0 061 in 2 15 mm 0 084 in 2 59 mm 0 102 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Int...

Page 1722: ...ransmission 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 b...

Page 1723: ...ng 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 B...

Page 1724: ...3SP 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 AN...

Page 1725: ...hing 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 Bu...

Page 1726: ...body Fig 66 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 Bushin...

Page 1727: ...nd or clutch is fully applied NOTE The accumulator is shown in the inverted position for illustrative purposes INSPECTION Inspect the accumulator piston and seal rings Fig 69 Replace the seal rings if...

Page 1728: ...Loosen band adjusting screw locknut Fig 72 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...

Page 1729: ...er plate Fig 74 GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve Fig 75 GOVERNOR BODY AND TRANSFER PLATE The transfer plate is des...

Page 1730: ...governor pressure One amp current produces zero kPa psi governor pres sure Zero amps sets the maximum governor pres sure The powertrain control module PCM turns on the trans control relay which suppli...

Page 1731: ...normal to initiate upshifts sooner The PCM compares elec tronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low...

Page 1732: ...nsor into governor body 7 Lubricate o ring on pressure solenoid with transmission fluid 8 Align pressure solenoid to bore in governor body Fig 81 9 Push solenoid into governor body 10 Place solenoid r...

Page 1733: ...new oil seal in housing using Seal Installer C 3995 A Fig 85 EXTENSION HOUSING SEAL REMOVAL 1 Raise vehicle 2 Mark propeller shaft and axle yoke for align ment reference 3 Disconnect and remove prope...

Page 1734: ...engine axle ratio combination needed to handle heavy loads DIAGNOSIS AND TESTING FLUID CONTAMINATION Transmission fluid contamination is generally a result of adding incorrect fluid failure to clean...

Page 1735: ...one minute with the vehicle on level ground The transmission fluid level can be checked two ways PROCEDURE ONE 1 Transmission fluid must be at normal operat ing temperature for accurate fluid level ch...

Page 1736: ...olding 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 transmissi...

Page 1737: ...ONT CLUTCH DESCRIPTION The front clutch assembly Fig 92 is composed of the front clutch retainer pressure plate clutch plates driving discs piston piston return spring return spring retainer and snap...

Page 1738: ...clutch piston inner and outer seals 7 Assemble Tool Handle C 4171 and Bushing Remover SP 3629 Fig 95 8 Insert remover tool in bushing and drive bush ing straight out of clutch retainer Fig 92 Front Cl...

Page 1739: ...ion of the check ball in the piston retainer The ball must move freely and not stick Replace the retainer bushing if worn scored or there is any doubt about bushing condition Inspect the piston and re...

Page 1740: ...t piston in bottom of retainer A thin strip of plastic about 0 015 0 020 in thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the...

Page 1741: ...is ton The pressure acts against the larger lower land to push the piston downward allowing the piston rod to extend though its guide against the apply lever Release of the servo at the 2 3 upshift is...

Page 1742: ...or warped Check the servo piston bore for wear If the bore is severely scored or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reu...

Page 1743: ...position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift lever Transmission shall not be able to shift from neutral to revers...

Page 1744: ...Steering Column 1 STEERING COLUMN 2 GEARSHIFT CABLE 3 GEARSHIFT CABLE LOCK TAB Fig 107 Gearshift Cable at Transmission RFE 1 GEARSHIFT CABLE 2 RFE TRANSMISSION 3 MANUAL LEVER Fig 108 Gearshift Cable...

Page 1745: ...le to the steering column shift lever Fig 111 by snapping the cable retaining ears into shifter bracket and snapping the cable eyelet on the steering column ball stud 8 Lock the shift cable adjustment...

Page 1746: ...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 between the gear te...

Page 1747: ...ly 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 21 338 AUTOMATIC TRANSMISSION 46RE...

Page 1748: ...vity facing down 2 Remove bushing with Tool Handle C 4171 and Bushing Remover SP 3550 Fig 117 REACTION SHAFT SUPPORT BUSHING REMOVAL 1 Assemble Cup Tool SP 3633 Nut SP 1191 and Bushing Remover SP 5301...

Page 1749: ...ined surfaces are worn 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...

Page 1750: ...tigage follow ing the instructions supplied with it Clearance between inner gear tooth and outer gear should be 0 08 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge F...

Page 1751: ...Bushing Installer Tools C 4171 and SP 5302 Then slide new bushing onto installer tool Fig 122 3 Start bushing in shaft Tap bushing into shaft until installer tool bottoms against support flange 4 Cle...

Page 1752: ...lts to 20 N m 175 in lbs torque 6 Install new pump seal with Installer Tool C 3860 A Fig 123 Use hammer or mallet to tap seal into place 7 Install new o ring on pump body Lubricate oil seal and o ring...

Page 1753: ...E 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 pressure is provid...

Page 1754: ...e 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 switch indicator light illuminates only when the overdrive switch...

Page 1755: ...ansfer 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 rem...

Page 1756: ...Position drain pan on workbench 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 15 Examine fluid for clutch material or metal fragments If fluid contains these items...

Page 1757: ...bly reference Fig 139 Fig 134 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PISTON 2 OVERDRIVE PISTON SPACER SELECT FIT Fig 135 Intermediate Shaft Spacer Location 1 INTERMEDIATE SHAFT...

Page 1758: ...and gasket Fig 143 Fig 139 Overdrive Clutch Component Position Typical 1 REACTION PLATE 2 CLUTCH PLATES 3 3 PRESSURE PLATE 4 CLUTCH DISCS 4 Fig 140 Overdrive Clutch Wave Spring Removal 1 WAVE SPRING...

Page 1759: ...NT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXI MATELY 830 POUNDS USE SPRING COMPRESSOR TOOL 6227 1 AND A HYDRAULIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHE...

Page 1760: ...utch hub retaining ring Fig 149 6 Release press load slowly and completely Fig 150 7 Remove Special Tool 6227 1 Then remove clutch pack from hub Fig 150 Fig 147 Geartrain Mounted In Shop Press 1 PRESS...

Page 1761: ...position of annulus gear and direct clutch drum for assembly alignment reference Fig 154 Use small center punch or scriber to make alignment marks Fig 150 Direct Clutch Pack Removal 1 SPECIAL TOOL 62...

Page 1762: ...rking Direct Clutch Drum And Annulus Gear For Assembly Alignment 1 DIRECT CLUTCH DRUM 2 HAMMER 3 PUNCH Fig 155 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2 DIRECT CLUTCH DRUM 3 AN...

Page 1763: ...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 distort...

Page 1764: ...overrunning 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 t...

Page 1765: ...lus gear before proceeding 12 Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly This will help hold bearing in place during installation...

Page 1766: ...1 CLUTCH DRUM 2 OVERRUNNING CLUTCH ASSEMBLY 3 EXPANDING TYPE SNAP RING PLIERS 4 CLUTCH DRUM 5 ANNULUS GEAR 6 OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT Fig 167 Planetary Gear Installation 1 P...

Page 1767: ...d with shoulder side facing upward Fig 174 19 Install clutch hub and clutch pack on direct clutch spring Fig 175 Be sure hub is started on sun gear splines before proceeding WARNING THE NEXT STEP IN G...

Page 1768: ...hub retaining ring Fig 172 46RE Direct Clutch Pack Components 1 CLUTCH DISCS 8 3 CLUTCH PLATES 7 2 PRESSURE PLATE 4 REACTION PLATE Fig 173 Correct Position Of Direct Clutch Reaction Plate 1 REACTION P...

Page 1769: ...Tighten bolt to 27 N m 20 ft lbs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 178 Be sure pin is seated in hole in case before installing snap ring 4 Install re...

Page 1770: ...ide case downward until locating ring locks in bearing groove and release snap ring 10 Install locating ring access cover and gasket in overdrive unit case Fig 183 Fig 179 Reaction Plug And Snap Ring...

Page 1771: ...ut into it Be sure unit is facing upward for access to direct clutch hub Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement 2 Determine correct...

Page 1772: ...Fig 187 Overdrive Clutch Pack Retaining Ring Installation 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig 188 Shaft End Play Measurement 1 SPECIAL TOOL 6312 2 SPECIAL TOOL 6311 3 SPECIAL TOOL C 4962 Fig 18...

Page 1773: ...drive piston retainer by a Aligning locating lugs on overdrive piston to the two mating holes in retainer b Lubricate overdrive piston seals with Mopart Door Ease or equivalent c Install piston over S...

Page 1774: ...occurs it will be nec essary to remove and disassemble overdrive unit to realign splines 11 Work overdrive unit forward on intermediate shaft until seated against transmission case 12 Install bolts at...

Page 1775: ...solvent Dry them with compressed air after clean ing INSPECTION Inspect condition of each clutch part after cleaning Replace the overrunning clutch roller and spring assembly if any rollers or springs...

Page 1776: ...Use blunt punch or chisel to stake case 11 Remove piston retainer from case Cover retainer with plastic sheeting or paper to keep it dust free 12 Clean case and cam thoroughly Be sure any chips shavin...

Page 1777: ...rive piston in overdrive piston retainer by aligning locating lugs on overdrive piston to the two mating holes in retainer a Aligning locating lugs on overdrive piston to the two mating holes in retai...

Page 1778: ...the fluid A good example of this is a cylinder filled with fluid and equipped with a piston that is closely fitted to the cylinder wall If a force is applied to the piston pressure will be developed...

Page 1779: ...ove an object PISTON TRAVEL The relationship between hydraulic lever and a mechanical lever is the same With a mechanical lever it s a weight to distance output rather than a pressure to area output U...

Page 1780: ...emove planetary snap ring from intermediate shaft Fig 209 Discard snap ring as it is not reus able 2 Remove front planetary gear and front annulus gear as assembly Fig 210 3 Remove front planetary gea...

Page 1781: ...SHER 3 SUN GEAR Fig 213 Sun Gear And Driving Shell Removal 1 INTERMEDIATE SHAFT 2 DRIVING SHELL 3 SUN GEAR Fig 214 Rear Planetary Thrust Washer Removal 1 SUN GEAR 2 REAR PLANETARY THRUST WASHER 3 DRIV...

Page 1782: ...ust 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 snap rings is not recommended ASSEMBL...

Page 1783: ...rs together and slide them onto shaft Be sure planetary pinions are seated on sun gear and that planetary carrier is seated on intermediate shaft 13 Place geartrain in upright position Rotate gears to...

Page 1784: ...hell Thrust Washer 1 TAB SLOTS 3 2 DRIVING SHELL 3 TABBED THRUST WASHER Fig 224 Installing Thrust Washer On Front Planetary Gear 1 TABBED THRUST WASHER 2 FRONT PLANETARY GEAR Fig 225 Assembling Front...

Page 1785: ...mp transferred through the control valves and passageways and enters the clutch through the hub of the reaction shaft support With pressure applied between the clutch retainer and piston the piston mo...

Page 1786: ...g motion 6 Remove and discard piston seals 7 Remove input shaft retaining ring It may be necessary to press the input shaft in slightly to relieve tension on the retaining ring 8 Press input shaft out...

Page 1787: ...r scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check condition of the fiber thrust washer and metal o...

Page 1788: ...tal tools will cut shave or score the seals 9 Install piston spring in retainer and on top of piston Concave side of spring faces downward toward piston 10 Install the spacer ring and wave spring into...

Page 1789: ...moves down over the plug The piston continues to move down until it hits the shoulder of the plug and fully applies the band The period of time from the initial application until the piston is against...

Page 1790: ...tch is in the ON position No upshift to fourth gear will occur if any of the fol lowing are true The transmission fluid temperature is below 10 C 50 F or above 121 C 250 F The shift to third is not ye...

Page 1791: ...it is controlled Some of the possibilities include variable force pulse width modulated con stant ON or duty cycle The variable force and pulse width modulated versions utilize similar methods to cont...

Page 1792: ...e adjustment ADJUSTMENTS TRANSMISSION THROTTLE VALVE CABLE A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneously with the throttle body le...

Page 1793: ...tion Fig 242 This will unlock the cable and allow for readjustment 6 Apply just enough tension on the T V cable B to remove any slack in the cable Pulling too tight will cause the T V lever on the tra...

Page 1794: ...t is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid If the...

Page 1795: ...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 244 Impeller 1 E...

Page 1796: ...Turbine 1 TURBINE VANE 4 PORTION OF TORQUE CONVERTER COVER 2 ENGINE ROTATION 5 ENGINE ROTATION 3 INPUT SHAFT 6 OIL FLOW WITHIN TURBINE SECTION AN AUTOMATIC TRANSMISSION 46RE 21 387 TORQUE CONVERTER Co...

Page 1797: ...gs to slip If the impeller and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to t...

Page 1798: ...tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine begins to match the speed of the impeller the fl...

Page 1799: ...d 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 transmission 3 Align torque converter to o...

Page 1800: ...he pressure line Other wise flow will be blocked and would cause an over heating condition and eventual transmission failure TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor TRS Fig...

Page 1801: ...tes R R R The transmission is hydraulically in REVERSE In the REVERSE gate N The transmission is transitioning between REVERSE and NEUTRAL Between the REVERSE and NEUTRAL gates N N N The vehicle is in...

Page 1802: ...the full rearward position measure the resistance between the Cluster Resistance Signal and the Clus ter Signal Return pins of the TRS The resistance should be 522 2 ohms If the resistance is not cor...

Page 1803: ...Move the transmission manual shaft lever to the manual LOW position 2 Install the TRS mounting bracket into the transmission case Using Adapter 8581 Fig 257 tighten the mounting bracket to 34 N m 300...

Page 1804: ...all times OPERATION The PCM prevents engagement of the converter clutch and overdrive clutch when fluid temperature is below approximately 10 C 50 F If fluid temperature exceeds 126 C 260 F the PCM ca...

Page 1805: ...4 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 1806: ...NER 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...

Page 1807: ...RING 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 THRO...

Page 1808: ...14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 C...

Page 1809: ...nt of heat produced in the fluid The pres sure regulator valve is located in the valve body near the manual valve The pressure regulator valve train controls the maximum pressure in the lines by meter...

Page 1810: ...blishes the line pres sure throughout the transmission It is varied accord ing to changes in throttle position and the transmission s internal condition within a range of 57 94 psi except in REVERSE F...

Page 1811: ...Fig 266 Regulator Valve in NEUTRAL Position 21 402 AUTOMATIC TRANSMISSION 46RE AN VALVE BODY Continued...

Page 1812: ...Fig 267 Regulator Valve in DRIVE Position AN AUTOMATIC TRANSMISSION 46RE 21 403 VALVE BODY Continued...

Page 1813: ...drive 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 th...

Page 1814: ...Fig 269 Kickdown Valve Wide Open Throttle Fig 270 Kickdown Limit Valve Low Speeds AN AUTOMATIC TRANSMISSION 46RE 21 405 VALVE BODY Continued...

Page 1815: ...uild 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 1816: ...d spring and a throttle plug After the 1 2 shift valve has com pleted its operation and applied the front band line pressure is directed to the 2 3 shift valve through the connecting passages from the...

Page 1817: ...Fig 274 1 2 Shift Control Valve Fig 275 2 3 Shift Valve Before Shift 21 408 AUTOMATIC TRANSMISSION 46RE AN VALVE BODY Continued...

Page 1818: ...on the 3 4 upshift valve Line pressure on the 3 4 shift valve overcomes valve spring pressure moving the valve to the upshift position Fig 278 This action exposes the feed passages to the 3 4 timing v...

Page 1819: ...side of the throttle pres sure plug in the regulator valve The higher engine speed and line pressure would open the vent too far and reduce line pressure too much Throttle pressure which increases wi...

Page 1820: ...ns of the transmis sion Once the TCC control valve has moved to the right Fig 281 line pressure is directed to the tip of the switch valve forcing the valve to the right The switch valve now vents oil...

Page 1821: ...Fig 280 Switch Valve Torque Converter Unlocked 21 412 AUTOMATIC TRANSMISSION 46RE AN VALVE BODY Continued...

Page 1822: ...mechanism 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...

Page 1823: ...huttle 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...

Page 1824: ...levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 285 5 Remove the transmission range sensor 6 Position drain pan under transmission oil pan 7 Remove tran...

Page 1825: ...pulling it straight out of bore in governor body Remove and discard solenoid O rings if worn cut or torn 6 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator h...

Page 1826: ...all and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 297 Fig 289 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 290 Sole...

Page 1827: ...Fig 293 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING Fig 294 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD Fig 295 Throttle Lever E Clip And Washer 1 THROTTLE LEVER SHAFT 2 E CLIP...

Page 1828: ...ing attaching screws Fig 301 22 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 302 23 Remove left side screw and remo...

Page 1829: ...VERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 301 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW 2 REMOVE THESE SCREWS 3 3 4 ACCUMULATOR HOUSIN...

Page 1830: ...rom transfer plate Fig 306 29 Remove the ECE check ball from the transfer plate Fig 307 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 30 Remove transfer plate from upper housing Fig 3...

Page 1831: ...UPPER HOUSING Fig 307 ECE Check Ball 1 ECE CHECK BALL 3 169 Fig 308 Transfer Plate 1 UPPER HOUSING 2 TRANSFER PLATE Fig 309 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PL...

Page 1832: ...covers Fig 314 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 314 9 Remove 1 2 shift control valve and spring Fig 314 10 Remove...

Page 1833: ...NER 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...

Page 1834: ...RING 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 THRO...

Page 1835: ...rings 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...

Page 1836: ...en a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a s...

Page 1837: ...e 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 pl...

Page 1838: ...r 4 Position lower housing separator plate on transfer plate Fig 322 5 Install lower housing on assembled transfer plate and upper housing Fig 323 6 Install and start all valve body screws by hand exc...

Page 1839: ...econd ary spring and install spring on end of valve b Install shuttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E clip in groove at end of shuttle valve...

Page 1840: ...NER 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...

Page 1841: ...TOR 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...

Page 1842: ...RING 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 THRO...

Page 1843: ...clutch valve and 3 4 shift valve springs in housing Fig 330 2 Loosely attach accumulator housing with right side screw Fig 330 Install only one screw at this time as accumulator must be free to pivot...

Page 1844: ...witch 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 spr...

Page 1845: ...es 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 In...

Page 1846: ...has not displaced into this cavity 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 sprin...

Page 1847: ...ne complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases...

Page 1848: ...TRANSMISSION FILL 488 GEARSHIFT CABLE DIAGNOSIS AND TESTING 489 GEARSHIFT CABLE 489 REMOVAL 489 INSTALLATION 490 ADJUSTMENTS 491 HOLDING CLUTCHES DESCRIPTION 492 OPERATION 492 INPUT CLUTCH ASSEMBLY D...

Page 1849: ...d gear ratio 2prime allows smoother 4 2 kickdowns at high speeds to provide 2nd gear pass ing performance over a wider highway cruising range The hydraulic portion of the transmission consists of the...

Page 1850: ...w temperatures The hydraulic control system design without elec tronic assist provides the transmission with PARK REVERSE NEUTRAL SECOND and THIRD gears based solely on driver shift lever selection Th...

Page 1851: ...ning clutch or line pressure problems A slipping clutch can often be determined by com paring which internal units are applied in the vari ous gear ranges The Clutch Application chart provides a basis...

Page 1852: ...ssion for proper opera tion in each gear position that is in question or if a specific element is in question check the pressure readings in at least two gear positions that employ that element Refer...

Page 1853: ...ld also release DIAGNOSIS AND TESTING CONVERTER HOUSING FLUID LEAK When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exi...

Page 1854: ...e Then remove bolts one at a time Rotate crankshaft with socket wrench on dampener bolt 12 Disconnect wires from solenoid and pressure switch assembly input and output speed sensors and line pressure...

Page 1855: ...ecord the input shaft end play Fig 13 NOTE When measuring the input shaft end play two stops will be felt When the input shaft is pushed inward and the dial indicator zeroed the first stop felt when t...

Page 1856: ...emove the primary oil filter and the oil cooler return filter Fig 15 15 Remove the cooler return filter bypass valve 16 Remove the bolts holding the valve body to the transmission case Fig 16 17 Remov...

Page 1857: ...ing from the input clutch assembly Fig 19 24 Remove the input clutch assembly from the transmission case Fig 19 25 Remove the number 5 bearing and selective thrust plate from the input clutch assembly...

Page 1858: ...38 Remove the park sprag gear from the output shaft Fig 24 39 Remove the input reverse planetary assembly Fig 25 40 Remove the number 12 bearing from the input reverse planetary assembly Fig 25 41 Rem...

Page 1859: ...1 BEARING NUMBER 8 5 BEARING NUMBER 7 2 BEARING NUMBER 9 6 THRUST PLATE SELECT 3 REACTION PLANETARY CARRIER 7 BEARING NUMBER 6 4 REACTION SUN GEAR 8 REACTION ANNULUS 21 450 AUTOMATIC TRANSMISSION 45RF...

Page 1860: ...Fig 25 Remove Input Reverse Planetary Assembly 1 INPUT REVERSE PLANETARY ASSEMBLY 2 BEARING NUMBER 9 3 BEARING NUMBER 12 Fig 26 Remove Low Reverse Clutch Retainer 1 LOW REVERSE OVERRUNNING CLUTCH ASSE...

Page 1861: ...ls or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the t...

Page 1862: ...ows 10 Install the 2C reaction plate into the trans mission case Fig 31 The reaction plate is direc tional The plate must be installed with the flat side toward the front of the transmission 11 Instal...

Page 1863: ...ed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmis sion case 18 Install the snap ring to hold the low reverse clutch retainer in...

Page 1864: ...side toward the reac tion planetary into the transmission case Fig 37 28 Install the flat 2C clutch snap ring into the transmission case Fig 36 29 Install the reaction sun gear into the reaction plan...

Page 1865: ...om End Play Tool Set 8266 and Dial Indicator C 3339 measure and record the output shaft end play Fig 40 The correct output shaft end play is 0 22 0 55 mm 0 009 0 021 in Adjust as necessary Install the...

Page 1866: ...C 3339 measure and record the input shaft end play Fig 43 The correct end play is 0 46 0 89 mm 0 018 0 035 in Adjust as nec essary Install the chosen thrust plater on the number 5 bearing and re measu...

Page 1867: ...Install the outer snap ring to hold the trans mission front cover into the transmission case Fig 44 48 Partially install the inner transmission front cover snap ring onto the oil pump Fig 44 49 Using...

Page 1868: ...retaining cross bolt to 16 N m 140 in lbs INSTALLATION 1 Check torque converter hub and hub drive flats for sharp edges burrs scratches or nicks Polish the hub and flats with 320 400 grit paper and c...

Page 1869: ...n transfer case nuts to 35 N m 26 ft lbs 17 Install rear transmission crossmember Tighten crossmember to frame bolts to 68 N m 50 ft lbs 18 Install rear support to transmission Tighten bolts to 47 N m...

Page 1870: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK NEUTRAL AN AUTOMATIC TRANSMISSION 45RFE 21 461 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1871: ...HYDRAULIC FLOW IN NEUTRAL OVER 8MPH 21 462 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1872: ...HYDRAULIC FLOW IN REVERSE AN AUTOMATIC TRANSMISSION 45RFE 21 463 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1873: ...HYDRAULIC FLOW IN REVERSE BLOCK 21 464 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1874: ...HYDRAULIC FLOW IN FIRST GEAR FROM N OR OD AN AUTOMATIC TRANSMISSION 45RFE 21 465 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1875: ...HYDRAULIC FLOW IN FIRST GEAR AFTER LAUNCH FROM REST 21 466 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1876: ...HYDRAULIC FLOW IN FIRST GEAR FROM K D AN AUTOMATIC TRANSMISSION 45RFE 21 467 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1877: ...HYDRAULIC FLOW IN SECOND GEAR 21 468 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1878: ...HYDRAULIC FLOW IN SECOND GEAR EMCC AN AUTOMATIC TRANSMISSION 45RFE 21 469 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1879: ...HYDRAULIC FLOW IN SECOND PRIME GEAR 21 470 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1880: ...HYDRAULIC FLOW IN SECOND PRIME GEAR EMCC AN AUTOMATIC TRANSMISSION 45RFE 21 471 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1881: ...HYDRAULIC FLOW IN DIRECT GEAR 21 472 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1882: ...HYDRAULIC FLOW IN DIRECT GEAR FAILSAFE AN AUTOMATIC TRANSMISSION 45RFE 21 473 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1883: ...HYDRAULIC FLOW IN DIRECT GEAR EMCC 21 474 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1884: ...HYDRAULIC FLOW IN FOURTH AN AUTOMATIC TRANSMISSION 45RFE 21 475 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1885: ...HYDRAULIC FLOW IN FOURTH EMCC 21 476 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1886: ...HYDRAULIC FLOW IN MANUAL LOW OR AUTOSTICK 1ST AN AUTOMATIC TRANSMISSION 45RFE 21 477 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1887: ...HYDRAULIC FLOW IN MANUAL SECOND 21 478 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1888: ...HYDRAULIC FLOW IN MANUAL SECOND FAILSAFE AN AUTOMATIC TRANSMISSION 45RFE 21 479 AUTOMATIC TRANSMISSION 45RFE Continued...

Page 1889: ...7 1 2ND Prime 1 50 1 3RD 1 0 1 4TH 0 75 1 REVERSE 3 00 1 TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Fitting cooler line at trans 17 5 155 Bolt torque convertor 31 23 Bolt nut crossmember 68 5...

Page 1890: ...5 40 Screw manual valve cam retaining 4 5 40 Bolt manual lever 28 2 250 SPECIAL TOOLS RFE TRANSMISSION Gauge Oil Pressure C 3292 Gauge Oil Pressure C 3293SP Dial Indicator C 3339 Installer Seal C 3860...

Page 1891: ...ssor Spring 8251 Installer Piston 8252 Installer Seal 8253 Installer Seal 8254 Installer Snap ring 8255 Stand Support 8257 Adapter Pressure Tap 8258 A 21 482 AUTOMATIC TRANSMISSION 45RFE AN AUTOMATIC...

Page 1892: ...e Input Clutch Pressure 8260 Plate Alignment 8261 End Play Set 8266 Compressor Spring 8285 Installer Bearing 8320 Wrench Filter 8321 Installer Piston 8504 AN AUTOMATIC TRANSMISSION 45RFE 21 483 AUTOMA...

Page 1893: ...ve the 4C clutch pack from the retainer bulkhead Fig 50 6 Using Spring Compressor 8250 and a suitable shop press compress the 4C piston return spring and remove the snap ring Fig 50 7 Remove the 4C pi...

Page 1894: ...to verify the selection 10 Install the 2C piston into the retainer bulk head Fig 50 11 Position the 2C Belleville spring onto the 2C piston 12 Position the 2C Belleville spring snap ring onto the 2C...

Page 1895: ...ding incorrect fluid failure to clean dipstick and fill tube when checking level engine coolant entering the fluid internal failure that generates debris overheat that generates sludge fluid break dow...

Page 1896: ...conds 4 Shift the transmission into PARK 5 Hook up DRB scan tool and select transmis sion 6 Select sensors 7 Read the transmission temperature value 8 Compare the fluid temperature value with the char...

Page 1897: ...o 14 12 N m 125 in lbs 5 Place bead of Mopar RTV sealant onto the transmission case sealing surface 6 Place pan in position on transmission 7 Install bolts to hold pan to transmission Tighten bolts to...

Page 1898: ...n Apply rearward force on cen ter of lever and remove pressure Engine starts must be possible c NEUTRAL position Normal position Engine starts must be possible d NEUTRAL position Engine running and br...

Page 1899: ...ct shift cable to the steering column shift lever Fig 62 by snapping the cable retaining ears into shifter bracket and snapping the cable eyelet on the steering column ball stud 8 Lock the shift cable...

Page 1900: ...ARK or NEUTRAL or if the engine will not start at all the transmission range sensor may be faulty Fig 60 Cable Mounting at Dash Panel 4X2 1 DASH PANEL 2 GEARSHIFT CABLE MOUNTING BRACKET 3 GEARSHIFT CA...

Page 1901: ...es are considered holding clutches The 2C and 4C clutches are located in the 4C retainer bulkhead Fig 64 while the Low Reverse clutch is located at the rear of the transmis sion case Fig 65 OPERATION...

Page 1902: ...REACTION PLATE 2 2C PISTON 9 SNAP RING 3 PLATE 10 RETURN SPRING 4 DISC 11 SEAL 5 2C BELLEVILLE SPRING 12 4C PISTON 6 SNAP RING 13 4C RETAINER BULKHEAD 7 SNAP RING SELECT AN AUTOMATIC TRANSMISSION 45RF...

Page 1903: ...ING SELECT 8 SEAL 2 REACTION PLATE 9 BELLEVILLE SPRING 3 DISC 10 RETAINER 4 PLATE 11 SNAP RING 5 L R CLUTCH RETAINER 12 OVERRUNNING CLUTCH 6 SEAL 13 SNAP RING 7 PISTON 21 494 AUTOMATIC TRANSMISSION 45...

Page 1904: ...g different components of the planetary geartrain UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first second second prime and third direct gears by pressurized fluid against the...

Page 1905: ...from the input clutch retainer Fig 68 2 Remove the reverse reaction plate from the input clutch retainer 3 Remove the reverse hub and reverse clutch pack from the input clutch retainer 4 Remove the nu...

Page 1906: ...nput clutch retainer 11 Remove the UD OD reaction plate tapered snap ring from the input clutch retainer 2 12 Remove the UD OD reaction plate from the input clutch retainer 13 Remove the UD OD reactio...

Page 1907: ...input hub The o rings on the input hub are color coded Be sure to make note of which o ring belongs in which location ASSEMBLY 1 Install all new seals and o rings onto the input shaft and input hub T...

Page 1908: ...CLUTCH RETAINER 4 SNAP RING 14 SEAL 5 SNAP RING 15 OD REV PISTON 6 UD BALANCE PISTON 16 BELLEVILLE SPRING 7 SNAP RING 17 SNAP RING 8 UD PISTON 18 SEAL RINGS 9 SPRING 19 INPUT SHAFT 10 DISC 20 LUBRICA...

Page 1909: ...CLUTCH RETAINER 4 SNAP RING 14 SEAL 5 SNAP RING 15 OD REV PISTON 6 UD BALANCE PISTON 16 BELLEVILLE SPRING 7 SNAP RING 17 SNAP RING 8 UD PISTON 18 SEAL RINGS 9 SPRING 19 INPUT SHAFT 10 DISC 20 LUBRICA...

Page 1910: ...Compressor 8251 compress the UD OD return spring pack and secure the piston in place with the snap ring Fig 74 13 Install the underdrive clutch pack into the input clutch retainer Fig 71 14 Install t...

Page 1911: ...E 12 DISC 4 REV OD REACTION PLATE 13 OD CLUTCH 5 BEARING NUMBER 4 14 SNAP RING TAPERED 6 SNAP RING FLAT 15 UD OD REACTION PLATE 7 REVERSE HUB SHAFT 16 SNAP RING FLAT 8 REVERSE CLUTCH 17 UD HUB SHAFT 9...

Page 1912: ...bbed ears into the input clutch retainer 20 Install the OD reverse reaction plate into the input clutch retainer The reaction plate is non direc tional Fig 75 21 Install the OD reverse reaction plate...

Page 1913: ...late to allow reverse clutch to move freely INPUT SPEED SENSOR DESCRIPTION The Input and Output Speed Sensors are two wire magnetic pickup devices that generate AC signals as rotation occurs They are...

Page 1914: ...ation as the primary input to the calculation The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL posi tions This is done to ensure con...

Page 1915: ...erse clutch and the over running clutch from the low reverse clutch retainer as an assembly Fig 82 4 Separate the low reverse clutch from the over running clutch Fig 82 Low Reverse Clutch Assembly 1 S...

Page 1916: ...eter is scored worn or damaged ASSEMBLY 1 Check the bleed orifice to ensure that it is not plugged or restricted 2 Install a new seal on the low reverse piston Lubricate the seal with Mopar ATF 4 type...

Page 1917: ...r hub rotates the oil pump drive gear As the drive gear rotates both driven gears the clearance between the gear teeth increases in the crescent area and creates a suction at the inlet side of the pum...

Page 1918: ...OIL PUMP VOLUME CHECK 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...

Page 1919: ...nosis 4 Re connect the To cooler line to the transmis sion cooler inlet 5 Refill the transmission to proper level DISASSEMBLY 1 Remove the bolts holding the reaction shaft support to the oil pump Fig...

Page 1920: ...s to the location from which they were removed CLEANING Clean pump and support components with solvent and dry them with compressed air INSPECTION Check condition of the seal rings and thrust washer o...

Page 1921: ...e from dirt or debris Make sure that all valves move freely in their proper bore Make sure that all gear pockets and bushings are free from excessive wear and scoring Replace the oil pump if any exces...

Page 1922: ...ation as input shaft rpm The Output Speed Sensor generates an AC signal in a similar fashion though its coil is excited by rota tion of the rear planetary carrier lugs The TCM interprets this informat...

Page 1923: ...drive OFF mode defaults to ON after the ignition 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...

Page 1924: ...al areas PRESSURE Pressure Fig 99 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...

Page 1925: ...f 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 t...

Page 1926: ...r is driven by the overdrive clutch REVERSE PLANETARY GEARTRAIN The reverse planetary geartrain is the middle of the three planetary sets The reverse planetary car rier can be driven by the overdrive...

Page 1927: ...worn The bushings are not serviceable Replace the driving shell if worn cracked or dam aged Replace planetary gear sets if gears pinion pins or carrier are damaged in any way Replace the annulus gears...

Page 1928: ...Manual second 2 Manual low 1 OPERATION MANUAL LOW 1 range provides first gear only Overrun braking is also provided in this range MANUAL SECOND 2 range provides first and sec ond gear only DRIVE rang...

Page 1929: ...the valves have hardened steel pop pets and ball valves The solenoids operate the valves directly which means that the solenoids must have very high outputs to close the valves against the siz able f...

Page 1930: ...es The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump and contains an o ring seal to better control oil flow The torque converter is a sealed...

Page 1931: ...he 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 107 Impeller 1 ENGINE FLEXPLATE 4 ENG...

Page 1932: ...through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 108 Turbi...

Page 1933: ...slippage condition could be obtained A hydraulic piston with friction material was added to the tur bine assembly to provide this mechanical lock up In order to reduce heat build up in the transmis s...

Page 1934: ...r locks 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 fr...

Page 1935: ...id duty cycle REMOVAL 1 Remove transmission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secur...

Page 1936: ...Starter Relay in Park and Neutral only Supply ground to the TCM for backup lamp con trol in Reverse only The TRS also has an integrated temperature sen sor thermistor that communicates transmission t...

Page 1937: ...a fric tional element The MS and UD solenoids are normally applied to allow transmission limp in in the event of an electri cal failure The continuity of the solenoids and circuits are periodically te...

Page 1938: ...ll the valve body into the transmission TRANSMISSION TEMPERATURE SENSOR DESCRIPTION The transmission temperature sensor is a ther mistor that is integral to the Transmission Range Sensor TRS OPERATION...

Page 1939: ...The valve body con tains the following components Fig 118 and Fig 119 Solenoid switch valve Manual valve Low reverse switch valve 5 Accumulators 7 check balls Fig 118 Valve Body Components 1 LOW REVE...

Page 1940: ...ecific gear or driving range The manual valve as the name implies is manually oper ated by the driver with a lever located on the top of the valve body The valve is connected mechanically by a cable t...

Page 1941: ...enoid and pressure switch assembly from the valve body 3 Remove the screw holding the detent spring Fig 124 onto the valve body 4 Remove the detent spring from the valve body 5 Remove the TRS selector...

Page 1942: ...balls when the transfer plate is removed from the valve body 10 Remove the screws holding the valve body to the valve body transfer plate 11 Remove the transfer plate from the valve body Note the loc...

Page 1943: ...s and fluid passages INSPECTION 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 1944: ...y if any bores are distorted or scored Inspect all of the accumulator springs The springs must be free of distortion warpage or broken coils Inspect all the fluid seals on the valve body Fig 130 Repla...

Page 1945: ...he detent spring onto the valve body Tighten the screw to 4 5 N m 40 in lbs 15 Install new clutch passage seals onto the valve body if necessary INSTALLATION 1 Check condition of seals on valve body a...

Page 1946: ...nt and rear bearings are mounted in aluminum retainer housings bolted to the case halves OPERATING RANGES Transfer case operating ranges are 2WD 2 wheel drive 4HI 4 wheel drive 4LO 4 wheel drive low r...

Page 1947: ...r case electronically controlled shift system malfunction 1 Verify proper operation per the appropriate diagnostic manual 2 If vehicle was operated for an extended period in 4HI mode on dry surface dr...

Page 1948: ...alled incorrectly 3 Replace suspect seal Abnormal tire wear 1 Extended operation in 4HI mode on dry surfaces 1 Operate vehicle in 2WD mode on dry surfaces REMOVAL 1 Shift transfer case into 2WD 2 Rais...

Page 1949: ...iner with pry tool to break sealer bead Pry only against retainer boss as shown Fig 5 7 Disengage oil pickup tube from oil pump and remove oil pump assembly Fig 6 8 Remove pick up tube o ring from oil...

Page 1950: ...om the transfer case FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Support transfer case so rear case is facing upward 2 Remove bolts holding front case to rear case The case alignment bolts require flat washe...

Page 1951: ...and detent plunger Fig 14 2 Remove mainshaft from mode sleeve and input gear pilot bearing Fig 11 Oil Pickup Tube Removal 1 CONNECTING HOSE 2 PICKUP SCREEN 3 PICKUP TUBE Fig 12 Mode Fork Spring Remov...

Page 1952: ...llation reference 5 Remove shift sector from front case Fig 17 6 Remove shift sector o ring Fig 18 Fig 15 Mode Fork And Sleeve Removal 1 MODE SLEEVE 2 MODE FORK AND RAIL Fig 16 Range Fork And Hub Remo...

Page 1953: ...ont bearing retainer attaching bolts Fig 22 Fig 22 Front Bearing Retainer Bolts 1 FRONT CASE 2 FRONT BEARING RETAINER 3 RETAINER BOLTS Fig 19 Mode Hub Retaining Ring Removal 1 MODE HUB 2 SNAP RING PLI...

Page 1954: ...bly Fig 25 Tap gear out of bearing with plastic mallet if necessary INPUT AND LOW RANGE GEAR 1 Remove snap ring that retains input gear in low range gear Fig 26 Fig 26 Input Gear Snap Ring Removal 1 I...

Page 1955: ...and shaft and the teeth on the sprocket Fig 31 Minor nicks and scratches can be smoothed with an oilstone However replace any part that is damaged Check the contact surfaces in the sprocket bore and...

Page 1956: ...and both thrust washers for wear or cracks Replace them if necessary Also replace the lock retaining ring if bent distorted or broken Fig 31 Mainshaft Mode Hub And Drive Sprocket 1 MODE HUB 3 MAINSHAF...

Page 1957: ...e shaft bearing sur faces Rough threads on the shaft can be chased if necessary Replace the shaft if the threads are dam aged bearing surfaces are scored or if any sprocket teeth are cracked or broken...

Page 1958: ...where indicated during assembly BEARINGS AND SEALS CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes 1 Remove t...

Page 1959: ...n tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 41 Once seal is started continue tap ping seal into bore until installer tool bottoms ag...

Page 1960: ...o it is flush with the lower edge of this chamfer Fig 44 Fig 42 Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 43 Output Shaft Rear Bearing...

Page 1961: ...pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 47 14 Install new pilot bearing with Installer 5065...

Page 1962: ...Install first thrust washer in low range gear Fig 52 Be sure washer tabs are properly aligned in gear notches 3 Install input gear in low range gear Be sure input gear is fully seated 4 Install remain...

Page 1963: ...seal retainer with fluid return hole in front of case CAUTION Do not block fluid return cavity on seal ing surface of retainer when applying Mopar Gas ket Maker or equivalent silicone adhesive sealer...

Page 1964: ...ated in low range gear and engaged to the input gear 4 Align and insert range fork pin in shift sector slot 5 Install assembled mainshaft Fig 58 Be sure shaft is seated in pilot bearing and input gear...

Page 1965: ...put shaft sprocket assembly drive chain and drive sprocket with transmission fluid 2 Assemble drive chain and front output shaft Fig 62 3 Start chain on mainshaft drive sprocket 4 Guide front shaft in...

Page 1966: ...ned and that mode fork rail extends through rear case before seating rear case on front case 8 Install case attaching bolts Alignment bolts at each end of case are only ones requiring washers Fig 67 9...

Page 1967: ...hesive sealer to mounting surface of extension housing Allow sealer to set up slightly before proceeding 5 Install extension housing on rear retainer 6 Install extension housing bolts and tighten to 2...

Page 1968: ...alf 27 34 20 25 Nut Companion Flange 122 176 90 130 Bolt Shift motor and Mode Sensor Assembly 16 25 12 18 Bolt Rear Retainer 27 34 20 25 Bolt Extension Housing 27 34 20 25 Nut Mounting 27 34 20 25 SPE...

Page 1969: ...staller Bearing 5064 Installer Bearing 5065 Installer Bushing 5066 Remover L 4454 Cup 8148 Installer Seal 7884 Installer Pump Housing Seal 7888 Wrench Spanner 6958 21 560 TRANSFER CASE NV233 AN TRANSF...

Page 1970: ...ange 4 Remove seal from front case with suitable pry tool Fig 71 INSTALLATION 1 Install new front output seal in front case with Installer Tool 8143 A as follows a Place new seal on tool Garter spring...

Page 1971: ...otor is active A mode sensor signal between 3 8 Volts and 0 8 Volts is considered to be undefined Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer cas...

Page 1972: ...ner with fluid port in bushing aligned with slot in retainer 3 Using Installer 8157 drive bushing into retainer until installer seats against case Fig 75 4 Using Installer D 163 install seal in rear r...

Page 1973: ...resistances between the ranges E and F shown for AWD 2WD and in between positions the TCCM may interpret the resistance as the AWD 2WD position an invalid fault position a valid in between position F...

Page 1974: ...speed high torque device The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges The motor is rated at 25 amps ma...

Page 1975: ...o replenish the lock patch material originally found on the bolts 4 Engage the wiring connectors to the shift motor and mode sensor 5 Install the transfer case front output shaft companion flange onto...

Page 1976: ...eration The low range provides a 2 72 1 reduction ratio The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings are mounted in aluminum retainer...

Page 1977: ...GNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION Transfer case difficult to shift or will not shift into desired range 1 Transfer case electronically controlled shift system malfunction 1 Verify prope...

Page 1978: ...a straight line and momentarily release the accelerator pedal to complete the shift 2 Incorrect tire pressure 2 Correct tire pressure as necessary 3 Excessive tire wear 3 Correct tire condition as ne...

Page 1979: ...assembly to the transfer case 5 Remove the shift motor and mode sensor assembly from the transfer case REAR RETAINER 1 Remove extension housing bolts 2 Tap extension housing with plastic or rawhide ma...

Page 1980: ...pump with pry tool 10 Remove bolts attaching rear case to front case Fig 9 Note position of the two black finish bolts at each end of the case These bolts go through the case dowels and require a wash...

Page 1981: ...N 1 Remove drive sprocket snap ring Fig 12 2 Remove drive sprocket and chain Fig 13 3 Remove front output shaft Fig 14 Fig 10 Loosening Removing Rear Case 1 MAINSHAFT 2 SCREWDRIVER 3 FRONT CASE 4 SCRE...

Page 1982: ...e fork and mainshaft as assembly Fig 17 Fig 14 Removing Front Output Shaft 1 FRONT OUTPUT SHAFT Fig 15 Detent Pin Spring And Plug Removal 1 PLUNGER 2 O RING 3 PLUG 4 SPRING Fig 16 Shift Rail Removal 1...

Page 1983: ...ring Fig 19 6 Remove clutch shaft thrust ring Fig 20 Fig 19 Remove the Intermediate Clutch Shaft Snap Ring 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT Fig 20 Remove the Intermediate Clutch Shaft Thrust Ri...

Page 1984: ...ft 11 Slide low range fork pin out of shift sector slot Fig 24 Fig 21 Remove the Intermediate Clutch Shaft 1 INTERMEDIATE CLUTCH SHAFT Fig 22 Remove the Differential Snap Ring 1 DIFFERENTIAL SNAP RING...

Page 1985: ...g 27 Position screwdriver in slots cast into retainer 3 Remove input gear snap ring Fig 28 Fig 25 Low Range Fork And Hub Removal 1 LOW RANGE FORK 2 FORK HUB Fig 26 Remove the Shift Sector O Ring 1 TRA...

Page 1986: ...viceable component If damaged replace gear and front case as an assembly Fig 29 Input And Low Range Gear Assembly Removal 1 INPUT LOW RANGE GEARS 2 SPECIAL TOOL 7829 A 3 SPECIAL TOOL C 4171 Fig 30 Rem...

Page 1987: ...ove thrust washers and planet gears from case pins Fig 34 6 Remove mainshaft and sprocket gears from bottom case Fig 35 Note gear position for reference before separating them Fig 33 Separating Differ...

Page 1988: ...and scratches can be smoothed with 320 400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear Fig 36 Minor nic...

Page 1989: ...r This surface must be clean and smooth to ensure proper seal life Replace the flange nut and seal washer as neither part should be reused Inspect the shaft threads sprocket teeth and bear ing surface...

Page 1990: ...ividual parts are not available The pump is only available as a complete assembly The pickup screen hose and tube are the only serviceable parts and are available separately ASSEMBLY Lubricate transfe...

Page 1991: ...Fig 44 8 Remove the input gear pilot bearing by insert ing a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 45 Fig 45 Remove In...

Page 1992: ...5066 Fig 49 Lubricate bearing after installation Fig 46 Install Input Gear Pilot Bearing 1 HANDLE C 4171 2 INSTALLER 8128 3 INPUT GEAR Fig 47 Front Bearing Retainer Seal Installation 1 FRONT BEARING...

Page 1993: ...tial components with auto matic transmission fluid 2 Install sprocket gear in differential bottom case Fig 53 Fig 50 Oil Pump Seal Installation 1 HOUSING SEAL 2 SPECIAL TOOL 7888 3 OIL PUMP FEED HOUSI...

Page 1994: ...differential and start the differential case bolts 7 Tighten differential case bolts to specified torque INPUT GEAR LOW RANGE 1 Assemble low range gear input gear thrust washers input gear and input g...

Page 1995: ...al surface of front bearing retainer 8 Install front bearing retainer Fig 59 Tighten retainer bolts to 16 25 N m 12 18 ft lbs torque SHIFT FORKS AND MAINSHAFT 1 Install new sector shaft o ring Fig 60...

Page 1996: ...mainshaft Fig 63 Coat bearing rollers with generous quantity of petroleum jelly to hold them in place 8 Install remaining bearing spacer on mainshaft Fig 63 Do not displace any bearings while install...

Page 1997: ...g 66 12 Install clutch shaft thrust ring Fig 67 Fig 64 Differential Installation 1 DIFFERENTIAL 2 MAINSHAFT Fig 65 Installing Differential Snap Ring 1 DIFFERENTIAL SNAP RING Fig 66 Installing Intermed...

Page 1998: ...leeve and fork on mainshaft Be sure mode sleeve splines are engaged in differen tial splines 16 Install mode fork and mainshaft assembly in case Fig 71 Rotate mainshaft slightly to engage shaft with l...

Page 1999: ...aft sprocket teeth 3 Install drive sprocket Fig 74 Engage drive sprocket teeth with chain Then engage sprocket splines with mainshaft splines Fig 72 Shift Rail Installation 1 SHIFT RAIL 2 MODE FORK Fi...

Page 2000: ...e sealer to seal surface of front case 5 Align and install rear case on front case Be sure case locating dowels are in place and that main shaft splines are engaged in oil pump inner gear 6 Install an...

Page 2001: ...r 7 Install extension housing bolts and tighten to 27 34 N m 20 25 ft lbs COMPANION FLANGE AND SHIFT MOTOR AND MODE SENSOR ASSEMBLY 1 Position the shift motor and mode sensor assembly onto the transfe...

Page 2002: ...rs Secure wire harness to clips on trans fer case 8 Align and connect the propeller shafts 9 Fill transfer case with correct fluid Refer to 21 TRANSMISSION TRANSAXLE TRANSFER CASE FLUID STANDARD PROCE...

Page 2003: ...iversal C 4171 Remover Bearing C 4210 Installer Bearing 5064 Installer Bearing 8128 Installer Bearing 5066 Installer Bearing 5066 Installer Seal 6952 A Remover Bearing L 4454 Cup 8148 21 594 TRANSFER...

Page 2004: ...0 40 ft lbs 5 Remove drain pan 6 Fill transfer case to bottom edge of fill plug opening with Mopar ATF 4 type 9602 Automatic Transmission fluid 7 Install and tighten fill plug to 41 54 N m 30 40 ft lb...

Page 2005: ...DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION MODE SENSOR DESCRIPTION The transfer case mode sensor Fig 85 is an elec tronic device whose output can be interpreted to indi cate...

Page 2006: ...de sensor position The various between gears positions can also be referred as the transfer case s coarse position These coarse positions come into play dur ing shift attempts SECTOR ANGLES VS TRANSFE...

Page 2007: ...ner with fluid port in bushing aligned with slot in retainer 3 Using Installer 8157 drive bushing into retainer until installer seats against case Fig 87 4 Using Installer D 163 install seal in rear r...

Page 2008: ...r resistances between the ranges E and F shown for AWD 2WD and in between positions the TCCM may interpret the resistance as the AWD 2WD position an invalid fault position a valid in between position...

Page 2009: ...speed high torque device The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges The motor is rated at 25 amps ma...

Page 2010: ...o replenish the lock patch material originally found on the bolts 4 Engage the wiring connectors to the shift motor and mode sensor 5 Install the transfer case front output shaft companion flange onto...

Page 2011: ......

Page 2012: ...hicle to shake Lateral runout of more than 2 0 mm 080 inch measured near the shoulder of the tire may cause the vehicle to shake Sometimes radial runout can be reduced Relocate the wheel and tire asse...

Page 2013: ...RD PROCEDURE MATCH MOUNTING Wheels and tires are match mounted at the factory This means that the high spot of the tire is matched to the low spot on the wheel rim Each are marked with a bright colore...

Page 2014: ...l excessive replace the tire If the high spot is within 101 6 mm 4 0 in of the first spot on the wheel the wheel may be out of specifications Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING If the high...

Page 2015: ...her on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire Off vehicle balancing is recommended For static balancing find the location of the heavy spot c...

Page 2016: ...RE IDENTIFICATION Tire type size aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire Refer to the chart to decipher the tire identification code...

Page 2017: ...apid center wear and loss of the tire s ability to cushion shocks Fig 12 Improper inflation can cause Uneven wear patterns Reduced tread life Reduced fuel economy Unsatisfactory ride Vehicle drift For...

Page 2018: ...nt to the orig inal equipment tires be used when replacement is needed Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehi cle The use of oversize tire...

Page 2019: ...eflate tire completely before removing the tire from the wheel Use lubrication such as a mild soap solution when dismounting or mounting tire Use tools free of burrs or sharp edges which could dam age...

Page 2020: ...ged nose is necessary to ensure proper retention of the wheels Do not use replacement studs or nuts with a different design or lesser quality DIAGNOSIS AND TESTING WHEEL INSPECTION Inspect wheels for...

Page 2021: ...fore installing the wheel be sure to remove any build up of corrosion on the wheel mounting surfaces Ensure wheels are installed with good metal to metal contact Improper installation could cause loos...

Page 2022: ...to remove wheel studs 1 Install the new stud into the hub flange 2 Install three washers onto the stud then install lug nut with the flat side of the nut against the washers 3 Tighten lug nut until th...

Page 2023: ......

Page 2024: ...te section of this group for proper procedures WATER LEAK TESTS WARNING DO NOT USE ELECTRIC SHOP LIGHTS OR TOOLS IN WATER TEST AREA PERSONAL INJURY CAN RESULT When the conditions causing a water leak...

Page 2025: ...to stop wind noise that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort After a repair pro cedure has been performed test vehicle to verify noise...

Page 2026: ...component seam loca tion is loose hold the two components tightly together and using a soldering gun with a flat tip melt the material securing the components together Do not over heat the affected a...

Page 2027: ...SPECIFICATIONS WELD LOCATIONS FRONT FENDER AND INNER WHEELHOUSE 23 4 BODY AN BODY Continued...

Page 2028: ...ROOF PANEL REGULAR CAB AN BODY 23 5 BODY Continued...

Page 2029: ...ROOF PANEL CLUB CAB 23 6 BODY AN BODY Continued...

Page 2030: ...BODY SIDE APERTURE REGULAR CAB AN BODY 23 7 BODY Continued...

Page 2031: ...BODY SIDE APERTURE REGULAR CAB 23 8 BODY AN BODY Continued...

Page 2032: ...BODY SIDE APERTURE REGULAR CAB AN BODY 23 9 BODY Continued...

Page 2033: ...BODY SIDE APERTURE REGULAR CAB 23 10 BODY AN BODY Continued...

Page 2034: ...BODY SIDE APERTURE CLUB CAB AN BODY 23 11 BODY Continued...

Page 2035: ...BODY SIDE APERTURE CLUB CAB 23 12 BODY AN BODY Continued...

Page 2036: ...BODY SIDE APERTURE CLUB CAB AN BODY 23 13 BODY Continued...

Page 2037: ...BODY SIDE APERTURE CLUB CAB 23 14 BODY AN BODY Continued...

Page 2038: ...CAB BACK PANEL REGULAR CAB AN BODY 23 15 BODY Continued...

Page 2039: ...CAB BACK PANEL CLUB CAB 23 16 BODY AN BODY Continued...

Page 2040: ...FLOOR PAN REGULAR CAB AN BODY 23 17 BODY Continued...

Page 2041: ...FLOOR PAN REGULAR CAB 23 18 BODY AN BODY Continued...

Page 2042: ...FLOOR PAN CLUB CAB AN BODY 23 19 BODY Continued...

Page 2043: ...FLOOR PAN CLUB CAB 23 20 BODY AN BODY Continued...

Page 2044: ...FLOOR PAN CLUB CAB AN BODY 23 21 BODY Continued...

Page 2045: ...COWL AND DASH PANEL 23 22 BODY AN BODY Continued...

Page 2046: ...COWL AND DASH PANEL AN BODY 23 23 BODY Continued...

Page 2047: ...COWL AND DASH 23 24 BODY AN BODY Continued...

Page 2048: ...CARGO BOX INNER SIDE PANEL AN BODY 23 25 BODY Continued...

Page 2049: ...CARGO BOX INNER SIDE PANEL 23 26 BODY AN BODY Continued...

Page 2050: ...CARGO BOX INNER SIDE PANEL AN BODY 23 27 BODY Continued...

Page 2051: ...CARGO BOX FRONT PANELS 23 28 BODY AN BODY Continued...

Page 2052: ...CARGO BOX FLOOR AN BODY 23 29 BODY Continued...

Page 2053: ...CARGO BOX FLOOR 23 30 BODY AN BODY Continued...

Page 2054: ...STRUCTURAL ADHESIVE LOCATIONS ROOF EXTENDED CAB 1 OUTER ROOF PANEL 2 STRUCTURAL ADHESIVE 3 ADHESIVE RIBBON 4 EXTENDED CAB FRAMING AN BODY 23 31 BODY Continued...

Page 2055: ...ROOF REGULAR CAB 1 OUTER ROOF PANEL 2 STRUCTURAL ADHESIVE 3 REGULAR CAB FRAMING 23 32 BODY AN BODY Continued...

Page 2056: ...REAR QUARTER PANEL REGULAR CAB 1 REAR QUARTER PANEL INNER UPPER REGULAR CAB 2 STRUCTURAL ADHESIVE 3 CAB BACK REINFORCEMENT REGULAR CAB AN BODY 23 33 BODY Continued...

Page 2057: ...REAR QUARTER PANEL EXTENDED CAB 23 34 BODY AN BODY Continued...

Page 2058: ...CARGO BOX INNER AND OUTER PANEL AN BODY 23 35 BODY Continued...

Page 2059: ...SEALER LOCATIONS APPLICATION METHODS 23 36 BODY AN BODY Continued...

Page 2060: ...SEALER LOCATION AN BODY 23 37 BODY Continued...

Page 2061: ...APPLICATION CUT AWAY 23 38 BODY AN BODY Continued...

Page 2062: ...COWL AND DASH PANEL AN BODY 23 39 BODY Continued...

Page 2063: ...COWL AND DASH PANEL 23 40 BODY AN BODY Continued...

Page 2064: ...FLOOR PAN AN BODY 23 41 BODY Continued...

Page 2065: ...CAB REAR PANEL 23 42 BODY AN BODY Continued...

Page 2066: ...CAB REAR PANEL AN BODY 23 43 BODY Continued...

Page 2067: ...ROOF PANEL 23 44 BODY AN BODY Continued...

Page 2068: ...CARGO BOX AN BODY 23 45 BODY Continued...

Page 2069: ...CARGO BOX 23 46 BODY AN BODY Continued...

Page 2070: ...DOORS AN BODY 23 47 BODY Continued...

Page 2071: ...BODY GAP AND FLUSH MEASUREMENTS 23 48 BODY AN BODY Continued...

Page 2072: ...BODY GAP AND FLUSH AN BODY 23 49 BODY Continued...

Page 2073: ...ab to Standard Box 18 7 3 0 0 0 1 5 F Cab to Extended Box 18 7 3 0 0 0 1 5 G Quarter Glass to Quarter Bottom 5 0 1 5 N A H Door to Quarter 0 0 2 5 N A I Quarter Glass to Door 5 0 1 5 3 6 1 5 J Door to...

Page 2074: ...BODY GAP AND FLUSH QUAD CAB AN BODY 23 51 BODY Continued...

Page 2075: ...BODY GAP AND FLUSH QUAD CAB 23 52 BODY AN BODY Continued...

Page 2076: ...Fuel Filler Door to Box 3 0 1 5 0 0 1 5 B Cargo to Standard Box 18 7 3 0 0 0 1 5 C Cargo to Extended Box 18 7 3 0 0 0 1 5 E Box to Tailgate U D N A 0 0 1 5 F Tailgate to Bumper 9 7 3 0 N A G Box to T...

Page 2077: ...BODY GAP AND FLUSH CARGO BOX 23 54 BODY AN BODY Continued...

Page 2078: ...BODY OPENING DIMENSIONS WINDSHIELD OPENING DOOR OPENING AN BODY 23 55 BODY Continued...

Page 2079: ...QUARTER WINDOW OPENING ENGINE COMPARTMENT OPENING 23 56 BODY AN BODY Continued...

Page 2080: ...BACKLITE OPENING AN BODY 23 57 BODY Continued...

Page 2081: ...N m 17 ft lbs Front bucket seat belt buckle anchor bolt 40 N m 29 ft lbs Front door hinge to hinge pillar bolts 28 N m 21 ft lbs Front door hinge to door nuts and bolts 28 N m 21 ft lbs Front seat be...

Page 2082: ...latch release handle 3 Remove bolts attaching tailgate latch release handle to tailgate 4 Disengage latch rods at tailgate latch release handle 5 Separate latch from tailgate and disengage latch rod...

Page 2083: ...ailgate check cable TAILGATE REMOVAL 1 Release tailgate latch and open tailgate 2 Disconnect tailgate check cable 3 Close tailgate until the notch in the right hand collar aligns with the pivot pin 4...

Page 2084: ...or latch and open door 2 Using a small flat blade depress the clips under the top of the exhauster frame 3 Separate air exhauster from vehicle INSTALLATION 1 Position air exhauster on door shut face F...

Page 2085: ...INSTALLATION 70 FRONT DOOR REMOVAL 1 Release door latch and open door 2 Using a suitable marker mark the outline of the door hinges on the door end to aid installation 3 Remove protective boot from d...

Page 2086: ...outer door belt weatherstrip 5 Lower glass to full down position and align glass regulator arm with access holes in inner door panel 6 Remove front glass run channel 7 Remove nuts attaching glass chan...

Page 2087: ...taching lower glass run chan nels to door panel Fig 5 4 Remove glass 5 Slide lower run channels downward to disen gage from upper run channels 6 Remove lower run channels from door INSTALLATION 1 Posi...

Page 2088: ...door hinge to hinge pil lar Tighten bolts to 28 N m 21 ft lbs torque 4 Install bolts attaching hinge to door Tighten bolts to 28 N m 21 ft lbs torque FRONT DOOR INSIDE HANDLE ACTUATOR DESCRIPTION The...

Page 2089: ...all water dam 11 Install door trim panel 12 Using the access hole in the door shut face loosen the latch adjustment screw and ensure the outside door handle is flush with door outer panel Tighten the...

Page 2090: ...er out of lock cylinder housing outside handle INSTALLATION 1 Push lock cylinder into lock cylinder housing outside handle Ensure the lock cylinder is fully seated in the handle 2 Install lock cylinde...

Page 2091: ...or window lock switch panel if equipped Engage clips attaching power win dow lock switch panel to door trim panel 3 Engage power mirror wire connector if equipped 4 Connect speaker harness wire connec...

Page 2092: ...s before installing it 2 Position the waterdam on the door inner panel and press it inward at the areas with the adhesive to attach it to the inner panel 3 Ensure that the retainer step pockets are po...

Page 2093: ...e in inner door panel 8 Separate window regulator from door panel INSTALLATION 1 Position regulator in door and align bolts with slotted holes in door inner panel 2 Install bolts attaching window regu...

Page 2094: ...quivalent mark hinge position on B pillar 5 Remove bolts attaching hinge to B pillar Fig 1 INSTALLATION 1 Align and position door on vehicle 2 Install bolts attaching hinge to B pillar Fig 1 Tighten b...

Page 2095: ...efer to door glass procedure in this section 5 Remove the bolts attaching bottom of rearward run channel to door inner panel 6 Remove nuts attaching stationary glass to door frame 7 Separate the rewar...

Page 2096: ...RUN CHANNELS REMOVAL 1 Remove trim panel 2 Remove waterdam 3 Ensure glass is in full up position and sup ported Remove bolts attaching the run channels to door inner panel Fig 6 4 Remove speaker if ne...

Page 2097: ...or is heat staked to the trim panel If the handle needs servicing refer to the heat staking procedure located in this section REAR DOOR LATCH REMOVAL 1 Remove trim panel 2 Peel waterdam back to access...

Page 2098: ...upper trim extension on rear door 2 Position trim panel at door 3 Engage harness connector for power window lock if equipped 4 Engage inside handle linkage rod to inside handle 5 Align trim panel reta...

Page 2099: ...nuts and remove the regulator attachment bolts 8 Disengage regulator wire harness 9 Remove the regulator Fig 13 INSTALLATION 1 Position the window regulator in the door 2 Install the fasteners attach...

Page 2100: ...components are part of the energy absorbing system used to protect the occupants in collisions The exterior sheet metal is repairable and adjustable for fit and finish Welded and bonded component syst...

Page 2101: ...m main body harness 5 Remove bolts attaching cargo box to frame rails Fig 2 6 Using a suitable lifting device separate cargo box from vehicle INSTALLATION 1 Position cargo box on frame rails 2 Install...

Page 2102: ...rip 7 Disconnect and plug windshield washer feed line from cowl 8 Disconnect vacuum line from cowl 9 Separate cowl grille from cowl INSTALLATION 1 Position cowl grille on cowl 2 Connect vacuum line to...

Page 2103: ...mblem 2 Position emblem properly on body Fig 4 3 Press emblem firmly to body with palm of hand 4 If temperature is below 21 C 70 F warm emblem with a heat lamp or gun to assure adhesion Do not exceed...

Page 2104: ...REMOVAL 1 Release primary hood latch 2 Release hood safety catch and open hood 3 Remove screws attaching bottom of grille to grille mounting bracket 4 Remove nuts attaching grille to hood Fig 7 5 Sepa...

Page 2105: ...ts attaching fender to lower radia tor closure panel Fig 8 14 Remove bolts attaching fender to hood hinge support bracket 15 Remove bolts attaching fender to upper cowl Fig 9 16 Remove bolts attaching...

Page 2106: ...aise and support the vehicle 3 Remove right front wheel 4 Remove wheel opening molding 5 Remove wheelhouse liner 6 Remove right headlamp module 7 Remove air cleaner element housing 8 Remove powertrain...

Page 2107: ...ve tape residue from roof joint 2 If molding is to be reused remove tape residue from back of molding Clean molding with MOPAR Super Kleen solvent or equivalent Wipe molding dry with lint free cloth A...

Page 2108: ...screws attaching the wheel open ing molding to the fender Fig 1 2 Separate the molding from the wheel opening INSTALLATION 1 Clean body surface with MOPAR Super Kleen solvent or equivalent Wipe surfa...

Page 2109: ...alla tion 2 Position the hinge on the vehicle and align all marks 3 Install the bolts attaching the hinge to the inner fender Tighten the bolts to 28 2 N m 250 in lbs torque 4 Install the nuts attachi...

Page 2110: ...OOD SILENCER PAD REMOVAL 1 Raise the hood 2 Remove the retainers attaching the silencer pad to the hood Fig 3 3 Remove the silencer pad from the hood INSTALLATION 1 Position the silencer pad on the ho...

Page 2111: ...eparate the release cable grommet from the dash panel hole 7 From the inside of the vehicle remove the screws attaching the hood release handle to the bot tom of the instrument panel Fig 6 8 Pull rout...

Page 2112: ...Release primary hood latch 2 Release hood safety catch and open hood 3 Remove bolts attaching hood safety latch to hood Fig 7 4 Separate safety latch from hood INSTALLATION 1 Position safety latch on...

Page 2113: ...ich in conjunction with the dual airbags and seat belts helps to improve occupant protection The instrument panel for this vehicle includes the following major features Cluster Bezel This molded plast...

Page 2114: ...f the vehicle These hard wired circuits are integral to several wire harnesses which are routed throughout the vehicle and retained by many different methods These circuits may be con nected to each o...

Page 2115: ...he vehicle glove box for more information on the features use and operation of all of the components and systems mounted on or in the instrument panel REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAG...

Page 2116: ...rument panel wire harness bulkhead con nector to the headlamp and dash wire harness bulkhead connector and disconnect the connector j Disconnect the two body wire harness connec tors from the two inst...

Page 2117: ...e instrument panel wire harness connector for the park brake switch to the switch terminal on the park brake mechanism g Reinstall the instrument panel wire harness ground take out eyelet terminal con...

Page 2118: ...h receiver housing and the instrument panel lower bezel to disengage the two integral snap fea tures of the housing from the their receptacles in the bezel 5 Pull the ash receiver and housing unit rea...

Page 2119: ...MPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE...

Page 2120: ...bottom of the ash receiver housing into their receptacles in the instru ment panel lower bezel 4 Align the snap features on the top of the ash receiver housing with their receptacles in the instru me...

Page 2121: ...vehicle Refer to 23 BODY INSTRUMENT PANEL INSTALLATION 7 Reconnect the battery negative cable CLUSTER BEZEL REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT...

Page 2122: ...onnector receptacle 4 Align the snap clips on the cluster bezel with the receptacles in the instrument panel base trim 5 Using hand pressure press firmly on the clus ter bezel over each of the snap cl...

Page 2123: ...llars Refer to 23 BODY INTERIOR A PILLAR TRIM INSTAL LATION 5 Reconnect the battery negative cable END CAP REMOVAL DRIVER SIDE 1 Insert a finger into the pull cup formation molded into the end cap and...

Page 2124: ...VAL PASSEN GER SIDE 6 Remove the screw that secures the outboard end of the glove box module to the right end of the instrument panel behind the passenger side end cap 7 Remove the four screws that se...

Page 2125: ...SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Position the glove bo...

Page 2126: ...15 12 Reinstall the lower bezel onto the instrument panel Refer to 23 BODY INSTRUMENT PANEL LOWER BEZEL INSTALLATION 13 Reinstall the cluster bezel onto the instru ment panel Refer to 23 BODY INSTRUME...

Page 2127: ...R SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY S...

Page 2128: ...TION 7 Reconnect the battery negative cable LOWER BEZEL REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENS...

Page 2129: ...to 2 N m 20 in lbs 6 Close and latch the glove box 7 Reinstall the cluster bezel onto the instrument panel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL INSTALLATION 8 Reinstall the steering column...

Page 2130: ...lower edge of the steering column opening cover to the instrument structural support Fig 20 Tighten the screws to 2 N m 20 in lbs 5 Reach under the left end of the instrument panel to access and engag...

Page 2131: ...E AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE T...

Page 2132: ...in lbs 3 Install and tighten the screw that secures each outboard end of the top cover to the instrument panel structural support beneath the end caps Tighten the screws to 2 N m 20 in lbs 4 Install...

Page 2133: ...117 REAR VIEW MIRROR REMOVAL 118 INSTALLATION 118 SHIFT BEZEL REMOVAL 118 INSTALLATION 118 SUN VISORS REMOVAL 119 INSTALLATION 119 REAR VIEW MIRROR SUPPORT BRACKET INSTALLATION 119 AIR EXHAUSTER CAB R...

Page 2134: ...pull outward to disen gage clips attaching A pillar trim to A pillar Fig 4 5 Separate A pillar trim from vehicle INSTALLATION 1 Position A pillar trim at A pillar align clips and press into place 2 I...

Page 2135: ...pillar with push in fasteners 1 Remove door sill cover as necessary to clear B pillar trim 2 Remove shoulder belt turning loop 3 Grasp B pillar trim panel and firmly pull out ward 4 Disconnect speake...

Page 2136: ...hor Refer to 8 ELEC TRICAL RESTRAINTS SEAT BELT RETRACTOR INSTALLATION 3 Install the lower c pillar trim and install the screws 4 Install the upper c pillar trim 5 Install the seat belt turning loop C...

Page 2137: ...y cowl trim cover from cowl to disengage clips 2 Separate cowl trim cover from vehicle INSTALLATION 1 Position cowl trim cover on cowl 2 Press cowl trim cover into place to engage clips DOOR SILL TRIM...

Page 2138: ...HEADLINER REMOVAL 1 Remove sun visors and visor hooks 2 Remove coat hooks 3 Remove overhead console if equipped Refer to Group 8V Overhead Console for removal procedure 4 Remove A pillar trim 5 Remove...

Page 2139: ...parate club cab quarter trim panel from quarter panel Fig 15 INSTALLATION 1 Position trim panel in vehicle 2 Route belt webbing through access slots in quarter trim panel 3 Position quarter trim panel...

Page 2140: ...3 Remove rear seat belt buckle anchor bolts 4 Route rear seat belt buckle through slots in rear of storage box 5 Separate storage box from vehicle INSTALLATION 1 Position storage box in vehicle 2 Rou...

Page 2141: ...late to floor pan 4 Disengage 4WD shift indicator lamp connector if equipped Fig 21 and Fig 22 5 Separate shift bezel from vehicle INSTALLATION 1 Position shift bezel in vehicle 2 Engage 4WD shift ind...

Page 2142: ...install the visor supports 2 Position the sunvisor in the visor supports and align the arm support bracket holes with the head liner holes 3 Install the screws that attach the sunvisor arm support bra...

Page 2143: ...ace for at least one minute NOTE Verify that the mirror support bracket is cor rectly aligned because the adhesive will cure rap idly 7 Allow the adhesive to cure for 8 10 minutes Remove any excess ad...

Page 2144: ...a two 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 bl...

Page 2145: ...ouch up color can be lightly finesse sanded 1500 grit and polished with rubbing compound 6 On vehicles with clear coat apply clear top coat to touch up paint with the same technique as described in St...

Page 2146: ...ION Seat assemblies transport the occupants in comfort and safety Seat assemblies also help position occu pants correctly in the event of airbag deployment Seat cushions coverings and electrical compo...

Page 2147: ...armrest console lid and remove the two screws attaching the latch bezel cover and remove the latch cover bezel and the latch button Fig 4 3 Using a drill stop and protecting the surround ing trim and...

Page 2148: ...R INERTIA LATCH COVER 1 Install the upper latch cover onto the upper latch inertia arm Ensure the check strap loops under the stud on the side of the lower stanchion post 2 Install the lower latch cov...

Page 2149: ...hing trim cover to seat track Fig 9 4 Remove rear bolts attaching rear seat track to floor pan 5 Move seat to full rearward position 6 Remove front screws attaching trim cover to seat track Fig 9 7 Re...

Page 2150: ...all bolts attaching front seat track to floor pan Tighten to 28 N m 20 ft lbs torque 3 Install front screws attaching trim cover to seat track 4 Move seat to full forward position 5 Install bolts atta...

Page 2151: ...cover Fig 13 4 Peel back lower corners of seat back cover to expose hinge bolts Fig 14 5 Remove the bolts attaching the hinge bracket to the seat back frame 6 Remove seat back from vehicle INSTALLATIO...

Page 2152: ...4 Disengage hook and loop fastener on rear of seat back Fig 15 5 Using a trim stick carefully pry off lumbar handle 6 Separate pad cover from seat back frame INSTALLATION BENCH SEAT BACK PAD COVER 1 P...

Page 2153: ...on cover off seat cushion INSTALLATION BENCH SEAT CUSHION COVER 1 Position the cushion cover on the frame 2 Route the seat belt buckles through the access hole in the cushion cover 3 Engage the J stra...

Page 2154: ...rom the seat lever adjuster 5 Separate the seat track from the frame INSTALLATION BENCH SEAT TRACK 1 Position the seat track on the frame 2 Install the push nut on the seat adjuster lever 3 Install th...

Page 2155: ...ER AND PINCH WELD FENCE PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER IF NOT STRUC TURAL INTEGRITY COULD BE COMPROMISED DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND TECHNICIANS SHOULD REV...

Page 2156: ...Firmly push glass against rear window glass opening fence 9 Bend tabs around edges of backlite opening fence to retain glass 10 Clean excess urethane from exterior with Mopar Super Clean or equivalen...

Page 2157: ...e wipers and cowl grille 3 With doors open remove the weatherstrip from the side windshield moldings 4 Remove the screws attaching the side wind shield molding to the A pillars Fig 4 5 Cut urethane bo...

Page 2158: ...ft apart Fig 8 3 Clean inside of windshield with MOPAR Glass Cleaner and lint free cloth 4 Apply clear glass primer 25 mm 1 in wide around perimeter of windshield and wipe with a new clean and dry lin...

Page 2159: ...ort Spacers 1 WINDSHIELD 2 SPACERS 3 SUPPORTS Fig 7 Center Windshield and Mark at Support Spacers 1 WINDSHIELD 2 INDEX MARKS 3 SUPPORT SPACERS Fig 8 Work Surface Set up and Molding Installation 1 WIND...

Page 2160: ...INSTALLATION 140 REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 140 INSTALLATION 140 REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 140 INSTALLATION 140 REAR DOOR OUTER BELT WEATHERSTRIP REMOVAL 141 INSTALLATIO...

Page 2161: ...ove door trim panel 2 Remove water dam as necessary to access lower glass run channels 3 Remove the bolts attaching the glass run chan nels 4 Remove glass 5 Pull the glass run weatherstrip and run cha...

Page 2162: ...ary seal and the tape from the inner door panel Fig 4 FRONT DOOR WEATHERSTRIP REMOVAL 1 Remove A pillar trim 2 Remove cowl panel and sill cover 3 Remove upper turning loop anchor bolt 4 Pull B pillar...

Page 2163: ...Remove trim panel 2 Remove inner beltline weatherstrip 3 Remove outer beltline weatherstrip 4 Pull weatherstrip from door frame and divider bar channel Fig 7 INSTALLATION 1 Position weatherstrip in d...

Page 2164: ...eatherstrip from pinch flange around door opening INSTALLATION 1 Clean pinch flange 2 Position the weatherstrip on the pinch flange around door opening and press into place 3 Install quarter panel tri...

Page 2165: ...where tape secures the weath erstrip is clean Use Mopar Super Clean or equiva lent 2 Position retainer on vehicle 3 Install screws attaching retainer to roof rail 4 Starting at the forward end of ret...

Page 2166: ...ve cap installed over it from the factory After servicing the refrigerant system always reinstall both of the service port caps DIAGNOSIS AND TESTING A C PERFORMANCE The air conditioning system is des...

Page 2167: ...ed 7 Compare the discharge air temperature read ing to the Performance Temperature and Pressure chart If the temperature reading is high clamp off both heater hoses inlet and outlet wait five min utes...

Page 2168: ...ulty fuse 2 Check the fuses in the Power Distribution Center and the junction block Repair the shorted circuit or component and replace the fuses if required 3 Faulty a c compressor clutch coil 3 Refe...

Page 2169: ...rigerant flow through the a c evaporator is restricted 3 Refer to Plumbing A C Evaporator Removal Installation in this group Replace the restricted a c orator if required 4 Faulty a c compressor 4 Ref...

Page 2170: ...a c condenser 3 Refer to Plumbing A C Condenser in this group Replace the restricted a c condenser if required 4 Restricted Filter Drier 4 See Filter Drier in the Removal and Installation section of...

Page 2171: ...ator The blend door Improper engine coolant temperature Obstructed cowl air intake Heater Diagnosis CONDITION POSSIBLE CAUSE CORRECTION INSUFFICIENT HEATER OUTPUT 1 Incorrect engine coolant level 1 Ch...

Page 2172: ...the atmosphere MANIFOLD GAUGE SET CONNECTIONS CAUTION Do not use an R 12 manifold gauge set on an R 134a system The refrigerants are not com patible and system damage will result LOW PRESSURE GAUGE H...

Page 2173: ...or hardwired to control head 9credit card9 resistor block COOLING FAN V 6 V 8 electrical mechanical cooling fan module I 4 2 5 electric fan Relay CLUTCH Electro magnetic Control relay PCM Draw 2 0 3 9...

Page 2174: ...INSTALLATION 18 AMBIENT TEMP SENSOR DESCRIPTION 18 OPERATION 18 DIAGNOSIS AND TESTING 18 AMBIENT TEMPERATURE SENSOR 18 REMOVAL 19 INSTALLATION 19 BLEND DOOR ACTUATOR DESCRIPTION 19 OPERATION 19 REMOV...

Page 2175: ...he PCM may delay compressor clutch engagement for up to thirty seconds Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES POWERTRAIN CONTROL MODULE DESCRIPTION DIAGNOSIS AND TESTING A C COMPRESSOR CLUT...

Page 2176: ...refrigerant system can remain fully charged during compressor clutch pulley or coil replacement The compressor clutch can be serviced in the vehicle 1 Disconnect and isolate the battery negative cabl...

Page 2177: ...aced if there is excessive wear or scoring If the friction surfaces are oily inspect the shaft and nose area of the compressor for oil Remove the felt from the front cover If the felt is saturated wit...

Page 2178: ...a clutch fail ure and severe damage to the front housing of the compressor 8 Install the original clutch shims on the com pressor shaft 9 Install the clutch plate Use the shaft protector Special Tool...

Page 2179: ...stribution Center PDC in the engine compart ment Refer to the PDC label for relay identification and location The compressor clutch relay cannot be repaired and if faulty or damaged it must be replace...

Page 2180: ...DC INSTALLATION 1 Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place 2 Install the PDC cover 3 Connect the battery...

Page 2181: ...Refer to 8 ELECTRICAL INSTRUMENT CLUSTER REMOVAL AND INSTALLATION 5 Connect the battery negative cable 6 Perform A C cool down test with DRB III A C LOSS OF CHARGE SWITCH DESCRIPTION The a c loss of c...

Page 2182: ...rings as they are made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the com pressor in the vehicle 2 Install and tighten the loss of charge switch o...

Page 2183: ...erature sensor signal circuit volt age to the HVAC control head unit Based upon the resistance in the sensor the HVAC control head unit senses a specific voltage on the temperature sensor signal circu...

Page 2184: ...blend door actuators The single zone blend door actuator is located on the driver side end of the heat er A C housing unit close to the dash panel In the dual zone system the same blend door actuator...

Page 2185: ...les in the two lower finger formations of the heater air conditioner hous ing near the dash panel 5 Remove the heater core shield from the distri bution housing 6 Disconnect the HVAC wire harness conn...

Page 2186: ...harness connector 4 Pull the front blower motor resistor and its wire harness out of the plenum panel and through the cowl plenum access hole far enough to access the wire harness connector 5 Remove t...

Page 2187: ...ally cali brated by the heater A C control module The mode door actuator cannot be adjusted or repaired and if damaged or faulty it must be replaced OPERATION The mode door actuator is connected to th...

Page 2188: ...splines that connects it to the linkage that drives the recirculation air door The recirculation door actuator does not require mechanical indexing to the recirculation air door as it is electronical...

Page 2189: ...HE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Position the recirculation door actua...

Page 2190: ...in the junction block Blower motor speed is controlled by regulating the ground path through the heater A C mode control switch the blower motor switch the blower motor resistor and the voltage reduct...

Page 2191: ...ON 1 Place the blower motor air spoiler and wheel assembly inside the heater A C housing and feed the blower motor wire harness connector through the grommet hole in the dash panel side of the housing...

Page 2192: ...oor panel and under the instrument panel Refer to 23 BODY INTERIOR CARPETS AND FLOOR MATS INSTALLATION HVAC HOUSING DESCRIPTION All vehicles are equipped with a common heater A C housing assembly The...

Page 2193: ...TH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE...

Page 2194: ...NG RE FRIGERANT STANDARD PROCEDURE 10 Reinstall the instrument panel in the vehicle Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY INSTALLA TION 11 Connect the battery negative cable 12...

Page 2195: ...TAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove the instrument panel from the vehicle Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PAN...

Page 2196: ...STANDARD PROCEDURE 46 REFRIGERANT OIL LEVEL 46 SUCTION LINE REMOVAL 46 INSTALLATION 47 REFRIGERANT LINE COUPLER DESCRIPTION 47 OPERATION 47 REMOVAL 48 INSTALLATION 48 PLUMBING DESCRIPTION REFRIGERANT...

Page 2197: ...NT AND REFRIGERANT OIL VAPOR OR MIST EXPOSURE MAY IRRITATE THE EYES NOSE AND OR THROAT WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM SERI OUS EYE INJURY CAN RESULT FROM DI...

Page 2198: ...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 oil container immediately after using Sto...

Page 2199: ...to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 2 Connect and dispense 0 283 kilograms 0 625 pounds or 10 ounces of R 134a refrigerant into the evacuated refrig...

Page 2200: ...or repaired and must not be removed or otherwise dis turbed The valve is only serviced as a part of the compressor assembly DIAGNOSIS AND TESTING A C COMPRESSOR When investigating an air conditioning...

Page 2201: ...ON BEFORE PERFORMING THE FOLLOWING OPERATION 1 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDITION ING PLUMBING REFRIGERANT STANDARD PROCEDURE 2 Disconnect and isolat...

Page 2202: ...ator The condenser is a heat exchanger that allows the high pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins thus causing the...

Page 2203: ...from the vehicle INSTALLATION WARNING Refer to 24 HEATING AIR CONDI TIONING PLUMBING WARNING AND Refer to 24 HEATING AIR CONDITIONING PLUMBING CAU TION BEFORE PERFORMING THE FOLLOWING OPERATION CAUTI...

Page 2204: ...the flow of refrigerant in the system A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose In addition the flexible hose r...

Page 2205: ...R PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT AND POSSIBLE PERSONAL INJURY NOTE If the evaporator is replaced add 60 millili ters 2 fluid ounces of refrigerant oil to the refrig erant sy...

Page 2206: ...ng on the liquid line tube fitting Connect and tighten the tube fitting on the front half of the liquid line to the tube fitting on the rear half of the liquid line Refer to 24 HEATING AIR CONDITIONIN...

Page 2207: ...et tube Connect both refrigerant lines to the accumulator Tighten the fasteners to 25 99 3 39 N m 230 30 in lbs 3 Tighten the accumulator retaining band screw to 4 5 N m 40 in lbs 4 Plug the wire harn...

Page 2208: ...Refill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE or Refer to 7 COOLING STANDARD PROCEDURE 8 Install the passenger side rear trim panel Refer to 23 BODY INTERIOR QUARTER PANEL TRIM INS...

Page 2209: ...tem R 134a refrigerant system service ports service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R 134a system is not accidentally con...

Page 2210: ...ation that meets SAE Standard J2210 and a manifold gauge set to the refrigerant system of the vehicle 2 Open the low and high side valves and start the charging station vacuum pump When the suc tion g...

Page 2211: ...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 ounce...

Page 2212: ...ittings Install the refrigerant line cou plers to the condenser and the accumulator Refer to 24 HEATING AIR CONDITIONING PLUMBING INSTALLATION Tighten the fasteners to 22 3 38 N m 200 30 in lbs 2 Inst...

Page 2213: ...Refer to 24 HEATING AIR CONDITIONING PLUMBING CAU TION BEFORE PERFORMING THE FOLLOWING OPERATION 1 Check to ensure that the garter spring is located within the cage of the male coupler fitting and th...

Page 2214: ...perating conditions for which the PCM monitors and sets DTC s Refer to Moni tored Systems Components and Non Monitored Cir cuits in this section Technicians must retrieve stored DTC s by connect ing t...

Page 2215: ...ngine icon on instrument panel G Generator lamp illuminated Generic Scan Tool P Code DRB Scan Tool Display Brief Description of DTC P0030 M 1 1 O2 Sensor Heater Relay Circuit Problem detected in oxyge...

Page 2216: ...heater element malfunction P0136 M 1 2 O2 Sensor Heater Circuit Malfunction Oxygen sensor heater element malfunction P0137 M 1 2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained bel...

Page 2217: ...0174 M 2 1 Fuel System Lean A lean air fuel mixture has been indicated by an abnormally rich correction factor P0175 M 2 1 Fuel System Rich A rich air fuel mixture has been indicated by an abnormally...

Page 2218: ...rmance P0219 Crankshaft Position Sensor Overspeed Signal Engine has exceeded rpm limits P0222 M Idle Validation Signals Both Low Problem detected with idle validation circuits within APPS P0223 M Idle...

Page 2219: ...em with voltage signal from CKP P0340 M No Cam Signal At PCM No fuel sync P0341 M Camshaft Position CMP Sensor Signal Problem with voltage signal from CMP P0350 Ignition Coil Draws Too Much Current A...

Page 2220: ...noid Circuit An open or shorted condition detected in the secondary air air switching aspirator solenoid control circuit P0420 M 1 1 Catalytic Converter Efficiency Catalyst 1 1 efficiency below requir...

Page 2221: ...co processors in the control module P0601 M Internal Controller Failure Internal control module fault condition check sum detected P0602 M ECM Fueling Calibration Error ECM Internal fault condition de...

Page 2222: ...en or shorted condition detected in the torque converter part throttle unlock solenoid control circuit 3 or 4 speed auto trans only P0748 M Governor Pressur Sol Control Trans Relay Circuits An open or...

Page 2223: ...mperature remains below normal operating temperatures during vehicle travel Thermostat P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay control circui...

Page 2224: ...d in the ASD or CNG shutoff relay control ckt P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto shutdown relay circuit P1389 No ASD Relay Output Voltage At PC...

Page 2225: ...ow P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control circuit of the high speed radiator fan control relay P1490 Low Speed Fan CTRL Relay Circuit An open or s...

Page 2226: ...e Sensor Volts Too Low A C pressure sensor input below minimum acceptable voltage P1599 A C Sensor Input Lo Problem detected in air conditioning electrical circuit P1680 Clutch Released Switch Circuit...

Page 2227: ...rol Module No CCD J1850 messages received from the body control module P1696 PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the control module P1697 PCM Failure...

Page 2228: ...or shorted condition is detected in the Transmission Relay control circuit This relay supplies power to the TCC P1765 M Trans 12 Volt Supply Relay Ctrl Circuit Current state of solenoid output port is...

Page 2229: ...ltage that is inversely propor tional to the amount of oxygen in the exhaust The information obtained by the sensor is used to calcu late the fuel injector pulse width This maintains a 14 7 to 1 Air F...

Page 2230: ...bons oxides of nitro gen and carbon monoxide The catalyst works best when the Air Fuel A F ratio is at or near the opti mum of 14 7 to 1 The PCM is programmed to maintain the optimum air fuel ratio of...

Page 2231: ...risen by at least 40 F since the engine has been started DESCRIPTION COMPONENT MONITORS There are several components that will affect vehi cle emissions if they malfunction If one of these com ponents...

Page 2232: ...in memory Other diagnostic trouble code criteria might include engine RPM limits or input voltages from other sensors or switches that must be present before verifying a diagnostic trouble code condi...

Page 2233: ...xt key cycle the MIL is not illuminated and both MIL states read OFF Diagnostic Trouble Codes DTCs With OBD II different DTC faults have different priorities according to regulations As a result the p...

Page 2234: ...d trip three required and turn off the MIL Misfire Good Trip If the following conditions are met the PCM will count one good trip three required in order to turn off the MIL Operating in Similar Condi...

Page 2235: ...t Done This Trip Indicates that the monitor has already been run and completed during the current trip MISFIRE Same Misfire Warm Up State Indicates if the misfire occurred when the engine was warmed u...

Page 2236: ...ts the emis sion of fuel tank vapors into the atmosphere When fuel evaporates in the fuel tank the vapors pass through vent hoses or tubes to a charcoal filled evap orative canister The canister tempo...

Page 2237: ...purge solenoid DCP regulates the rate of vapor flow from the EVAP can ister to the intake manifold The Powertrain Control Module PCM operates the solenoid During the cold start warm up period and the...

Page 2238: ...ponent to relieve tank pressure If equipped with a California emissions package and a Leak Detection Pump LDP the cap must be tight ened securely If cap is left loose a Diagnostic Trouble Code DTC may...

Page 2239: ...enoid is energized with a fixed duration pulse Subsequent fixed pulses occur when the diaphragm reaches the switch closure point The spring in the pump is set so that the system will achieve an equali...

Page 2240: ...ray Refer to 8 Battery for procedures 8 Carefully remove vapor vacuum lines at LDP 9 Disconnect electrical connector at LDP 10 Remove 3 LDP mounting screws Fig 7 and remove LDP from vehicle INSTALLATI...

Page 2241: ...em consists of a PCV valve mounted on the cylinder head valve cover with a hose extending from the valve to the intake manifold Fig 8 Another hose connects the opposite cylinder head valve cover to th...

Page 2242: ...spring forces the plunger back against the seat Fig 12 This will prevent vapors from flowing through the valve During periods of high manifold vacuum such as idle or cruising speeds vacuum is suffici...

Page 2243: ...vapors from flowing through the valve During periods of high manifold vacuum such as idle or cruising speeds vacuum is sufficient to com pletely compress spring It will then pull the plunger to the t...

Page 2244: ...e To prevent damage to PCV valve locating tabs valve must be pointed downward for removal Do not force valve from oil filler tube 3 After valve is removed check condition of valve o ring Fig 21 Also P...

Page 2245: ...er tube Fig 23 Two locating tabs are located on the side of the valve Fig 23 These 2 tabs fit into a cam lock in the oil filler tube An o ring seals the valve to the filler tube 1 Disconnect PCV line...

Page 2246: ...VAPOR CANISTER DESCRIPTION A maintenance free EVAP canister is used on all vehicles The EVAP canister is located under the vehicle inside the left frame rail in front of the fuel tank Fig 24 OPERATIO...

Page 2247: ...EVAP canister is located below the vehicle inside the left frame rail in front of the fuel tank Fig 25 1 Position canister locating pins into mounting bracket grommets Fig 25 and install mounting nut...

Page 2248: ...sler 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 c...

Page 2249: ...Fig 1 NEW VEHICLE PREPARATION FORM 30 2 NEW VEHICLE PREPARATION AN INTRODUCTION Continued...

Page 2250: ...fuses 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...

Page 2251: ...minutes after 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 exc...

Page 2252: ...ary cavities are full to the maximum level as indicated POWER STEERING RESERVOIR CAUTION Only use fluid that meets specified requirements Petroleum fluids such as MoparT Power Steering Fluid are speci...

Page 2253: ...ended Refer to the Service Information for specificate Mopart antifreeze recom mendation antifreeze and distilled water Use a higher concentration up to 65 if a lower freeze point is required Do not u...

Page 2254: ...e tire placard or the Safety Certifica tion Label check that the correct tires are mounted on the vehicle Fig 9 2 Install valve stem extensions as required 3 Using the tire placard or the Safety Certi...

Page 2255: ...s are aligned properly NOTE Painted on accent strips require a unique paint for touch ups 4 Check that the door panels have even gaps and fit well with adjacent body panels Fig 13 5 Check that the tai...

Page 2256: ...Fig 13 Door Panel and Fender Fit Fig 14 Tailgate Fit and Alignment Fig 15 Hood Fit and Alignment Fig 16 Keyless Entry Transmitter AN NEW VEHICLE PREPARATION 30 9 EXTERIOR Continued...

Page 2257: ...ld 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 Partially close the door to check the open...

Page 2258: ...LIGHTS AND SWITCHES 1 Remove protective film from all switch bezels 2 Operate and visually inspect all interior lights and switches including Dome map lamps Vanity mirror lamps Glove box light Ashtray...

Page 2259: ...proper seat belt retraction 4 Check that safety labels regarding the use of seat belts and air bags are in place such as on the sun visors Fig 26 5 Ensure head restraints are properly installed Inspec...

Page 2260: ...all seat headrests 5 Check that all seats are securely located in their adjustable tracks INSPECTION WINDOWS DOORS AND LOCKS 1 Check all power window switches for proper operation Fig 27 2 Run all pow...

Page 2261: ...the parking brake operation Check the engine s performance Check the transmission s performance for smooth quiet operation If the vehicle is a 4x4 check that the transfer case shifts easily among all...

Page 2262: ...holds If it does not hold the transmission requires further service 2 Make sure shift lever operates easily smoothly Fig 31 Check for smooth shifting Check for proper upshifting and downshifting MANUA...

Page 2263: ...on when the parking brake is applied and is off when the brake is released INSPECTION SERVICE BRAKES 1 Check brake warning light operation at vehicle startup 2 Check ABS warning light operation at ve...

Page 2264: ...wer motor in all speeds Fig 39 4 Operate system in all modes heat defrost etc 5 Operate the rear heater if equipped 6 Check for hot air output at all outlets 7 Operate temperature switch Fig 39 8 Ensu...

Page 2265: ...Fig 40 INSPECTION MIRROR 1 Check operation of rearview mirror s day night function if equipped 2 Check ease of adjustment for all mirrors power or manual Fig 41 and Fig 42 Fig 39 HEATER AND A C CONTRO...

Page 2266: ...works properly INSPECTION GAUGES WARNING LIGHTS 1 Ensure that all gauges instrument indicator lights warning lights and instrument panel lights are functioning properly Fig 45 2 Inspect operation of m...

Page 2267: ...least once a week Snow should be washed away more often since it can trap harmful contaminants Dry all horizontal surfaces 2 The IOD fuse should be removed in order to prevent battery drain and possib...

Page 2268: ...s equipped with this feature When using the RKE transmitter to unlock the doors pressing the unlock button once when the feature is enabled unlocks only the driver s door Pushing the RKE transmitter u...

Page 2269: ...s surfaces Remove all protective covers Remove undercoat overspray excess window sealer and excess weatherstrip adhesive Inspect interior trim seats carpeting and mold ings Clean as necessary Remove s...

Page 2270: ...INSTALLATION SEAT BELT TURNING LOOP 8O 32 ADJUSTER REMOVAL SEAT BELT TURNING LOOP 8O 32 ADJUSTER ASSEMBLY DESCRIPTION ROCKER ARM 9 160 ADJUSTER ASSEMBLY INSTALLATION ROCKER ARM 9 160 9 237 ADJUSTER AS...

Page 2271: ...198 21 381 ASSEMBLY SINGLE CARDAN UNIVERSAL JOINTS 3 11 ASSEMBLY TRANSFER CASE NV233 21 549 ASSEMBLY TRANSFER CASE NV244 21 581 ASSEMBLY VALVE BODY 21 245 21 428 21 535 ASSEMBLY WHEEL CYLINDERS 5 28...

Page 2272: ...FT 9 238 9 31 9 90 BEARINGS INSTALLATION CRANKSHAFT MAIN 9 242 9 39 9 94 BEARINGS INSTALLATION DIFFERENTIAL CASE 3 103 3 41 3 72 BEARINGS OPERATION CRANKSHAFT MAIN 9 241 9 35 9 93 BEARINGS REMOVAL AXL...

Page 2273: ...138 BOX SEAL REMOVAL CARGO 23 138 B PILLAR TRIM INSTALLATION 23 113 B PILLAR TRIM REMOVAL 23 112 BRACKET INSTALLATION INSIDE HOOD RELEASE 23 105 BRACKET INSTALLATION OVERHEAD CONSOLE 8M 5 BRACKET INS...

Page 2274: ...OVERDRIVE PISTON RETAINER DISASSEMBLY OVERRUNNING CLUTCH 21 182 21 366 CAM OVERDRIVE PISTON RETAINER INSPECTION OVERRUNNING CLUTCH 21 182 21 366 CAM OVERDRIVE PISTON RETAINER OPERATION OVERRUNNING CLU...

Page 2275: ...TION 8J 15 CHECK OUT STANDARD PROCEDURE OWNER 30 22 CHECK VALVE DESCRIPTION 8R 7 CHECK VALVE INSTALLATION 8R 8 CHECK VALVE OPERATION 8R 7 CHECK VALVE REMOVAL 8R 7 CHECKING BATTERY ELECTROLYTE LEVEL ST...

Page 2276: ...RD PROCEDURE ERASING TRANSMITTER 8M 11 CODES STANDARD PROCEDURE SETTING TRANSMITTER 8M 11 CODES SPECIFICATIONS 2001 AN PAINT COLOR 23 121 COIL DIAGNOSIS AND TESTING A C COMPRESSOR CLUTCH 24 10 COIL RE...

Page 2277: ...11 6 CONVERTER DESCRIPTION TORQUE 21 202 21 385 21 521 CONVERTER INSTALLATION TORQUE 21 207 21 390 21 526 CONVERTER OPERATION TORQUE 21 205 21 388 21 525 CONVERTER REMOVAL TORQUE 21 207 21 390 21 526...

Page 2278: ...9 147 CYLINDER HEAD INSTALLATION RIGHT 9 148 CYLINDER HEAD OPERATION 9 20 9 231 9 82 CYLINDER HEAD REMOVAL 9 21 9 231 9 83 CYLINDER HEAD REMOVAL LEFT 9 143 CYLINDER HEAD REMOVAL RIGHT 9 144 CYLINDER H...

Page 2279: ...CATOR DESCRIPTION 8J 18 DOOR AJAR INDICATOR OPERATION 8J 18 DOOR AJAR SWITCH DESCRIPTION 8L 26 DOOR AJAR SWITCH DIAGNOSIS AND TESTING 8L 27 DOOR AJAR SWITCH OPERATION 8L 26 DOOR CYLINDER LOCK SWITCH D...

Page 2280: ...DESCRIPTION 25 1 END INSTALLATION INNER TIE ROD 19 17 END INSTALLATION OUTER TIE ROD 19 18 END REMOVAL INNER TIE ROD 19 17 END REMOVAL OUTER TIE ROD 19 17 END CAP INSTALLATION 23 100 END SPLASH SHIELD...

Page 2281: ...ADIATOR 7 61 FAN ELECTRIC OPERATION RADIATOR 7 61 FAN ELECTRIC REMOVAL RADIATOR 7 61 FAN VISCOUS CLEANING RADIATOR 7 61 FAN VISCOUS INSPECTION RADIATOR 7 61 FAN DRIVE DIAGNOSIS AND TESTING VISCOUS 7 4...

Page 2282: ...3 139 FRONT DOOR OUTSIDE HANDLE INSTALLATION 23 64 FRONT DOOR OUTSIDE HANDLE REMOVAL 23 63 FRONT DOOR UPPER INSTALLATION SPEAKER 8A 18 FRONT DOOR UPPER REMOVAL SPEAKER 8A 18 FRONT DOOR WATERDAM INSTAL...

Page 2283: ...THERSTRIP INSTALLATION FRONT DOOR 23 138 GLASS RUN WEATHERSTRIP INSTALLATION REAR DOOR 23 140 GLASS RUN WEATHERSTRIP REMOVAL FRONT DOOR 23 138 GLASS RUN WEATHERSTRIP REMOVAL REAR DOOR 23 140 GLASS WEA...

Page 2284: ...23 87 HOOD LATCH SAFETY CATCH INSPECTION 30 4 HOOD RELEASE BRACKET INSTALLATION INSIDE 23 105 HOOD RELEASE BRACKET REMOVAL INSIDE 23 104 HOOD RELEASE CABLE INSTALLATION 23 88 HOOD RELEASE CABLE REMOV...

Page 2285: ...CV JOINT 3 21 INNER REMOVAL CV JOINT 3 20 INNER BELT WEATHERSTRIP INSTALLATION FRONT DOOR 23 139 INNER BELT WEATHERSTRIP INSTALLATION REAR DOOR 23 140 INNER BELT WEATHERSTRIP REMOVAL FRONT DOOR 23 139...

Page 2286: ...KEY IMMOBILIZER MODULE DESCRIPTION SENTRY 8E 15 KEY IMMOBILIZER MODULE INSTALLATION SENTRY 8E 17 KEY IMMOBILIZER MODULE OPERATION SENTRY 8E 16 KEY IMMOBILIZER MODULE REMOVAL SENTRY 8E 17 KEY IMMOBILI...

Page 2287: ...ATION 21 505 LINE PRESSURE LP SENSOR OPERATION 21 505 LINE PRESSURE LP SENSOR REMOVAL 21 505 LINES DESCRIPTION BRAKE 5 10 LINES DESCRIPTION FUEL 14 7 LINES DESCRIPTION REFRIGERANT 24 31 LINES DESCRIPT...

Page 2288: ...15 MIRROR REMOVAL REAR VIEW 23 118 MIRROR REMOVAL SIDE VIEW 23 84 MIRROR REMOVAL SIDEVIEW 8N 16 MIRROR GRID DESCRIPTION HEATED 8G 5 MIRROR SUPPORT BRACKET INSTALLATION REAR VIEW 23 119 MIRROR SWITCH...

Page 2289: ...UAL 21 74 O2 HEATER RELAY DESCRIPTION 14 47 O2 HEATER RELAY INSTALLATION 14 47 O2 HEATER RELAY OPERATION 14 47 O2 HEATER RELAY REMOVAL 14 47 O2 SENSOR DESCRIPTION 14 47 O2 SENSOR OPERATION 14 47 ODOME...

Page 2290: ...23 68 PANEL INSTALLATION VALANCE 13 13 PANEL REMOVAL QUARTER TRIM 23 116 PANEL REMOVAL REAR DOOR TRIM 23 75 PANEL REMOVAL TRIM 23 67 PANEL REMOVAL VALANCE 13 13 PANEL DEMISTER DUCTS INSTALLATION INST...

Page 2291: ...TING 8N 10 POWER LOCK SWITCH INSTALLATION 8N 11 POWER LOCK SWITCH OPERATION 8N 10 POWER LOCK SWITCH REMOVAL 8N 11 POWER LOCK SYSTEM DESCRIPTION 8N 1 POWER LOCK SYSTEM OPERATION 8N 3 POWER MIRROR SWITC...

Page 2292: ...OVAL LEAK DETECTION 25 27 PUMP REMOVAL OIL 9 113 9 190 9 261 9 56 PUMP AMPERAGE TEST DIAGNOSIS AND TESTING FUEL 14 9 PUMP BYPASS DESCRIPTION WATER 7 57 PUMP BYPASS OPERATION WATER 7 58 PUMP CAPACITY T...

Page 2293: ...LATION 23 128 REAR SEAT BACK CLUB CAB REMOVAL 23 128 REAR SEAT BELT RETRACTOR INSTALLATION 8O 28 REAR SEAT BELT RETRACTOR REMOVAL 8O 27 REAR SEAT CUSHION COVER INSTALLATION QUAD CAB 23 130 REAR SEAT C...

Page 2294: ...RESERVOIR INSTALLATION VACUUM 8P 8 RESERVOIR INSTALLATION WASHER 8R 13 RESERVOIR OPERATION VACUUM 8P 7 RESERVOIR OPERATION WASHER 8R 12 RESERVOIR REMOVAL FLUID 5 21 RESERVOIR REMOVAL VACUUM 8P 8 RESE...

Page 2295: ...UB CAB REMOVAL REAR 23 128 SEAT BELT RETRACTOR INSTALLATION REAR 8O 28 SEAT BELT RETRACTOR REMOVAL REAR 8O 27 SEAT BELT BUCKLE INSTALLATION FRONT 8O 23 SEAT BELT BUCKLE REMOVAL FRONT 8O 22 SEAT BELT S...

Page 2296: ...SASSEMBLY PLANETARY GEARTRAIN OUTPUT 21 187 21 371 SHAFT FRONT INSTALLATION PROPELLER 3 8 SHAFT FRONT REMOVAL PROPELLER 3 8 SHAFT INSPECTION PLANETARY GEARTRAIN OUTPUT 21 187 21 373 SHAFT INSTALLATION...

Page 2297: ...IONS SPECIFICATIONS 24 8 SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS 23 31 SPECIFICATIONS TIRE SPECIFICATION 22 9 SPECIFICATIONS TORQUE 7 17 SPECIFICATIONS TORQUE 9 138 9 18 9 227 9 75 SPECIFICATIONS...

Page 2298: ...9 SWITCH DESCRIPTION CLUTCH PEDAL POSITION 6 15 SWITCH DESCRIPTION DOOR AJAR 8L 26 SWITCH DESCRIPTION DOOR CYLINDER LOCK 8N 5 SWITCH DESCRIPTION DRIVER SEAT 8N 17 SWITCH DESCRIPTION HEADLAMP 8L 14 SWI...

Page 2299: ...OCEDURE REFRIGERANT 24 34 24 45 SYSTEM CLEANING REVERSE FLUSHING STANDARD PROCEDURE COOLING 7 16 SYSTEM EVACUATE STANDARD PROCEDURE REFRIGERANT 24 45 SYSTEM FLOW 3 9L 5 9L ENGINE DESCRIPTION COOLING 7...

Page 2300: ...ERATION 9 120 TIMING CHAIN STRETCH INSPECTION MEASURING 9 121 TIMING CHAIN WEAR STANDARD PROCEDURE CHECKING 9 60 TIMING CHAIN WEAR STANDARD PROCEDURE MEASURING 9 200 TIMING DRIVE SYSTEM DESCRIPTION 9...

Page 2301: ...N CONTROL MODULE OPERATION 8E 18 TRANSMISSION CONTROL RELAY DESCRIPTION 21 527 TRANSMISSION CONTROL RELAY OPERATION 21 527 TRANSMISSION FILL STANDARD PROCEDURE 21 147 21 328 21 488 TRANSMISSION FLUID...

Page 2302: ...21 254 21 438 VALVE BODY ASSEMBLY 21 245 21 428 21 535 VALVE BODY CLEANING 21 244 21 427 21 534 VALVE BODY DESCRIPTION 21 213 21 396 21 530 VALVE BODY DISASSEMBLY 21 233 21 416 21 532 VALVE BODY INSP...

Page 2303: ...R SECONDARY 23 141 WEATHERSTRIP REMOVAL COWL 23 138 WEATHERSTRIP REMOVAL FRONT DOOR 23 139 WEATHERSTRIP REMOVAL FRONT DOOR 2ND 23 139 WEATHERSTRIP REMOVAL FRONT DOOR GLASS RUN 23 138 WEATHERSTRIP REMO...

Page 2304: ...7 WIPER RELAY REMOVAL 8R 19 WIPERS WASHERS DESCRIPTION 8R 1 WIPERS WASHERS OPERATION 8R 2 WIPERS WASHERS ROAD TEST INSPECTION WINDSHIELD 30 18 WIRE SPLICING STANDARD PROCEDURE 8W 01 11 WIRING INSPECTI...

Page 2305: ......

Page 2306: ...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 2307: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

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