manualshive.com logo in svg

Dodge dakota 2002, Service Manual

The Dodge Dakota 2002 Service Manual is a comprehensive guide for maintaining and repairing your vehicle. This manual provides step-by-step instructions and diagrams to help you troubleshoot and fix issues with your Dodge Dakota. Download it for free from manualshive.com to keep your truck running smoothly.

Share
Download
background image

CARDAN UNIVERSAL JOINTS -

DISASSEMBLY, SINGLE . . . . . . . . . . . . . . . . . . 3-9

CARGO BOX - INSTALLATION

. . . . . . . . . . . 23-37

CARGO BOX - REMOVAL . . . . . . . . . . . . . . . 23-37
CARGO BOX - TIE DOWN -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-37

CARGO BOX - TIE DOWN - REMOVAL

. . . . 23-37

CARGO LAMP INDICATOR -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J-20

CARGO LAMP INDICATOR - OPERATION

. . 8J-20

CARPETS AND FLOOR MATS -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-66

CARPETS AND FLOOR MATS - REMOVAL

. 23-66

CASCADE OVERFLOW VALVE -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-77

CASCADE OVERFLOW VALVE -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-77

CASE - NV241 GENII - ASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-604

CASE - NV241 GENII - CLEANING,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-602

CASE - NV241 GENII - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

CASE - NV241 GENII - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-591

CASE - NV241 GENII - DIAGNOSIS AND

TESTING, TRANSFER . . . . . . . . . . . . . . . . . 21-592

CASE - NV241 GENII - DISASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-593

CASE - NV241 GENII - INSPECTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-602

CASE - NV241 GENII - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-614

CASE - NV241 GENII - OPERATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-591

CASE - NV241 GENII - REMOVAL,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-593

CASE - NV243 - ASSEMBLY, TRANSFER

. . 21-670

CASE - NV243 - CLEANING, TRANSFER

. . 21-668

CASE - NV243 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

CASE - NV243 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-658

CASE - NV243 - DIAGNOSIS AND

TESTING, TRANSFER . . . . . . . . . . . . . . . . . 21-659

CASE - NV243 - DISASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-660

CASE - NV243 - INSPECTION, TRANSFER . 21-668
CASE - NV243 - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-679

CASE - NV243 - OPERATION, TRANSFER

. 21-659

CASE - NV243 - REMOVAL, TRANSFER

. . 21-660

CASE - NV271 - ASSEMBLY, TRANSFER

. . 21-637

CASE - NV271 - CLEANING, TRANSFER

. . 21-635

CASE - NV271 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

CASE - NV271 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-623

CASE - NV271 - DIAGNOSIS AND

TESTING, TRANSFER . . . . . . . . . . . . . . . . . 21-624

CASE - NV271 - DISASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-625

CASE - NV271 - INSPECTION, TRANSFER . 21-635
CASE - NV271 - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-649

CASE - NV271 - OPERATION, TRANSFER

. 21-623

CASE - NV271 - REMOVAL, TRANSFER

. . 21-625

CASE - NV273 - ASSEMBLY, TRANSFER

. . 21-701

CASE - NV273 - CLEANING, TRANSFER

. . 21-698

CASE - NV273 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

CASE - NV273 - DESCRIPTION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-687

CASE - NV273 - DIAGNOSIS AND

TESTING, TRANSFER . . . . . . . . . . . . . . . . . 21-688

CASE - NV273 - DISASSEMBLY,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-689

CASE - NV273 - INSPECTION, TRANSFER . 21-699
CASE - NV273 - INSTALLATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-713

CASE - NV273 - OPERATION, TRANSFER

. 21-688

CASE - NV273 - REMOVAL, TRANSFER

. . 21-689

CASE BEARINGS - INSTALLATION,

DIFFERENTIAL . . . . . . 3-121,3-148,3-39,3-65,3-94

CASE BEARINGS - REMOVAL,

DIFFERENTIAL . . . . . . 3-121,3-148,3-39,3-64,3-93

CASE CONTROL MODULE -

DESCRIPTION, TRANSFER . . . . . . . . . . . . . 8E-15

CASE CONTROL MODULE - OPERATION,

TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15

CASE, NV241 GENII - TRANSFER

. . . . . . . 21-614

CASE, NV241/NV243 - TRANSFER

. . . . . . 21-615,

21-680

CASE, NV243 - TRANSFER

. . . . . . . . . . . . 21-680

CASE, NV271 - TRANSFER

. . . . . . . . . . . . 21-649

CASE NV271/NV273, SPECIAL TOOLS -

TRANSFER . . . . . . . . . . . . . . . . . . . 21-650,21-714

CASE, NV273 - TRANSFER

. . . . . . . . . . . . 21-713

CASE SKID PLATE - INSTALLATION,

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

CASE SKID PLATE - REMOVAL,

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

CASTER ADJUSTMENT - STANDARD

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

CASTER AND TOE ADJUSTMENT -

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

CATALYTIC CONVERTER - DESCRIPTION

. . . 11-4

CATALYTIC CONVERTER - OPERATION

. . . . . 11-4

CATCH - INSTALLATION, LATCH STRIKER

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

CATCH - REMOVAL, LATCH STRIKER /

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

CAUSES OF BURNT FLUID - DIAGNOSIS

AND TESTING . . . . . . . . . . 21-201,21-381,21-541

CAUTION - SERVICE CAUTIONS

. . . . . . . . . 24-33

CAUTION, HALF SHAFT

. . . . . . . . . . . . . . . . . 3-11

CAUTION, INTERIOR

. . . . . . . . . . . . . . . . . . 23-63

CAUTION, REFRIGERANT HOSES/LINES/

TUBES PRECAUTIONS. . . . . . . . . . . . . . . . . . 24-33

CAUTIONS, CAUTION - SERVICE

. . . . . . . . . 24-33

CENTER - DESCRIPTION, ELECTRONIC

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

CENTER - DIAGNOSIS AND TESTING,

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

CENTER - INSTALLATION, ELECTRONIC

VEHICLE INFO . . . . . . . . . . . . . . . . . . . . . . 8M-10

CENTER & LEFT OUTBOARD -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-45

CENTER & LEFT OUTBOARD - REMOVAL . . 8O-43
CENTER - OPERATION, ELECTRONIC

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

CENTER - REMOVAL, ELECTRONIC

VEHICLE INFO . . . . . . . . . . . . . . . . . . . . . . 8M-10

CENTER ANCHOR & RIGHT OUTBOARD -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-45

CENTER ANCHOR & RIGHT OUTBOARD -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-43

CENTER ARMREST / SEAT BACK -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-78

CENTER ARMREST / SEAT BACK -

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

CENTER BEARING - ADJUSTMENTS

. . . . . . . . 3-8

CENTER BEARING - INSTALLATION

. . . . . . . . 3-8

CENTER BEARING - REMOVAL

. . . . . . . . . . . . 3-8

CENTER BEZEL - INSTALLATION,

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 23-58

CENTER BEZEL - REMOVAL,

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 23-58

CENTER HIGH MOUNTED STOP LAMP -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8L-10

CENTER HIGH MOUNTED STOP LAMP -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-10

CENTER HIGH MOUNTED STOP LAMP

UNIT - INSTALLATION . . . . . . . . . . . . . . . . . 8L-10

CENTER HIGH MOUNTED STOP LAMP

UNIT - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-10

CENTER PROGRAMMING - STANDARD

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

CENTER SEAT - INSTALLATION

. . . . . . . . . . 23-77

CENTER SEAT - REMOVAL

. . . . . . . . . . . . . 23-76

CENTER SEAT BACK HINGE -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-80

CENTER SEAT BACK HINGE - REMOVAL . . . 23-79
CENTER SEAT BACK INERTIA HINGE

COVER - INSTALLATION . . . . . . . . . . . . . . . 23-78

CENTER SEAT BACK INERTIA HINGE

COVER - REMOVAL . . . . . . . . . . . . . . . . . . . 23-78

CENTER SEAT BACK LID - INSTALLATION

. 23-80

CENTER SEAT BACK LID - REMOVAL

. . . . . 23-80

CENTER SEAT BELT - INSTALLATION,

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-27

CENTER SEAT BELT - REMOVAL, FRONT

. . 8O-26

CENTER SEAT BELT & RETRACTOR -

INSTALLATION, FRONT . . . . . . . . . . . . . . . . 8O-26

CENTER SEAT BELT & RETRACTOR -

INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8O-40

CENTER SEAT BELT & RETRACTOR -

REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . . 8O-25

CENTER SEAT BELT & RETRACTOR -

REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8O-39

CENTER SEAT CUSHION - INSTALLATION . . 23-80
CENTER SEAT CUSHION - REMOVAL

. . . . . 23-80

CENTER SEAT CUSHION COVER -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-81

CENTER SEAT CUSHION COVER -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23-81

CENTERING - STANDARD PROCEDURE,

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

CERTIFICATION LABEL - DESCRIPTION,

VEHICLE SAFETY . . . . . . . . . . . . . . . . . . . Intro.-1

CHAIN COVER(S) - INSTALLATION,

TIMING BELT . . . . . . . . . . 9-169,9-278,9-404,9-81

CHAIN COVER(S) - REMOVAL, TIMING

BELT . . . . . . . . . . . . . . . . 9-168,9-278,9-404,9-80

CHAIN STRETCH - INSPECTION,

MEASURING TIMING . . . . . . . . . . . . . 9-279,9-405

CHAIN WEAR - STANDARD PROCEDURE,

MEASURING TIMING . . . . . . . . . . . . . . . . . . 9-165

CHAIN WEAR, STANDARD PROCEDURE -

MEASURING TIMING . . . . . . . . . . . . . . . . . . . 9-76

CHAIN/TENSIONER - DESCRIPTION,

TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-222

CHAIN/TENSIONER - OPERATION,

TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-222

CHANNEL - INSTALLATION, GLASS RUN

. . 23-21,

23-31

CHANNEL - REMOVAL, GLASS RUN . . 23-21,23-30
CHARGE - STANDARD PROCEDURE,

REFRIGERANT SYSTEM . . . . . . . . . . 24-35,24-52

CHARGE AIR COOLER AND PLUMBING -

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

CHARGE AIR COOLER AND PLUMBING -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 11-15

CHARGE AIR COOLER AND PLUMBING -

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 11-16

CHARGE AIR COOLER AND PLUMBING -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 11-16

CHARGE AIR COOLER AND PLUMBING -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

CHARGE AIR COOLER AND PLUMBING -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

CHARGE AIR COOLER SYSTEM - LEAKS

- DIAGNOSIS AND TESTING . . . . . . . . . . . . 11-15

CHARGE CAPACITY - SPECIFICATIONS

. . . . 24-35

CHARGING - DESCRIPTION

. . . . . . . . . . . . . 8F-19

CHARGING - OPERATION

. . . . . . . . . . . . . . 8F-19

CHARGING - STANDARD PROCEDURE,

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

CHARGING SYSTEM - DIAGNOSIS AND

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

CHARGING SYSTEM - SPECIFICATIONS,

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

CHART - SPECIFICATIONS, TORQUE

. . . . . . . . 5-6

CHART, SPECIFICATIONS - TORQUE

. . . . . . . 5-40

CHART, SPECIFICATIONS - TORQUE

. . . . . 19-18,

19-22,19-34,19-41

CHART, SPECIFICATIONS - TORQUE

. . 2-10,2-28,

2-39

CHART, SPECIFICATIONS - TORQUE

. . . . . . 22-13

CHARTS - DIAGNOSIS AND TESTING,

DIAGNOSIS . . . . . . . . . . . . . . . . . . 21-144,21-325

CHARTS - DIAGNOSIS AND TESTING,

SMOKE DIAGNOSIS . . . . . . . . . . . . . . . . . . . 9-285

CHECK - STANDARD PROCEDURE,

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

CHECK - STANDARD PROCEDURE, FLUID

LEVEL . . . . . . . . . . . . . . . . 21-201,21-381,21-542

CHECK - STANDARD PROCEDURE, OIL

PUMP VOLUME . . . . . . . . . . . . . . . . . . . . . 21-563

CHECK CABLE - INSTALLATION

. . . . . . . . . 23-15

CHECK CABLE - REMOVAL

. . . . . . . . . . . . . 23-15

CHECK GAUGES INDICATOR -

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

CHECK GAUGES INDICATOR -

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

CHECK VALVE - DESCRIPTION

. . . . . . . . . . . 8R-8

CHECK VALVE - INSTALLATION

. . . . . . . . . . 8R-9

CHECK VALVE - OPERATION

. . . . . . . . . . . . . 8R-8

CHECK VALVE - REMOVAL

. . . . . . . . . . . . . . 8R-8

CHECKING - STANDARD PROCEDURE,

POWER STEERING FLUID LEVEL . . . . . . . . 19-42

6

INDEX

DR

Description

Group-Page

Description

Group-Page

Description

Group-Page

Summary of Contents for dakota 2002

Page 1: ...8I Ignition Control 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...

Page 2: ...TION LABEL DESCRIPTION A vehicle safety certification label Fig 1 is attached to every DaimlerChrysler Corporation vehi cle The label certifies that the vehicle conforms to all applicable Federal Moto...

Page 3: ...the authenticity of the vehi cle and official documentation The formula to use the check digit is not released to the general public POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 Man...

Page 4: ...emoved without defacing label information and destroying label The label contains the vehicle s emission specifica tions and vacuum hose routings All hoses must be connected and routed according to th...

Page 5: ...t be used because of the plate overlap BODY CODE PLATE LINE 4 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13 14 AND 15 Transmission Codes DGT 4 speed Automatic 46RE DG4 4 speed Automatic 45RFE DGP...

Page 6: ...soline EZA 5 7 L 8 cyl SMPI Gasoline EML 5 9 L 8 cyl SMPI Gasoline ETC 5 9 L 6 cyl Cummins Turbo Diesel ETH 5 9 L 6 cyl Cummins Turbo Diesel High Output EWA 8 0 L 10 cyl MPI Gasoline BODY CODE PLATE L...

Page 7: ...bolt strength classes are 9 8 and 10 9 The metric strength class identification number is imprinted on the head of the bolt The higher the class number the greater the bolt strength Some metric nuts...

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

Page 9: ...Fig 7 FASTENER STRENGTH 8 INTRODUCTION DR FASTENER IDENTIFICATION Continued...

Page 10: ...AE units or vise versa CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in lbs x 0 11298 Newton Meters N m N m x 8 851 in lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7...

Page 11: ...Fig 8 METRIC CONVERSION CHART 10 INTRODUCTION DR METRIC SYSTEM Continued...

Page 12: ...N Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 9 Fig 9 TORQUE SPECI...

Page 13: ......

Page 14: ...YMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations Fig 1 FLUID TYPES DESCRIPTION DESCRIPTION FUE...

Page 15: ...d this requirement SAE VISCOSITY An SAE viscosity grade is used to specify the vis cosity of engine oil Use only engine oils with multi ple viscosities such as 5W 30 or 10W 30 These are specified with...

Page 16: ...r head area near the exhaust valves and engine block Then coolant carries the heat to the radiator where the tube fin radiator can transfer the heat to the air The use of aluminum cylinder blocks cyli...

Page 17: ...lubricant for the NV243 transfer case is Mopart ATF 4 Automatic Transmission Fluid DESCRIPTION TRANSFER CASE NV273 Recommended lubricant for the NV273 transfer case is Mopart ATF 4 Automatic Transmiss...

Page 18: ...35 gal ENGINE OIL WITH FILTER 3 7L 4 7 L 5 0 qts 4 7L 5 6 L 6 0 qts 5 7L 6 6 L 7 0 qts 5 9L 4 7 L 5 0 qts 8 0L 6 6 L 7 0 qts 5 9L DIESEL 10 4 L 11 0 qts 2DESCRIPTION SPECIFICATION COOLING SYSTEM 3 7L...

Page 19: ...e the vehicle is on level ground will improve the accuracy of the oil level reading Add oil only when the level is at or below the ADD or MIN mark Check the windshield washer solvent and add if requir...

Page 20: ...ange front axle fluid 4X4 X Inspect brake linings X Inspect engine air cleaner filter replace if necessary X Replace spark plugs X Inspect PCV valve replace as necessary X Drain and refill automatic t...

Page 21: ...e as necessary X Drain and refill automatic tranmission fluid change filter and adjust bands 46RE 47RE 48RE X Drain and refill automatic tranmission fluid and change main sump filter 45RFE 545RFE only...

Page 22: ...d replace if required 3 7L 4 7L 5 7L 5 9L 8 0L X Drain and refill automatic tranmission fluid change filter and adjust bands 46RE 47RE 48RE X Drain and refill automatic tranmission fluid and change ma...

Page 23: ...X Inspect PCV valve replace as necessary X Inspect auto tension drive belt and replace if required 3 7L 4 7L 5 7L 5 9L 8 0L X X Drain and refill automatic tranmission fluid change filter and adjust b...

Page 24: ...000 48 000 54 000 60 000 66 000 Kilometers 58 000 67 000 77 000 84 000 96 000 106 000 Months 36 42 48 54 60 66 Change engine oil and engine oil filter X X X X X X Check transfer case fluid level X Lu...

Page 25: ...545RFE only X Miles 102 000 108 000 114 000 120 000 Kilometers 163 000 173 000 182 000 192 000 Months 102 108 114 120 Change engine oil and engine oil filter X X X X Check transfer case fluid level X...

Page 26: ...charging system can result 2 When using another vehicle as a booster source park the booster vehicle within cable reach Turn off all accessories set the parking brake place the automatic transmission...

Page 27: ...e A body side sill A steering linkage component A drive shaft The engine or transmission oil pan The fuel tank A front suspension arm NOTE Use the correct frame rail lifting locations only Fig 7 and F...

Page 28: ...ted by the towing device Do not allow passengers to ride in a vehicle being towed Always observe state and local laws regarding towing regulations Do not tow a vehicle in a manner that could jeopardiz...

Page 29: ...ked and keys are not avail able use a flat bed hauler A Wheel lift or Sling type device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dol lies FOUR WHEEL DRIV...

Page 30: ...ure thane bushings should be tightened with the vehi cle at normal ride height It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued If springs are no...

Page 31: ...ng System Diagnosis Chart below for additional information 1 Inspect tires for size air pressure and tread wear 2 Inspect front wheel bearings for wear 3 Inspect front wheels for excessive radial or l...

Page 32: ...m the ground at the centerline of the rear lower control arm bolt front tip Fig 2 4 Measure and record the height from the ground at the front spindle centerline Static Load Radius Fig 2 5 Subtract th...

Page 33: ...e vehicle at normal ride height Fig 3 STANDARD PROCEDURE TOE ADJUSTMENT 4X4 SUSPENSION HEIGHT MESUREMENT MUST BE PERFORMED BEFORE AN ALIGN MENT The wheel toe position adjustment is the final adjustmen...

Page 34: ...aightening the wheels Secure the steering wheel with the front wheels in the straight ahead position 2 Loosen the tie rod jam nuts NOTE Each front wheel should be adjusted for one half of the total to...

Page 35: ...nt specifications are in degrees SPECIFICATIONS DESCRIP TION SPECIFICATION VEHICLE 1500 WHEEL BASE CASTER 3 0 Max 75 Target CAMBER 50 TOTAL TOE IN 10 4X2 120 5 in 4 0 0 10 4X2 140 5 in 4 2 0 10 4X2 16...

Page 36: ...SPECIAL TOOLS WHEEL ALIGNMENT 8876 CAMBER CASTER ADJUSTMENT TOOL DR WHEEL ALIGNMENT 2 7 WHEEL ALIGNMENT Continued...

Page 37: ...KNUCKLE DESCRIPTION 17 OPERATION 17 REMOVAL 17 INSTALLATION 18 LOWER BALL JOINT DIAGNOSIS AND TESTING LOWER BALL JOINT 18 REMOVAL 18 INSTALLATION 19 LOWER CONTROL ARM REMOVAL REMOVAL 4X4 LD 20 REMOVA...

Page 38: ...the fasteners are torqued If springs are not at their normal ride position vehicle ride comfort could be affected and premature bushing wear may occur DESCRIPTION The upper control arm bolts on frame...

Page 39: ...tional 90 Lower Suspension Arm Ball Joint Nut HD 4X2 only 135 100 Upper Suspension Arm Frame Nuts LD 132 97 Upper Suspension Arm Frame Nuts HD 4X2 only 170 125 Upper Suspension Arm Ball Joint Nut 1500...

Page 40: ...8682 TORSION BAR LOADER UNLOADER 8686 TORSION BAR BUSHING REMOVAL INSTALL 8835 RECEIVER DRIVER BALLJOINT 8698 BALL JOINT PRESS C 4212F 2WD LOWER CONTROL ARM BUSHING REMOVAL INSTALL 8836 DR FRONT INDE...

Page 41: ...ecure the cross member in a vise NOTE Extreme pressure lubrication must be used on the threaded portions of the tool This will increase the longevity of the tool and insure proper operation during the...

Page 42: ...ly orient the bushing voids in the correct position to within 10 The correct position places the long narrow void out board of the bushing and the short wide void inboard of the bushing Fig 8 Fig 5 TO...

Page 43: ...IGNMENT STANDARD PROCEDURE INSTALLATION TORSION BAR CROSS MEMBER BUSHING NOTE Extreme pressure lubrication must be used on the threaded portions of the tool This will increase the longevity of the too...

Page 44: ...N 3 Reset the vehicle ride height Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE 4 Perform a wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE HUB BEARING REMOVAL RE...

Page 45: ...REMOVAL 4 Remove the ABS wheel speed sensor if equipped Refer to 5 BRAKES ELECTRICAL FRONT WHEEL SPEED SENSOR REMOVAL Fig 15 5 Remove the three hub bearing mounting bolts from the steering knuckle Fi...

Page 46: ...s a single casting with legs machined for the upper and lower ball joints The knuckle also has machined mounting locations for the front brake calipers and hub bearing OPERATION The steering knuckle p...

Page 47: ...CE DURE 10 Remove the support and lower the vehicle 11 Perform a wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE LOWER BALL JOINT DIAGNOSIS AND TESTING LOWER BALL JOINT NOTE...

Page 48: ...ly 5 Remove the support for the halfshaft and install into position If Equipped 6 Install the steering knuckle Refer to 2 SUS PENSION FRONT KNUCKLE INSTALLATION 7 Install the tie rod end into the stee...

Page 49: ...ool at the shock hole 6 Tighten the spring compressor nut against bell shaped adapter finger tight then loosen 1 2 turn NOTE This will hold the spring in place until the lower suspension arm is separa...

Page 50: ...ol arm and steering knuckle 7 Position the lower ball joint into the steering knuckle 8 Install the retaining nut on the lower ball joint and tighten to 52 N m 38 ft lbs on 1500 series only an additio...

Page 51: ...teering knuckle 5 Position the lower ball joint into the steering knuckle 6 Install the retaining nut on the lower ball joint and tighten to 52 N m 38 ft lbs on 1500 series only an additional 90 turn...

Page 52: ...nd remove the shock absorber REMOVAL 4X4 1 Raise and support the vehicle 2 Remove the tire and wheel assembly 3 Support the lower control arm outboard end 4 Remove the upper shock nut and with the ins...

Page 53: ...nsion must be at curb height for stabilizer bar installation 1 If removed install the bushings on the stabi lizer bar 2 Position the stabilizer bar on the frame cross member brackets and install the b...

Page 54: ...OT interchangeable The bars are identified and stamped R or L for right or left The bars do not have a front or rear end and can be installed with either end facing forward 1 Raise and support the veh...

Page 55: ...ped with a lubrication fitting grease the joint then road test the vehicle before performing test 1 Raise the front of the vehicle Place safety floor stands under both lower control arms as far outboa...

Page 56: ...bolts and tighten to 132 N m 97 ft lbs LD or 170 N m 125 ft lbs HD 4X2 only 2 Insert the ball joint in steering knuckle and tighten the upper ball joint nut to 54 N m 40 ft lbs on 1500 series only an...

Page 57: ...R SUSPENSION ARM REMOVAL 35 INSTALLATION 35 SHOCK DIAGNOSIS AND TESTING SHOCK 35 REMOVAL 35 INSTALLATION 35 SPRING REMOVAL 36 INSTALLATION 36 STABILIZER BAR REMOVAL 37 INSTALLATION 37 FRONT LINK COIL...

Page 58: ...ushings should be tightened with the vehi cle at normal ride height It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued If springs are not at their...

Page 59: ...ting bolts 1 4 inch each Fig 3 Then tap the bolts with a hammer to loosen the hub bearing from the steering knuckle 8 Remove the hub bearing mounting bolts and remove the hub bearing 9 Remove the roto...

Page 60: ...n 6 Position the hub spacer Fig 8 and brake shield Fig 9 on bolts just installed in knuckle NOTE If the vehicle is equipped with a wheel speed sensor the brake shield must be positioned on the hub bea...

Page 61: ...INSTALLATION 15 Install the sensor wire to the steering knuckle and frame and if equipped Connect the wheel speed sensor wire under the hood 16 Install the wheel and tire assemblies Refer to 22 TIRES...

Page 62: ...n to install upper ball stud Fig 15 Fig 12 LOWER BALL JOINT REMOVAL 1 SPECIAL TOOL C4212 F 2 SPECIAL TOOL 8975 2 3 KNUCKLE 4 SPECIAL TOOL 8975 4 Fig 13 LOWER BALL JOINT INSTALLATION 1 SPECIAL TOOL C42...

Page 63: ...bracket Fig 16 3 Remove the nut and bolt at the frame rail and remove the upper suspension arm REMOVAL RIGHT 1 Raise and support the vehicle 2 Disconnect the exhaust system at the mani folds 3 Disconn...

Page 64: ...y the hydraulic valving and may be intermit tent This condition is not repairable and the shock absorber must be replaced The shock absorbers are not refillable or adjust able If a malfunction occurs...

Page 65: ...ing seats in the upper mount 3 Connect the stabilizer bar links and shock absorbers to the axle bracket Connect the track bar to the frame rail bracket 4 Install the upper suspension arm 5 Install the...

Page 66: ...lamps from the frame rails and remove the stabilizer bar INSTALLATION 1 Position the stabilizer bar on the frame rail and install the clamps and bolts Ensure the bar is centered with equal spacing on...

Page 67: ...al ride position vehicle ride comfort could be affected and premature bush ing wear may occur DIAGNOSIS AND TESTING SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by...

Page 68: ...135 100 Spring Clamp U Bolts Nuts 149 110 Spring Front Rear Bolt Nut 163 120 Spring Spring Rear Shackle Nuts 163 120 Jounce Bumper Bolts 40 30 Auxialiary Spring Bumpers 41 30 BUSHINGS REMOVAL 1 Remove...

Page 69: ...mper to the bracket Fig 2 Tighten the nut to 61 N m 45 ft lbs SHOCK REMOVAL 1 Raise vehicle and support the axle 2 Remove the upper shock bolt and nut Fig 3 3 Remove the lower shock bolt and nut 4 Rem...

Page 70: ...nstall the eye pivot bolt and nut 3 Align the rear of the spring into the shackle and install the bolt and nut 4 Tighten the spring front and rear eye pivot bolt snug do not torque 5 Install the sprin...

Page 71: ...he hole NOTE THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINT ING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING 3 Apply a small amount of lubricant oil o...

Page 72: ...HE ISOLATOR MAY RESULT 7 Use an appropriate pry bar to bend open the spring clinch clip If necessary remove the existing spring clinch clip isolators 8 Repeat procedure for the other side of the vehi...

Page 73: ......

Page 74: ...GLE CARDAN UNIVERSAL JOINTS DISASSEMBLY 9 ASSEMBLY 9 PROPELLER SHAFT DIAGNOSIS AND TESTING PROPELLER SHAFT VIBRATION Tires that are out of round or wheels that are unbalanced will cause a low frequenc...

Page 75: ...rified with the following procedure 1 Raise the vehicle 2 Clean all the foreign material from the propel ler shaft and the universal joints 3 Inspect the propeller shaft for missing balance weights br...

Page 76: ...ase and axle are within specifications Correct as necessary and re measure propeller shaft runout 8 Replace the propeller shaft if the runout still exceeds the limits RUNOUT SPECIFICATIONS Front of Sh...

Page 77: ...eller Shaft Angle C 6 Rotate propeller shaft 90 degrees and place Inclinometer on companion flange yoke bearing par allel to the shaft Fig 6 Center bubble in sight glass and record measurement This me...

Page 78: ...wo piece Fig 8 propeller shaft is the same as those for a one piece propeller shaft Fig 7 UNIVERSAL JOINT ANGLE EXAMPLE 1 4 9 Angle C 2 3 2 Angle B 3 Input Yoke 4 3 0 Angle A 5 Output Yoke Fig 8 UNIVE...

Page 79: ...rt vehicle 3 Remove exhaust crossover pipe 4 Mark a line across the axle companion flange and propeller shaft flange yoke Fig 9 for installa tion reference 5 Remove companion flange bolts 6 Remove dus...

Page 80: ...opeller shaft flange yoke Fig 11 for installa tion reference 4 Mark the outline of the center bearing Fig 12 on the crossmember for installation reference if equipped 5 Remove center bearing mounting...

Page 81: ...inger on shaft and drive into posi tion with appropriate installer tool 2 Install new center bearing on shaft with Bear ing Installer Tool 6052 Drive on shaft with hammer until bearing is seated 3 Cle...

Page 82: ...the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap Fig 16 7 If the bearing cap will not pull out of the yoke by hand after pressing tap...

Page 83: ...g cap into the yoke bore enough to install a snap ring 5 Install a snap ring 6 Repeat Step 3 and Step 4to install the opposite bearing cap If the joint is stiff or binding strike the yoke with a soft...

Page 84: ...caused by another component of the vehicle com ing in contact with the half shafts CLUNKING NOISE DURING ACCELERATION This noise may be a result of a damaged or worn C V joint A torn boot or loose mi...

Page 85: ...he axle output shaft Push firmly to engage the axle output shaft snap ring into the inner C V housing 5 Install upper ball joint into the knuckle 6 Install upper ball joint nut and tighten to spec ifi...

Page 86: ...10 Remove ball from the bearing cage Fig 7 11 Repeat step above until all six balls are removed from the bearing cage 12 Lift cage and inner race upward and out from the housing Fig 8 13 Turn inner ra...

Page 87: ...nd install the balls Fig 13 9 Place new clamps onto new boot and slide boot onto the shaft to it s original position 10 Apply the rest of grease to the C V joint and boot Fig 7 BEARING 1 HOUSING 2 INN...

Page 88: ...both boot clamps Fig 15 with Clamp Installer C 4975A Place tool on clamp bridge and tighten tool until jaws of the tool are closed Fig 12 BEARING CAGE AND HOUSING 1 OUTER RACE 2 BEARING CAGE WINDOW 3...

Page 89: ...nts for exces sive wear and damage Replace the tripod as a unit only if necessary INSTALLATION 1 Clean all C V joint components and shaft 2 Slide new boot down the half shaft 3 Install tripod and trip...

Page 90: ...the shaft This measure ment should be 260 mm 10 25 in NOTE If measurement is not correct allow more or less air into the boot 10 Secure both boot clamps with Clamp Installer C 4975A Place tool on clam...

Page 91: ...housing not having the proper offset and squareness Gear noise usually happens at a specific speed range The noise can also occur during a specific type of driving condition These conditions are acce...

Page 92: ...INE SNAP A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged can be caused by High engine idle speed Transmission shift operation Loose engine transmission transfer case...

Page 93: ...ngs for further damage Avoid erratic use of clutch Differential Gears Scored 1 Insufficient lubrication 1 Replace scored gears Fill differential with the correct fluid type and quantity 2 Improper gra...

Page 94: ...ace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Place transmission in netural 2 Raise and support the...

Page 95: ...ing from the center line of the ring gear to the back face of the pinion is 99 690 mm 3 925 in The stan dard depth provides the best teeth contact pattern Compensation for pinion depth variance is ach...

Page 96: ...shim s If the number is 0 no change is necessary PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance New Pinion Gear Depth Variance 24 23 22 21 0 1 2 3 4 4 0 008 0 007 0 006 0 005 0 004 0 0...

Page 97: ...n the housing so dial probe and scooter block are flush against the surface of the pinion height block Hold scooter block in place and zero the dial indica tor Tighten dial indicator face lock screw 7...

Page 98: ...d together The gear back lash measurement determines the thickness of the shim used on the ring gear side of the differential case Subtract the gear backlash shim thickness from the total overall shim...

Page 99: ...tal 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 shims needed to preload the new differential case bea...

Page 100: ...erential case dummy bearings and dummy shim from the housing 27 Install new side bearing cones and cups on differential case 28 Install Spreader W 129 B and Adapter Plates 8142 A on the housing and sp...

Page 101: ...ing and pinion gears This will produce low noise and long gear life Gears which are not positioned properly may be noisy and have shorten gear life 1 Wipe clean each tooth of the ring gear 2 Apply gea...

Page 102: ...NS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3 55 3 92 Differential Case Flange Runout 0 076 mm 0 003 in Differential Side Gear Clearance 0 0 15 mm 0 0 006 in Ring Gear Diameter 205 mm...

Page 103: ...Hole Plug 34 25 Differential Cover Bolts 22 15 Bearing Cap Bolts 61 45 Ring Gear Bolts 108 80 Pinion Nut 271 475 200 350 SPECIAL TOOLS PULLER C 293 PA ADAPTER C 293 42 ADAPTER C 293 48 PLUG C 293 3 PU...

Page 104: ...REMOVER 8401 REMOVER 8831 INSTALLER 8695 INSTALLER 8694 INSTALLER 8693 INSTALLER 8692 INSTALLER 6448 REMOVER C 4660 A CUP 8150 DR FRONT AXLE C205F 3 31 FRONT AXLE C205F Continued...

Page 105: ...NION BLOCK 8177 PINION DEPTH SET 6775 SPREADER W 129 B PILOTS C 3288 B DIAL INDICATOR C 3339 DUMMY SHIM 8107 DUMMY BEARING 8398 INSTALLER C 3718 ADAPTER PLATES 8142A 3 32 FRONT AXLE C205F DR FRONT AXL...

Page 106: ...re clean 2 Install a new axle shaft seal with Installer 8694 and Handle C 4171 3 Lubricate seal lip with gear lubricant 4 Insert axle shaft through seal bearing and engage it into side gear splines Pu...

Page 107: ...1 Remove skid plate if equipped 2 Remove both half shafts 3 Mark the propeller shaft and pinion companion flange Fig 31 for installation reference 4 Remove the front propeller shaft 5 Rotate the pinio...

Page 108: ...inion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end play Fig 35 CAUTION Do not exceed 271 N m 200 ft lbs the minimum tightening torque when installing the compan...

Page 109: ...s and the differential housing Pinion bearing preload is set and main tained by the use of a collapsible spacer The stamped steel cover provides a means for inspection and servicing the differential O...

Page 110: ...r 0 50 mm 0 020 in If the housing is over spread it could be distorted or damaged 8 Remove dial indicator 9 While holding the differential case in position remove bearing cap bolts and caps 10 Remove...

Page 111: ...gs or differ ential case are replaced Refer to adjustments for Differential Bearing Preload and Gear Backlash pro cedures 1 Install Spreader W 129 B with the Adapter Plates 8142 A and install the safe...

Page 112: ...ilicone Sealant or equivalent to the housing cover CAUTION If cover is not installed within 3 to 5 min utes the cover must be cleaned and new RTV applied or adhesion quality will be compromised 11 Ins...

Page 113: ...to two of the threaded holes in the companion flange 180 apart 10 Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes Tighten the b...

Page 114: ...nd record thickness of shims Fig 49 FRONT PINION BEARING CUP 1 HOUSING 2 REMOVER 3 HANDLE Fig 50 REAR PINION BEARING CUP 1 HOUSING 2 REMOVER 3 HANDLE Fig 51 COLLAPSIBLE SPACER 1 COLLAPSIBLE SPACER 2 R...

Page 115: ...Driver Handle C 4171 Fig 53 and verify cup is seated 3 Install front pinion bearing cup with Installer 8693 and Handle C 4171 Fig 54 and verify cup is seated 4 Lubricate front pinion bearing and inst...

Page 116: ...rotating torque frequently to avoid over crushing the collapsible spacer Fig 60 The pinion rotating torque should be Original Bearings 1 to 2 5 N m 10 to 20 in lbs New Bearings 2 0 to 2 8 N m 18 to 25...

Page 117: ...ing and verify gear mesh backlash and contact pattern 19 Install differential cover and fill with gear lubricant Fig 59 PINION NUT 1 DIFFERENTIAL HOUSING 2 COMPANION FLANGE HOLDER 3 TORQUE WRENCH Fig...

Page 118: ...e gears are splined to the axle shafts DIAGNOSIS AND TESTING GEAR NOISE Axle gear noise can be caused by insufficient lubri cant incorrect backlash tooth contact worn damaged gears or the carrier hous...

Page 119: ...e accessories brackets and drive belts DRIVELINE SNAP A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged can be caused by High engine idle speed Transmission shift opera...

Page 120: ...for further damage Avoid erratic use of clutch Differential Gears Scored 1 Insufficient lubrication 1 Replace scored gears Fill differential with the correct fluid type and quantity 2 Improper grade...

Page 121: ...per specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Remove wheels and tires 2 Remove brake calipers and rotors 3 Disconnect ABS wheel speed sensors 4 Disconnect axle vent hos...

Page 122: ...nment ADJUSTMENTS Ring and pinion gears are supplied as matched sets only Compensation for pinion depth variance is achieved with a select shim The shim is located between the rear pinion bearing and...

Page 123: ...inion In most cases this adjustment can be used to achieve the correct gear tooth pattern and set the case bearing preload 1 Remove adjuster lock bolts and adjuster locks Fig 5 2 Loosen the differenti...

Page 124: ...should not vary more than 0 05 mm 0 002 in between measuring points If measurement does vary inspect the gears for burrs the differential case flange and ring gear mounting GEAR TOOTH CONTACT PATTERN...

Page 125: ...from the pinion gear using the adjusters Pinion gear set too low Fig 12 Increase pinion gear height by increasing the pinion depth shim thickness Pinion gear set too high Fig 13 Decrease pin ion depth...

Page 126: ...aring Preload New Bearing 3 4 5 6 N m 30 50 in lbs Pinion Bearing Preload Differential Case Bearing Preload Original Bearing 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lb...

Page 127: ...SEAL INSTALLER 8882 INSTALLER D 146 SPLITTER 1130 BRIDGE 938 PINION DEPTH SET 6730 ARBOR DISCS 8289 PINION BLOCK 8878 BEARING INSTALLER 8881 3 54 FRONT AXLE 9 1 4 AA DR FRONT AXLE 9 1 4 AA Continued...

Page 128: ...PINION INSTALLER 8982 CUP INSTALLER 8886 PINION DRIVER 8976 PLUG 8888 SEAL INSTALLER 8885 REMOVER EXTRACTOR 6310 RECEIVER 8498 PULLER C 293 PA DR FRONT AXLE 9 1 4 AA 3 55 FRONT AXLE 9 1 4 AA Continued...

Page 129: ...ive they must be replaced as a unit CAUTION Clamp only the narrow forged portion of the yoke in the vise To avoid distorting the yoke do not over tighten the vise jaws 1 Remove the bearing cap retaini...

Page 130: ...ially forced out of the yoke 7 Repeat the above procedure for the remaining bearing cap and remove spider from the propeller shaft yoke Fig 15 HUB BEARING BOLTS 1 STUB SHAFT 2 BEARING BOLTS 3 AXLE SHA...

Page 131: ...er 6 Install axle washer and nut Tighten axle nut to 179 N m 132 ft lbs 7 Rotate axle several 5 to 10 times to seat the wheel bearing 8 Tighten axle nut to final torque of 356 N m 263 ft lbs 9 Align n...

Page 132: ...into the axle housing 4 Install axle shaft and hub bearings Fig 21 AXLE SHAFT SEAL 1 ADJUSTER THREADS 2 SEAL Fig 22 SEAL RECEIVER 1 RECEIVER 2 EXTRACTOR FOOT Fig 23 SEAL EXTRACTOR 1 EXTRACTOR ROD 2 E...

Page 133: ...al with Installer 8882 and Handle C 4171 Fig 28 2 Apply a light coat of teflon thread sealant to the pinion flange splines 3 Lightly tap the pinion flange onto the pinion until a few threads are showi...

Page 134: ...the two side gears As a result the pinion gears revolve with the pinion mate shaft but do not rotate around it Fig 29 When turning corners the outside wheel must travel a greater distance than the in...

Page 135: ...inion shaft lock bolt 2 Remove pinion shaft Fig 33 3 Rotate differential pinion gears to differential window and remove pinion gears and thrust washers Fig 34 4 Remove differential side gears and thru...

Page 136: ...steam kerosene or gasoline for cleaning 2 Lubricate differential case bearing 3 Install differential case with bearings cups into the housing 4 Install bearing caps and bolts Fig 38 Tighten the bearin...

Page 137: ...5 Tighten bearing cap bolts to 85 N m 63 ft lbs 16 Tighten adjuster lock bolts to 25 N m 18 ft lbs Fig 39 17 Measure ring gear backlash and check gear tooth contact pattern Refer to Adjustments for pr...

Page 138: ...ng gear to differential case 7 Drive ring gear from differential case with a soft hammer Fig 42 8 Hold pinion flange with Flange Wrench 8979 Fig 43 and remove pinion flange nut and washer 9 Remove pin...

Page 139: ...ing cup 17 Remove rear pinion bearing cup from the housing with a punch and hammer if bearing is replaced INSTALLATION 1 Install front pinion bearing cup Fig 47 with Installer D 146 and Handle C 4171...

Page 140: ...A and a press 5 Install new collapsible spacer Fig 51 6 Lubricate pinion and bearings Fig 48 REAR PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 49 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fi...

Page 141: ...ral times then verify pinion rotating torque again 16 Position the ring gear on differential case and start two new ring gear bolts 17 Install the rest of the new ring gear bolts and tighten them alte...

Page 142: ...ential case The engine power is transmitted to the axle shafts through the pinion mate and side gears The side gears are splined to the axle shafts DIAGNOSIS AND TESTING GEAR NOISE Axle gear noise can...

Page 143: ...Fig 1 9 1 4 AXLE 3 70 REAR AXLE 9 1 4 DR REAR AXLE 9 1 4 Continued...

Page 144: ...earend vibra tion Do not overlook engine accessories brackets and drive belts NOTE All driveline components should be exam ined before starting any repair DRIVELINE SNAP A snap or clunk noise when the...

Page 145: ...ferential bearings 1 Replace case and inspect gears and bearings for further damage Set differential bearing pre load properly 2 Excessive ring gear backlash 2 Replace case and inspect gears and beari...

Page 146: ...ation 3 Ice spotted pavement 3 Replace gears and examine remaining parts for damage 4 Improper adjustments 4 Replace gears and examine remaining parts for damage Ensure ring gear backlash is correct A...

Page 147: ...Ring gear and pinion are supplied as matched sets only The identifying numbers for the ring gear and pinion are painted onto the pinion gear shaft Fig 2 and the side of the ring gear A plus number mi...

Page 148: ...n the housing Take measurements with Pinion Gauge Set and Dial Indi cator C 3339 Fig 4 1 Assemble Pinion Height Block 6739 Pinion Block 8542 and rear pinion bearing onto Screw 6741 Fig 4 2 Insert asse...

Page 149: ...gear correctly and can cause excessive differen tial case free play and ring gear noise NOTE The differential bearing cups will not always immediately follow the threaded adjusters as they are moved d...

Page 150: ...en 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 thre...

Page 151: ...heck each gear independently If it necessary to replace a side gear replace both gears as a matched set 1 Install the axle shafts and C locks and pinion mate shaft 2 Measure each side gear clearance I...

Page 152: ...and re measure the side gear clearance 6 Compare both clearance measurements If the difference is less than 0 012 inch 0 305 mm add clearance recorded when the C lock was installed to thrust washer t...

Page 153: ...ear Bolts 157 115 Pinion Nut Minimum 285 210 Adjuster Lock Screw 10 7 5 90 Backing Plate Bolts 65 48 Pinion Mate Shaft Lock Screw 11 8 Axle U Bolt Nuts 149 110 SPECIAL TOOLS PULLER 6790 REMOVER 6310 I...

Page 154: ...HOLDER 6719 PULLER C 452 INSTALLER C 3718 WRENCH C 4164 PULLER C 293 PA ADAPTERS C 293 37 PLUG SP 3289 ADAPTERS C 293 47 INSTALLER C 4340 FIXTURE 8138 DR REAR AXLE 9 1 4 3 81 REAR AXLE 9 1 4 Continued...

Page 155: ...5 REMOVER C 4307 INSTALLER C 4308 INSTALLER D 130 INSTALLER C 3095 A TRAC LOK TOOLS 8140 TRAC LOK TOOLS 6960 PINION BLOCK 8540 ARBOR DISCS 8541 PINION GAUGE SET 6775 3 82 REAR AXLE 9 1 4 DR REAR AXLE...

Page 156: ...ft Fig 21 carefully to prevent damage to the shaft bearing and seal in the axle tube INSTALLATION 1 Lubricate bearing bore and seal lip with gear lubricant 2 Insall axle shaft and engage into side gea...

Page 157: ...5 1 NOTE When tool contacts the axle tube the seal is installed to the correct depth 3 Install the axle shaft 4 Install differential cover and fill with gear lubricant to the bottom of the fill plug h...

Page 158: ...seal 2 Install new pinion seal with Installer C 3860 A and Handle C 4171 Fig 25 3 Install companion flange on the end of the shaft with the reference marks aligned 4 Install two bolts into the threade...

Page 159: ...rs at the outside of the differential housing Pinion bearing preload is set and maintained by the use of a collapsible spacer The removable differential cover provides a means for inspection and servi...

Page 160: ...l bearing cap bolts 9 Loosen differential bearing adjusters through the axle tubes with Wrench C 4164 Fig 31 10 Hold differential case while removing bearing caps and adjusters 11 Remove differential...

Page 161: ...n be used to keep the adjusters in position 2 Install differential assembly into the housing 3 Install differential bearing caps in their origi nal locations Fig 34 4 Install bearing cap bolts and tig...

Page 162: ...ERATION This differential clutches are engaged by two con current forces The first being the preload force exerted through Belleville spring washers within the clutch packs The second is the separatin...

Page 163: ...tool to studs 5 Use torque wrench on special tool to rotate wheel and read rotating torque Fig 37 6 If rotating torque is less than 41 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the...

Page 164: ...11 Loosen Forcing Screw in small increments until clutch pack tension is relieved Then turn the case with the turning bar Fig 43 12 Rotate differential case until the pinion gears can be removed 13 R...

Page 165: ...nt with gear lubricant before assembly 2 Assemble the clutch discs into packs and secure disc packs with retaining clips Fig 45 3 Position assembled clutch disc packs on the side gear hubs 4 Install c...

Page 166: ...l thrust washers behind pinion gears and align washers with a small screw driver Insert mate shaft into each pinion gear to ver ify alignment 14 Remove forcing screw step plate and threaded adapter 15...

Page 167: ...ring gear bolts from the differential case 7 Drive ring gear off the differential case with a rawhide hammer Fig 50 8 Install bolts into two of the threaded holes in the companion flange 180 apart 9...

Page 168: ...inion bearing cup from housing Fig 54 with Remover C 4307 and Handle C 4171 17 Remove collapsible spacer from the pinion shaft Fig 55 Fig 52 PINION GEAR 1 RAWHIDE HAMMER Fig 53 FRONT PINION BEARING CU...

Page 169: ...urface of the pinion bearing cups 2 Install rear pinion bearing cup Fig 58 with Installer C 4308 and Driver Handle C 4171 and ver ify cup is seated 3 Install front pinion bearing cup Fig 59 with Insta...

Page 170: ...nd a press Fig 59 FRONT PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 60 PINION SEAL INSTALLER 1 HANDLE 2 INSTALLER 3 HOUSING Fig 61 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fig 62 REAR PINIO...

Page 171: ...Never loosen pinion nut to decrease pin ion rotating torque and never exceed specified pre load torque If preload torque or rotating torque is exceeded a new collapsible spacer must be installed 15 Sl...

Page 172: ...lts and alternately tighten to 156 N m 115 ft lbs Fig 66 CAUTION Never reuse the ring gear bolts The bolts can fracture causing extensive damage 21 Install differential in housing and verify gear mesh...

Page 173: ...r from the propeller shaft The propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case The engine power...

Page 174: ...y a Damaged drive shaft Missing drive shaft balance weight s Worn or out of balance wheels Loose wheel lug nuts Worn U joint s Loose broken springs Damaged axle shaft bearing s Loose pinion gear nut E...

Page 175: ...for further damage Avoid erratic use of clutch Differential Gears Scored 1 Insufficient lubrication 1 Replace scored gears Fill differential with the correct fluid type and quantity 2 Improper grade...

Page 176: ...lace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Raise and support the vehicle 2 Position a lifting de...

Page 177: ...one nut 6740 hand tight Then check tool rotating torque with an inch pound torque wrench The rotat ing torque should be 1 7 2 26 N m 15 20 in lbs Fig 1 4 Place Arbor Disc 6732 on Arbor D 115 3 in posi...

Page 178: ...lding the differential case toward the pinion gear turn bearing adjusters with Spanner Wrench 8883 Fig 6 until they make contact with the differ ential bearings cups 5 Back off the ring gear side adju...

Page 179: ...may be noisy and have shorten gear life 1 Wipe clean each tooth of the ring gear 2 Apply gear marking compound to all of the ring gear teeth 3 Verify bearing cap bolts are torque specifica tion 4 Appl...

Page 180: ...usters Pinion gear is set too low Fig 13 Increase the pinion gear height by increasing the pinion depth shim thickness Pinion gear is set too high Fig 14 Decrease the pinion depth by decreasing the pi...

Page 181: ...iff Case Bearing Preload New Bearings 3 4 5 6 N m 30 50 in lbs Pinion Bearing Preload Diff Case Bearing Preload Original Bearings 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs...

Page 182: ...RIDGE 938 PINION DEPTH GAUGE 6730 GAUGE BLOCK 8899 ARBOR DISCS 6732 PULLER C 293 PA ADAPTERS 8879 ADJUSTER WRENCH 8883 BEARING INSTALLER 8956 DR REAR AXLE 10 1 2 AA 3 109 REAR AXLE 10 1 2 AA Continued...

Page 183: ...NION INSTALLER 8981 CUP INSTALLER 8959 CUP INSTALLER 8960 CUP INSTALLER 8961 FLANGE PULLER 8992 FLANGE WRENCH 8979 PINION DRIVER 8977 PLUG 8888 3 110 REAR AXLE 10 1 2 AA DR REAR AXLE 10 1 2 AA Continu...

Page 184: ...titeT 242 on cleaned existing bolts 1 Clean axle flange and hub 2 Install new axle shaft gasket 3 Slide axle shaft into the axle tube 4 Install axle shaft flange bolts and tighten to 129 N m 95 ft lbs...

Page 185: ...62 and Handle C 4171 3 Pack bearings with the appropriate grease 4 Install rear bearing and install new grease seal with Installer 8963 and Handle C 4171 5 Slide hub on the axle tube and install front...

Page 186: ...ol or slide hammer mounted screw INSTALLATION 1 Install new pinion seal with Installer 8896 and Handle C 4171 Fig 23 2 Apply a light coat of teflon sealant to the pin ion flange splines 3 Lightly tap...

Page 187: ...e differential OPERATION During straight ahead driving the differential pin ion gears do not rotate on the pinion mate shaft This occurs because input torque applied to the gears is divided and distri...

Page 188: ...anner Wrench 8883 8 Remove differential case from the housing 9 Remove bearing cups and tag them left and right for installation reference DISASSEMBLY 1 Remove pinion shaft with a hammer and punch fro...

Page 189: ...ns 1 Lubricate all differential components with axle lubricant 2 Install differential side gears and thrust wash ers Fig 33 3 Install first pinion gear into the differential window and side gears Rota...

Page 190: ...and bolts Fig 36 Tighten the bearing cap bolts finger tight NOTE Do not torque bearing cap and bolts at this time 5 Slide differential case toward the pinion gear until the gears make contact zero bac...

Page 191: ...bricant type 21 Install fill plug and tighten to 32 N m 24 ft lbs DIFFERENTIAL TRAC RITE DESCRIPTION The Trac Rite differential is a helical gear differ ential The differential has two side gears six...

Page 192: ...d polished out with crocus cloth 1 Inspect pinion gears teeth for chips and cracks Fig 42 2 Inspect pinion gears shafts and brake shoes for scratches flat spots or worn Fig 42 3 Inspect side gears tee...

Page 193: ...gear thrust washer side gear and spacer Fig 45 4 Install one set of pinion gears into the bores next to the brake shoes with the pinion shaft facing up 5 Install other side gear and thrust washer Fig...

Page 194: ...Install Plug 8888 into the end of the case 3 Remove differental case bearings with Bearing Splitter 1130 and Bridge 938 Fig 47 INSTALLATION 1 Install differenial case bearings with Installer 8956 and...

Page 195: ...the exciter ring if it is not being replaced 5 Place differential case in a vise with soft metal jaw protectors 6 Remove bolts holding ring gear to differential case 7 Drive ring gear from differenti...

Page 196: ...ront pinion bearing cup from the housing with a punch and hammer and discard cup CAUTION Do not reuse front pinion bearing cup 17 Remove rear pinion bearing cup from the housing with a punch and hamme...

Page 197: ...5 Install new collapsible spacer Fig 59 6 Lubricate pinion and bearings Fig 56 REAR PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 57 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fig 58 REAR PINIO...

Page 198: ...bearings 14 Measure pinion rotating torque with an inch pound torque wrench Fig 63 Tighten pinion nut in small increments until pinion rotating torque is New Pinion Bearings 1 7 2 8 N m 15 25 in lbs...

Page 199: ...pattern 23 Measure final rotating torque with an inch pound torque wrench The final pinion rotating torque plus differential case bearing preload is New Bearings 3 4 5 6 N m 30 50 in lbs Original Bea...

Page 200: ...r from the propeller shaft The propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case The engine power...

Page 201: ...y a Damaged drive shaft Missing drive shaft balance weight s Worn or out of balance wheels Loose wheel lug nuts Worn U joint s Loose broken springs Damaged axle shaft bearing s Loose pinion gear nut E...

Page 202: ...for further damage Avoid erratic use of clutch Differential Gears Scored 1 Insufficient lubrication 1 Replace scored gears Fill differential with the correct fluid type and quantity 2 Improper grade...

Page 203: ...ace as necessary Ensure that the bearing caps are torqued tot he proper specification 9 Housing not machined properly 9 Replace housing REMOVAL 1 Raise and support the vehicle 2 Position a lifting dev...

Page 204: ...ight Then check tool rotating torque with an inch pound torque wrench The rotat ing torque should be 1 7 2 26 N m 15 20 in lbs Fig 1 4 Place Arbor Discs 8289 on Arbor D 115 3 in position in the housin...

Page 205: ...lding the differential case toward the pinion gear turn bearing adjusters with Spanner Wrench 8883 Fig 6 until they make contact with the differ ential bearings cups 5 Back off the ring gear side adju...

Page 206: ...rly may be noisy and have shorten gear life 1 Wipe clean each tooth of the ring gear 2 Apply gear marking compound to all of the ring gear teeth 3 Verify bearing cap bolts are torque specifica tion 4...

Page 207: ...sters Pinion gear is set too low Fig 13 Increase pin ion gear height by increasing the pinion depth shim thickness Pinion gear is set too high Fig 14 Decrease pinion depth by decreasing the pinion dep...

Page 208: ...se Bearing Preload New Bearing 3 4 5 6 N m 30 50 in lbs Pinion Bearing Preload Differential Case Bearing Preload Original Bearing 2 8 5 1 N m 25 45 in lbs TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs...

Page 209: ...ER WRENCH 8883 PINION BLOCK 8897 FLANGE PULLER 8992 FLANGE WRENCH 8979 PINION DRIVER 8977 PINION INSTALLER 8981 SOCKET 8954 BEARING INSTALLER 8965 3 136 REAR AXLE 11 1 2 AA DR REAR AXLE 11 1 2 AA Cont...

Page 210: ...BEARING INSTALLER D 389 CUP INSTALLER 8153 CUP INSTALLER 8960 CUP INSTALLER 8961 CUP INSTALLER 8968 SEAL INSTALLER 8896 SEAL INSTALLER 8963 DR REAR AXLE 11 1 2 AA 3 137 REAR AXLE 11 1 2 AA Continued...

Page 211: ...tube 4 Install axle shaft flange bolts and tighten to 129 N m 95 ft lbs AXLE BEARINGS REMOVAL 1 Remove axle shaft flange bolts and remove shaft 2 Remove retianer ring Fig 16 from the axle shaft tube...

Page 212: ...ear ing grease 4 Install rear bearing and install new grease seal with Installer 8963 and Handle C 4171 5 Slide hub on the axle tube and install front bearing into the hub 6 Install hub bearing nut wi...

Page 213: ...inion Flange Puller 8992 Fig 22 8 Remove pinion shaft seal with a pry tool or slide hammer mounted screw INSTALLATION 1 Install new pinion seal with Installer 8896 Fig 23 2 Apply a light coat of teflo...

Page 214: ...urs because input torque applied to the gears is divided and distributed equally between the two side gears As a result the pinion gears revolve with the pinion mate shaft but do not rotate around it...

Page 215: ...differential case from the housing 9 Remove bearing cups and tag them left and right for installation reference DISASSEMBLY 1 Remove ring gear 2 Remove pinion shaft with a hammer and punch from the si...

Page 216: ...orignial locations 1 Lubricate all differential components with axle lubricant 2 Install differential side gears and thrust wash ers Fig 33 Fig 30 FIRST PINION GEAR 1 DIFFERENTIAL WINDOW 2 PINION GEAR...

Page 217: ...on the cups will hold them in place during installation 4 Install bearing caps and bolts Fig 36 Tighten the bearing cap bolts finger tight NOTE Do not torque bearing cap and bolts at this time 5 Slide...

Page 218: ...capacity and lubricant type 21 Install fill plug and tighten to 32 N m 24 ft lbs DIFFERENTIAL TRAC RITE DESCRIPTION The Trac Rite differential is a helical gear differ ential The differential has two...

Page 219: ...d polished out with crocus cloth 1 Inspect pinion gears teeth for chips and cracks Fig 42 2 Inspect pinion gears shafts and brake shoes for scratches flat spots or worn Fig 42 3 Inspect side gears tee...

Page 220: ...d upside down but if install wrong pinion gear will not fit 3 Install side gear thrust washer side gear and spacer Fig 45 Fig 42 PINION GEAR AND BRAKE SHOE 1 BRAKE SHOES 2 PINION GEAR 3 PINION SHAFT F...

Page 221: ...ENTIAL CASE BEARINGS REMOVAL 1 Remove differential case from the housing 2 Install Plug 8964 into the end of the case 3 Remove differental case bearings with Bearing Splitter 1130 and Bridge 938 Fig 4...

Page 222: ...ring off the differential case with a hammer and punch Fig 49 NOTE Do not remove the exciter ring if it is not being replaced 5 Place differential case in a vise with soft metal jaw protectors 6 Remo...

Page 223: ...pinion depth shim from the pinion gear shaft and record thickness of the shims 16 Remove front pinion bearing cup from the housing with a punch and hammer and discard cup CAUTION Do not reuse front pi...

Page 224: ...Install new collapsible spacer Fig 59 6 Lubricate pinion and bearings Fig 56 REAR PINION BEARING CUP 1 INSTALLER 2 HANDLE Fig 57 PINION DEPTH SHIM 1 PINION DEPTH SHIM 2 PINION GEAR Fig 58 REAR PINION...

Page 225: ...n rotating torque with an inch pound torque wrench Fig 63 Tighten pinion nut in small increments until pinion rotating torque is New Pinion Bearings 1 7 2 8 N m 15 25 in lbs Original Pinion Bearings 1...

Page 226: ...ating torque with an inch pound torque wrench The final pinion rotating torque plus differential case bearing preload is New Bearings 3 4 5 6 N m 30 50 in lbs Original Bearings 2 8 5 1 N m 25 45 in lb...

Page 227: ......

Page 228: ...STALLATION INSTALLATION REAR BRAKE HOSE 9 INSTALLATION REAR TUBE HOSE ASSEMBLY 9 INSTALLATION FRONT BRAKE HOSE 9 BRAKE PADS SHOES REMOVAL 10 INSTALLATION 10 DISC BRAKE CALIPERS DESCRIPTION 11 OPERATIO...

Page 229: ...36 INSTALLATION 36 CABLE TENSIONER ADJUSTMENTS ADJUSTMENT 37 RELEASE HANDLE REMOVAL 38 INSTALLATION 38 BRAKES BASE DIAGNOSIS AND TESTING BASE BRAKE SYSTEM Base brake components consist of the brake sh...

Page 230: ...ake lines and hoses can also cause a spongy pedal The proper course of action is to bleed the system and replace thin drums and substandard quality brake hoses if suspected HARD PEDAL OR HIGH PEDAL EF...

Page 231: ...s become covered with grease and grit during repair Contaminated lining should be replaced to avoid fur ther brake problems WHEEL AND TIRE PROBLEMS Some conditions attributed to brake components may a...

Page 232: ...bleeding until fluid stream is clear and free of bubbles Then move to the next wheel STANDARD PROCEDURE PRESSURE BLEEDING Use Mopar brake fluid or an equivalent quality fluid meeting SAE J1703 F and...

Page 233: ...trical connector to the adjustable pedal switch 3 Install the lower drivers side bezel Fig 2 Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL DR SIDE BEZEL INSTALLA TION HYDRAULIC MECHANICAL SPECIF...

Page 234: ...Vacuum Dual Diaphragm BRAKE LINES STANDARD PROCEDURE STANDARD PROCEDURE DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs However double wall steel tub...

Page 235: ...pedal to keep pressure on the brake system 2 Raise and support the vehicle 3 Remove the brake line from the hose at the frame Fig 5 4 Remove the brake hose clip at the top of the hose located at the...

Page 236: ...top of the hose located at the frame Fig 5 6 Install the brake line to the hose at the frame Fig 5 7 Lower the vehicle and remove the support 8 Remove the prop rod 9 Bleed the brake system Refer to 5...

Page 237: ...hoe from the cali per adapter Fig 12 8 Remove the outboard brake shoe from the cali per adapter Fig 13 9 Remove the anti rattle springs from the caliper adapter Fig 14 and Fig 15 NOTE Anti rattle spri...

Page 238: ...is tons and brake shoes and obtain firm pedal 11 Top off master cylinder fluid level DISC BRAKE CALIPERS DESCRIPTION The calipers are a single piston type in the rear and dual piston type in the front...

Page 239: ...otor surface clear each revolution The caliper piston seal controls the amount of pis ton extension needed to compensate for normal lining wear During brake application the seal is deflected out ward...

Page 240: ...ston during removal Fig 22 4 To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port Use only enough air pressure to ease the piston ou...

Page 241: ...iper Fig 25 11 Remove caliper bleed screw INSPECTION The piston is made from a phenolic resin plastic material and should be smooth and clean The piston must be replaced if cracked or scored Do not at...

Page 242: ...e 5 Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle Fig 28 6 Seat dust boot in caliper Fig 29 with Handle C 4171 and Installer HD...

Page 243: ...the disc brake caliper Fig 19 or Fig 20 CAUTION Verify brake hose is not twisted or kinked before tightening fitting bolt 2 Install the banjo bolt with new copper washers to the caliper Tighten to 27...

Page 244: ...RAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 3 Remove the caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPER ADAPTER REMOVAL 4 Remove the rotor Refer to 5 BRAKES HY DRAULIC MEC...

Page 245: ...oir and caps before checking fluid level If not cleaned dirt could enter the fluid The fluid fill level is indicated on the side of the master cylinder reservoir Fig 33 The correct fluid level is to t...

Page 246: ...fer to 5 BRAKES STANDARD PROCEDURE BRAKE JUNCTION BLOCK REMOVAL 1 Remove the brake lines from the junction block Fig 35 2 Remove the junction block mounting bolt and remove the junction block from the...

Page 247: ...eck valve is faulty Pro ceed to the POWER BOOSTER VACUUM TEST 6 If the POWER BOOSTER VACUUM TEST passes rebuild booster vacuum reserve as follows Release brake pedal Increase engine speed to 1500 rpm...

Page 248: ...cylinder NOTE Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster REMOVAL HYDROBOOST 1 Remove the brake lines from the mast...

Page 249: ...utput rod to enter inside of the master cylinder plunger sleeve during installation Proper position is obtained when the output rod is centered perpen dicular to the master cylinder mounting hole Fig...

Page 250: ...assembly to the vehicle Fig 44 2 Install the mounting bolts Fig 44 and tighten to 28 N m 21 ft lbs 3 Reconnect the accelerator cable to the pedal 4 Install the module mounting bolts and tighten to 38...

Page 251: ...drive motor Fig 45 nor drive mechanism are subject to the mechanical stress of brake or accelerator application SYSTEM FEATURES Range of Adjustment The pedals may be adjusted up to 3 in 75 mm Pedal Ad...

Page 252: ...REMOVAL 2 Disconnect vacuum line at booster 3 Remove clip securing booster push rod to brake pedal Refer to 5 BRAKES HYDRAULIC MECHAN ICAL PEDAL REMOVAL Fig 47 4 Remove the nuts from the booster mount...

Page 253: ...not retain a charge the booster must be replaced 2 With the engine off depress the brake pedal several times to discharge the accumulator Grasp the accumulator and see if it wobbles or turns If it do...

Page 254: ...fluid foaming occurs wait for foam to dis sipate and repeat steps 7 and 8 REMOVAL NOTE If the booster is being replaced because the power steering fluid is contaminated flush the power steering system...

Page 255: ...E BOOSTER STANDARD PROCEDURE ROTORS REMOVAL REMOVAL REAR 1 Raise and support the vehicle 2 Remove the tire and wheel assembly 3 Remove the disc brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DIS...

Page 256: ...L 1 Remove wheel and tire assembly 2 Remove the disc brake caliper Refer to 5 BRAKES HYDRAULIC MECHANICAL DISC BRAKE CALIPERS REMOVAL 3 Remove the caliper adapter Refer to 5 BRAKES HYDRAULIC MECHANICA...

Page 257: ...rake shoes outward and into contact with the drum section of the rotor The contact of shoe to rotor parks the vehicle A torsion locking mechanism is used to hold the pedal in an applied position Parki...

Page 258: ...e parking brake cable Fig 58 3 Loosen cable adjuster nut 4 Remove the rear park brake cable from the intermediate park brake cable 5 Compress tabs on cable end fitting on the rear park brake cable to...

Page 259: ...k brake adjustment procedure Refer to 5 BRAKES PARKING BRAKE CABLE TENSIONER ADJUSTMENTS 10 Lower the vehicle INSTALLATION REAR PARK BRAKE CABLE 1 Push each cable end through the brake cable support p...

Page 260: ...AL DRIVELINE REAR AXLE 9 1 4 AXLE SHAFTS REMOVAL 8 Disassemble the rear park brake shoes Fig 56 CLEANING REAR DRUM IN HAT BRAKE Clean the individual brake components including the support plate exteri...

Page 261: ...ELINE REAR AXLE 9 1 4 AXLE SHAFTS INSTALLATION 3 Install the park brake cable to the lever behind the support plate 4 Unlock the park brake cable 5 Install the disc brake rotor Refer to 5 BRAKES HYDRA...

Page 262: ...l tool 10 Repeat step 8 above and measure shoes in both directions 11 Install brake rotor on the axleshaft Refer to 5 BRAKES HYDRAULIC MECHANICAL ROTORS INSTALLATION 12 Rotate rotor to verify that the...

Page 263: ...heel until brake drag is eliminated 9 Repeat adjustment at opposite wheel Be sure adjustment is equal at both wheels 10 Install support plate access hole plugs 11 Adjust parking brake cable and lower...

Page 264: ...t binding or seized 6 Check the rear brake shoe adjustment with standard brake gauge Refer to 5 BRAKES PARK ING BRAKE SHOES ADJUSTMENTS 7 Install the rotors Refer to 5 BRAKES HY DRAULIC MECHANICAL ROT...

Page 265: ...ket latches released slide the handle and bracket assembly down and out of the instru ment panel receptacle INSTALLATION 1 Position the park brake release handle to the instrument panel 2 Slide the ha...

Page 266: ...brakes in tandem The ABS elec trical system is separate from other electrical circuits in the vehicle A specially programmed controller antilock brake unit operates the system components ABS system ma...

Page 267: ...hen the Dump valve dumps off pres sure until the wheel unlocks This will continue until the wheels quit slipping altogether STANDARD PROCEDURE ABS BRAKE BLEEDING ABS system bleeding requires conventio...

Page 268: ...equency to determine a deceleration rate that would indicate a possible wheel locking tendency The signal strength of any magnetic induction sen sor is directly affected by Magnetic field strength the...

Page 269: ...ignition switch is turned on and the vehicle is driven The CAB monitors the system inputs and outputs circuits to verify the system is operating properly If the CAB senses a malfunction in the system...

Page 270: ...ut off In order to decrease the rear brake pressure the outlet valve for the rear brake circuit is pulsed This allows fluid to enter the low pressure accumulator LPA in the hydraulic control unit HCU...

Page 271: ...y cables to the battery 6 Remove the prop rod on the brake pedal 7 Bleed ABS brake system Refer to 5 BRAKES STANDARD PROCEDURE RWAL VALVE DESCRIPTION Rear Wheel Antilock RWAL brake system is stan dard...

Page 272: ...ations may be noticed as the isolation valve is opened REMOVAL 1 Install a prop rod on the brake pedal to keep pressure on the brake system 2 Disconnect the battery cables from the battery 3 Remove th...

Page 273: ......

Page 274: ...nk between the engine and the transmission The system is designed to ensure that the full torque output of the engine is transfered to the transmission while isolating the transmission from the engine...

Page 275: ...clutch disc and pressure plate surfaces will cause chatter slip and grab Inspect components for oil hydraulic fluid or water road splash contamination Oil contamination indicates a leak at either the...

Page 276: ...an result in flywheel cracking or warpage after installation it can also weaken the fly wheel and interfere with proper clutch release Clean the crankshaft flange before mounting the flywheel Dirt and...

Page 277: ...h cover and disc Alert driver to problem cause 2 Driver frequently rides slips clutch Results in rapid wear and overheating of disc and cover 2 Correct condition of flywheel and pressure plate surface...

Page 278: ...lutch master or slave cylinder plunger dragging and r binding 1 Master or slave cylinder components worn or corroded 1 Replace clutch hydraulic linkage assembly Release bearing is noisy 1 Release bear...

Page 279: ...plate disc and alignment tool INSTALLATION 1 Check runout and free operation of new clutch disc 2 Lubricate crankshaft pilot bearing with a NLGI 2 rated grease 3 Install clutch alignment tool in clut...

Page 280: ...are installed prop erly Fig 7 NOTE If release lever is installed correctly the lever part number will be toward the bottom of the transmission and right side up There is also a stamped I in the lever...

Page 281: ...engines to correct housing bore runout They are not avail able for diesel engines 1 Remove the clutch housing 2 Remove the clutch cover and disc 3 Replace one of the flywheel bolts with an appropriate...

Page 282: ...e housing face Fig 12 with indicator plunger on the rim of the housing bore 2 Rotate crankshaft until indicator plunger is at the 10 O clock position and zero the dial indicator 3 Measure and record f...

Page 283: ...ls are in good condition and properly seated 3 Transfer slave cylinder release fork and boot fork pivot stud and wire hose brackets to new hous ing 4 Align and install clutch housing on transmis sion...

Page 284: ...el runout whenever misalignment is suspected Flywheel runout should not exceed 0 08 mm 0 003 in Measure runout at the outer edge of the flywheel face with a dial indicator Mount the indicator on a stu...

Page 285: ...an oxy acetylene torch to remove the old gear or to heat and expand a new gear The high temperature of the torch flame can cause localized heating that will damage the fly wheel In addition using the...

Page 286: ...on clutch master cylinder reser voir is tight This will avoid spillage during removal 10 Remove clutch master cylinder nuts holding the to the dash panel 11 Remove clutch cylinders reservoir and con n...

Page 287: ...vent starter motor engagement unless the clutch pedal is depressed An input from this switch is also used to either shut down and or prevent operation of the speed con trol system when the clutch peda...

Page 288: ...g tem perature It allows the engine to reach normal oper ating temperature as quickly as possible It also maintains normal operating temperature and pre vents overheating The cooling system provides a...

Page 289: ...ator pressure cap Vertically mounted thermostat Coolant reserve recovery system Transmission oil cooler Coolant Coolant flow circuits for the 5 9L diesel engine are shown in Fig 3 Fig 1 Engine Cooling...

Page 290: ...the clamp has the same size width Fig 4 OPERATION OPERATION COOLING SYSTEM The cooling system regulates engine operating tem perature It allows the engine to reach normal oper ating temperature as qu...

Page 291: ...Fig 3 Cooling System Circulation Diesel Engine 7 4 COOLING DR COOLING Continued...

Page 292: ...n actual problem a DTC is stored The DTC will be stored in the ECM mem ory for eventual display to the service technician Refer to 25 EMISSIONS CONTROL DESCRIP TION ACCESSING DIAGNOSTIC TROUBLE CODES...

Page 293: ...eavier than oil An alternative method is to operate engine for a short period to churn the oil After this is done remove the engine dipstick and inspect for water globules Also inspect the transmissio...

Page 294: ...pm while observing coolant If internal engine combustion gases are leaking into cooling system bubbles will appear in coolant If bub bles do not appear internal combustion gas leakage is not present D...

Page 295: ...r radiator cooling fins 5 Clean all debris away from A C and radiator cooling fins 6 Coolant mixture incorrect 6 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE refill with correct mixture...

Page 296: ...SERVOIR BOTTLE TEMPERATURE GAUGE MAY READ HIGH 1 Radiator cap defective 1 Replace radiator cap 2 Radiator neck surface damaged 2 Replace radiator HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING 1 Vacuum...

Page 297: ...CKS ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the com plaint Abnormal loads on the cooling system such as the following may be the cause PROLONGED IDLE VERY HIGH AMBIE...

Page 298: ...e operating OK 3 Check gauge operation Refer to 8 ELECTRICAL INSTRUMENT CLUSTER ENGINE TEMPERATURE GAUGE DESCRIPTION Repair as necessary 4 Coolant level low in cold ambient temperatures accompanied wi...

Page 299: ...cap not installed tightly If cap is loose boiling point of coolant will be lowered Also refer to the following Step 6 5 Tighten cap 6 Poor seals at the radiator cap 6 a Check condition of cap and cap...

Page 300: ...en or cardboard is being reducing airflow 14 Remove bug screen or cardboard 15 Thermostat partially or completely shut 15 Check thermostat operation and replace as necessary Refer to 7 COOLING ENGINE...

Page 301: ...ter cooling system causing a thermostat to open late 6 a Check for cylinder head gasket leaks Refer to 7 COOLING DIAGNOSIS AND TESTING b Check for coolant in the engine oil Inspect for white steam emi...

Page 302: ...t reserve overflow tank is plugged Clean vent and repair as necessary d Reserve overflow tank is internally blocked or plugged Check for blockage and repair as necessary NOISY VISCOUS FAN DRIVE 1 Fan...

Page 303: ...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 304: ...tem This is done using air pressure in the opposite direction of normal coolant flow It is usually only necessary with very dirty systems with evidence of partial plugging REVERSE FLUSHING RADIATOR Di...

Page 305: ...the thermo stat opens upper radiator hose is warm to the touch 5 If necessary add a 50 50 mixture of anti freeze and water to the degass bottle to maintain the proper coolant level in the degas bottle...

Page 306: ...ipped with two one way check valves jiggle pins The check valves are used as a servicing feature and will vent air when the system is being filled Water pressure or flow will hold the valves closed 2...

Page 307: ...5 9L 13 112 Thermostat Housing Bolts 5 9L 23 16 Power Steering Oil Cooler Bolts 6 55 Transmission Auxiliary Oil Cooler Bolts 6 55 Transmission Oil Cooler Tube Nuts 31 5 24 Coolant Bottle Bolts 8 5 75...

Page 308: ...Cooling System Pressure Tester 7700A Adapter Pins 8346 DR COOLING 7 21 COOLING Continued...

Page 309: ...adjust belt tension on the 3 7L or 4 7L engine These engines are equipped with an automatic belt tensioner Fig 1 The tensioner maintains correct belt tension at all times Due to use of this belt tens...

Page 310: ...ering assist loss of air conditioning capac ity reduced generator output rate and greatly reduced belt life It is not necessary to adjust belt tension on the 3 9L or 5 9L engines These engines are equ...

Page 311: ...g 4 BELT TENSIONERS 5 9L DIESEL DESCRIPTION Drive belts on all engines are equipped with a spring loaded automatic belt tensioner Fig 5 This tensioner maintains constant belt tension at all times and...

Page 312: ...the ribbed surface of the belt from rib to rib Fig 7 are considered normal These are not a reason to replace the belt However cracks running along a rib not across are not nor mal Any belt with crack...

Page 313: ...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 314: ...BACK TO THE FREEARM POSITION SEVER DAM AGE MAY OCCUR TO THE TENSIONER Belt tension is not adjustable Belt adjustment is maintained by an automatic spring load belt ten sioner 1 Disconnect negative ba...

Page 315: ...DRIVE BELT DIAGNOSIS CHART for further belt diagnosis NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle Before replacing a belt to resolve a noise condition insp...

Page 316: ...g failure 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 Re...

Page 317: ...on between 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 b...

Page 318: ...ELT TENSIONERS DESCRIPTION DRIVE BELTS 5 9L DIESEL DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts small cracks that run across the ribbed...

Page 319: ...EAR 1 Pulley misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Replace p...

Page 320: ...SE Objectional 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 Belt mi...

Page 321: ...Y DRIVE BELT TENSIONERS DESCRIP TION 1 A 1 2 inch square hole is provided in the auto matic belt tensioner Attach a 1 2 inch drive long handle ratchet to this hole 2 Rotate ratchet and tensioner assem...

Page 322: ...TING THERMOSTAT 48 REMOVAL 48 INSTALLATION 49 ENGINE COOLANT THERMOSTAT 3 7L 4 7L DESCRIPTION 50 OPERATION 51 DIAGNOSIS AND TESTING THERMOSTAT 51 REMOVAL 51 INSTALLATION 51 ENGINE COOLANT THERMOSTAT 5...

Page 323: ...always be a minimum of 44 percent year round in all climates If percentage is lower than 44 per cent engine parts may be eroded by cavitation and cooling system components may be severely damaged by c...

Page 324: ...ze Mixing of coolants other than specified non HOAT or other HOAT may result in engine damage that may not be covered under the new vehicle warranty and decreased corrosion protection COOLANT PERFORMA...

Page 325: ...y hose from radiator 2 Remove the coolant container to fan shroud mounting bolt 3 Tilt the container backward towards the engine to disengage the mounting pin locking features and lift the container a...

Page 326: ...ing system Refer to 7 COOLING STANDARD PROCEDURE RADIATOR FAN REMOVAL CAUTION If the viscous fan drive is replaced because of mechanical damage the cooling fan blades should also be inspected Inspect...

Page 327: ...uching flat surface replace fan if clearance between opposite blade and surface is greater than 2 0 mm 090 inch Rocking motion of opposite blades should not exceed 2 0 mm 090 inch Test all blades in t...

Page 328: ...CAUTION Some engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives Installation of the wrong fan or viscous fan drive can result in engine overheating CLEANING...

Page 329: ...ne coolant The 5 9L gas powered engine has the block heater located on the right side of engine next to the oil filter Fig 6 The 3 7L 4 7L gas powered engines have the block heater located to the rear...

Page 330: ...RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS An optional engine block heater is available on all models The heater is equipped with a power cord The heater is mounted in a...

Page 331: ...e PCM uses inputs from the ECT sensor for the following calculations for engine coolant temperature gauge operation through CCD or PCI J1850 communications Injector pulse width Spark advance curves AS...

Page 332: ...CT sensor Refer to Heating and Air Conditioning section for information 4 Disconnect electrical connector from sensor Fig 14 5 Remove sensor from cylinder block 5 9L Diesel The Engine Coolant Temperat...

Page 333: ...4 Remove the sensor from the intake manifold 8 0L V 10 The Engine Coolant Temperature ECT sensor on the 8 0L V 10 engine is threaded into the thermostat housing Fig 17 WARNING HOT PRESSURIZED COOLANT...

Page 334: ...cooling system Refer to 7 COOLING 8 0L V 10 1 Apply thread sealant to sensor threads 2 Install sensor to engine 3 Tighten sensor to 11 N m 8 ft lbs torque 4 Connect electrical connector to sensor 5 Re...

Page 335: ...in the coolant into a clean container for reuse If the thermostat is being replaced be sure that the replacement is the specified thermostat for the vehicle model and engine type Factory installed the...

Page 336: ...ON 1 Clean the mating areas of the intake manifold and thermostat housing 2 Install the thermostat spring side down into the recessed machined groove on the intake manifold Fig 22 3 Install the gasket...

Page 337: ...r testing A pellet type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator On all engines the thermostat is closed below 195 F 90 C A...

Page 338: ...an container for reuse If the thermostat is being replaced be sure that the replacement is the specified thermostat for the vehicle model and engine type 1 Disconnect the negative battery cable 2 Drai...

Page 339: ...use overheat ing OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat When heated the pellet expands overcoming closing spring tension and water pump pressure...

Page 340: ...eating device 5 Place a commercially available radiator ther mometer into the water 6 Apply heat to the water while observing the thermostat and thermometer 7 The thermostat will begin to open at 85 5...

Page 341: ...he fan will remain at a reduced rpm regardless of engine speed Only when sufficient heat is present will the vis cous fan drive engage This is when the air flowing through the radiator core causes a r...

Page 342: ...8 C 190 F Fan drive engagement should start to occur at be tween 3 7L Automatic 93 C 99 C 200 F 210 F 3 7L Manual 4 7L Automatic 5 9L 85 to 91 C 185 to 195 F 4 7L Manual 74 to 79 C 165 to 175 F Engage...

Page 343: ...e transmis sion is in park or neutral 2 Stat and allow engine to reach normal operat ing termeratures 3 With engine idling connect the DRB III and select appropraite model year and engine option 4 Lac...

Page 344: ...ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only an original equi...

Page 345: ...ards engine 2 Install the rubber insulators to the lower radi ator mounting features alignment dowel and support bracket at the lower part of the radiator 3 Lower the radiator into position while guid...

Page 346: ...THE RESERVE OVERFLOW TANK AFTER PRES SURE BUILD UP HAS BEEN RELEASED REMOVE CAP FROM FILLER NECK 2 Drain a small amount of coolant from the radi ator until the ends of the radiator tubes are visible t...

Page 347: ...rovided in the lower radiator support for each engine application 3 Install two upper radiator mounting bolts Tighten bolts to 11 N m 95 in lbs torque 4 Connect both radiator hoses and install hose cl...

Page 348: ...THE WARNING WORDS DO NOT OPEN HOT ON RADIATOR PRESSURE CAP ARE A SAFETY PRECAUTION WHEN HOT PRESSURE BUILDS UP IN COOLING SYSTEM TO PREVENT SCALDING OR INJURY RADIATOR CAP SHOULD NOT BE REMOVED WHILE...

Page 349: ...e overflow system with a completely sealed diaphragm spring and a rubber gasket This gasket is used to seal to radiator filler neck top surface Use of proper cap will allow coolant return to radiator...

Page 350: ...system Refer to 7 COOLING STANDARD PROCEDURE Do not waste reusable coolant If solution is clean drain coolant into a clean container for reuse 3 Remove the radiator fan Refer to 7 COOL ING ENGINE RAD...

Page 351: ...er to 7 COOLING AC CESSORY DRIVE DRIVE BELTS INSTALLATION Fig 41 10 Install the fan Refer to 7 COOLING EN GINE RADIATOR FAN INSTALLATION 11 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 12...

Page 352: ...cle at this time WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP ALWAYS WEAR SAFETY GLAS...

Page 353: ...ating surfaces 2 Using a new gasket position water pump and install the mounting bolts Fig 48 Tighten the water pump mounting bolts to 58 N m 43 ft lbs 3 Spin the water pump to be sure that the pump i...

Page 354: ...ure Additional lubrica tion is not necessary OPERATION The diesel engine water pump draws coolant from radiator outlet and circulates it through engine heater core and back to radiator inlet The crank...

Page 355: ...ry Do not remove any refriger ant lines from A C compressor WARNING THE A C SYSTEM IS UNDER PRESSURE EVEN WITH THE ENGINE OFF REFER TO REFRIG ERANT WARNINGS IN SECTION 24 HEATING AND AIR CONDITIONING...

Page 356: ...THOUT AIR CONDITIONING A water pump bypass hose Fig 56 is used between the intake manifold and water pump on all gas powered engines To test for leaks Refer to 7 COOLING DIAGNOSIS AND TESTING 1 Partia...

Page 357: ...DRIVE BELTS INSTALLA TION CAUTION When installing the serpentine accessory drive belt the belt must be routed correctly If not the engine may overheat due to the water pump rotating in the wrong direc...

Page 358: ...olts Tighten moubting bolts to 24 N m 18 ft lbs 2 Install heater hoses 3 Install upper and lower radiator hoses 4 Install belt tensioner assembly 5 Install idler pulleys 6 Install A C compressor and a...

Page 359: ...engine have an internal ther mostat that controls fluid flow through the cooler When the transmission fluid is cold less than operating temperature the fluid is routed through the cooler bypass when t...

Page 360: ...ghten the bolts to 16 N m 140 in lbs 4 inspect the quick connect fittings for debris and install the quick connect fitting on the cooler tube until an audible click is heard Pull apart the con nection...

Page 361: ...PLUMBING REMOVAL 2 Place a drain pan under the oil cooler 3 Raise the vehicle 4 Disconnect the oil cooler quick connect fittings from the transmission lines 5 Remove the charge air cooler to oil coole...

Page 362: ...LE AUTOMATIC 47RE FLUID STANDARD PROCEDURE INSTALLATION 1 Position oil cooler on cylinder block 2 Install two mounting bolts to cooler at the cyl inder block Torque bolts to 77N m 57 ft lbs 3 Install...

Page 363: ......

Page 364: ...udio system rely upon resources shared with other electronic modules in the vehicle over the Programmable Com munication Interface PCI bus network The data bus network allows the sharing of sensor inf...

Page 365: ...S OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY AUDIO SYSTEM DIAG...

Page 366: ...e tape head 3 Clean head with Mopar Cassette Head Cleaner 4 Faulty tape deck 4 Exchange or replace radio if required NO COMPACT DISC OPERATION 1 Faulty CD 1 Insert known good CD and test operation 2 F...

Page 367: ...nals that are broadcast by local commercial radio stations in both the Amplitude Modulating AM and Frequency Modulating FM frequency ranges These electromagnetic radio fre quency signals induce small...

Page 368: ...of an ohm resistance High or infinite resistance indicates a damaged or open antenna conductor If OK go to Test 3 If not OK isolate and test each of the individual antenna conductor components Replac...

Page 369: ...ument panel cable 4 Install the right side kick panel 5 Insert the antenna body through the hole in the fender and install adapter 6 Install the antenna cap nut Tighten to 7 N m 65 in lbs 7 Install th...

Page 370: ...nd include an electronic digital clock function These radio receivers can only be serviced by an authorized radio repair station See the latest War ranty Policies and Procedures manual for a current l...

Page 371: ...r crimped to each end One end is secured to the engine cylinder head s The other is secured to the plenum at the exhaust heat shield forward outer attaching stud Resistor type spark plugs This type of...

Page 372: ...bolts from the cylinder heads Fig 11 3 Remove nut from heat shield and remove strap Fig 10 ENGINE TO HEAT SHIELD 5 9L AND 8 0L ENGINE 1 Disconnect and isolate the battery negative cable 2 Remove the a...

Page 373: ...dio switch units are normally open resistor multiplexed momentary switches that are hard wired to the Inte grated Power Module IPM through the clockspring The IPM sends a five volt reference signal to...

Page 374: ...REMOTE RADIO SWITCH TEST TABLE Switch Switch Position Resistance Right White Volume Up 1 210 Kilohms 1 Right White Volume Down 3 010 Kilohms 1 Right White Mode Advance 0 0511 Kilohms 1 Left Black See...

Page 375: ...OSSIBLE PERSONAL INJURY 1 Install remote radio switch to the steering wheel 2 Connect the wire harness to the remote radio switch 3 Install the speed control switches Refer to 8 ELECTRICAL SPEED CONTR...

Page 376: ...ck the amplifier fuse if equipped in the IPM If OK go to Step 3 If not OK repair the shorted circuit or component as required and replace the faulty fuse 3 Turn the ignition switch to the ON position...

Page 377: ...onnect electrical harness connector and remove speaker REAR CAB SIDE SPEAKER 1 Disconnect and isolate the battery negative cable 2 Remove B pillar lower trim Refer to 23 BODY INTERIOR B PILLAR LOWER T...

Page 378: ...T PANEL END SPEAKER 1 Connect electrical harness connector and install speaker 2 Install instrument panel top cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER INSTALLATION 3 Connect...

Page 379: ......

Page 380: ...pen and the headlamp switch is in the park lamp or headlamp position the chime will sound until the headlamp switch is turned off the door is closed or the battery protection time out expires KEY IN I...

Page 381: ...ystem will not deploy If the instrument cluster does not receive a message from the air bag module for 3 consecutive seconds the Instrument will illuminate the warning indicator The air bag module tra...

Page 382: ...RATION 5 VOLT SUPPLIES 11 OPERATION IGNITION CIRCUIT SENSE 12 REMOVAL 12 INSTALLATION 12 SENTRY KEY IMMOBILIZER MODULE DESCRIPTION 13 OPERATION 13 STANDARD PROCEDURE PCM SKIM PROGRAMMING 14 REMOVAL 15...

Page 383: ...system A standard node terminates the bus through an 11 KW resistor and a 330 pF capacitor The modules bias the bus when transmitting a message The PCI bus uses low and high voltage lev els to genera...

Page 384: ...when a system fault is detected Faults are stored in a diagnostic program memory and are accessible with the DRB III scan tool ABS faults remain in memory until cleared or until after the vehicle is s...

Page 385: ...tion Sensor CKP Data link connection for DRB scan tool Engine Coolant Temperature ECT sensor Ground circuits Fuel Pressure Sensor Battery Temperature Fan speed Inlet Air Temperature Sensor Pressure Se...

Page 386: ...nt On this model the inte grated power module must be positioned aside in order to access the front control module The front control module mates to the power distribution cen ter to form the Integrat...

Page 387: ...or straight in 2 Install the front control module retaining screws Torque the screws to 7 in lbs 3 Install the integrated power module Refer to 8 ELECTRICAL POWER DISTRIBUTION INTE GRATED POWER MODULE...

Page 388: ...dures If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate test the heated seat switch Refer to Diagnosis and Testing Heated Seat Switch in Heated Seats for...

Page 389: ...h ON Engine start up crank Engine warm up Idle Cruise Acceleration Deceleration Wide open throttle WOT Ignition switch OFF The ignition switch On engine start up crank engine warm up acceleration dece...

Page 390: ...ure the PCM will begin monitoring O2S sensor input The system will then leave the warm up mode and go into closed loop operation IDLE MODE When the engine is at operating temperature this is a Closed...

Page 391: ...de During wide open throttle operation the PCM receives the following inputs Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold air temperature sensor Manifol...

Page 392: ...shaft position sensor signal Crankshaft position sensor Data link connection for DRB scan tool EATX module if equipped Engine coolant temperature sensor Fuel level through J1850 circuitry Generator ba...

Page 393: ...HICLES ORIGINAL IDEN TIFICATION NUMBER VIN AND THE VEHI CLES ORIGINAL MILEAGE IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE DTC MAY BE SET The PCM is located in the engine compartment attached to...

Page 394: ...includes a rolling code algorithm strategy which helps to reduce the possibility of unauthorized SKIS disarming The rolling code algorithm ensures secu rity by preventing an override of the SKIS thro...

Page 395: ...secured access mode by entering the vehicle four digit PIN 5 Select ENTER to update PCM VIN NOTE If three attempts are made to enter secure access mode using an incorrect PIN secured access mode will...

Page 396: ...INSTALLATION NOTE If the SKIM is replaced with a new unit a DRBIIIT scan tool MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders Refer to 8 ELECTRICAL VEHICLE...

Page 397: ...l remain in this state as long as there is traffic other than run or start messages and will return to Sleep mode if the bus goes without traffic for 20 1 seconds SHIFT REQUIREMENTS If the TCCM is in...

Page 398: ...0 msec per D channel transition in the des tination gear s direction while monitoring the mode sensor channel transitions Disengage the shift motor when the correct mode sensor code is recognized Soli...

Page 399: ...es the 2WD AWD D channel when being driven in the 4H direction then one final 1 0 second drive toward 4H is attempted If the transfer case then reaches any of the 4H posi tions the shift is considered...

Page 400: ...mpartment near the right inner fender OPERATION The Transmission Control Module TCM controls all electronic operations of the transmission The TCM receives information regarding vehicle opera tion fro...

Page 401: ...he gear ratio is 2 1 In direct drive 3rd gear the gear ratio changes to 1 1 The gear ratio changes as clutches are applied and released By monitoring the length of time it takes for the gear ratio to...

Page 402: ...ol This program allows the electronic transmission system to recalibrate itself This will provide the proper transmission operation The quick learn pro cedure should be performed if any of the followi...

Page 403: ...2 Move the vehicle forward to a speed of at least 16 km h 10 MPH and come to a stop This ensures no air is present in the UD hydraulic circuit 3 Perform repeated N D shifts at a stop while pausing in...

Page 404: ...the LR CVI becomes stable and the manual 2 1 becomes smooth LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT NOTE The transmission oil temperature must be above 110 F 43 C 1 With the vehicle at a stop perform...

Page 405: ......

Page 406: ...17 OPERATION 17 REMOVAL 17 INSTALLATION 18 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on gasoline engine equipped mod els Diesel engine equipped vehic...

Page 407: ...t are used in these systems must perform within specifications It is important that the battery starting and charging systems be thor oughly tested and inspected any time a battery needs to be charged...

Page 408: ...ions are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The battery has an i...

Page 409: ...ed 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads 8 Slow driving or prolonged idlin...

Page 410: ...rts cleaning brush to remove any acid film Fig 2 Rinse the battery with clean water Ensure that the cleaning solution does not enter the battery cells through the vent holes If the battery is being re...

Page 411: ...exceed the original equipment specification for the vehicle being serviced Battery sizes and ratings are discussed in more detail below Group Size The outside dimensions and ter minal placement of th...

Page 412: ...positive and negative plates to prevent them from contacting or shorting against one another These dissimilar metal plates are submerged in a sulfuric acid and water solution called an electrolyte The...

Page 413: ...rged when All of the battery cells are gassing freely during battery charging A green color is visible in the sight glass of the battery built in test indicator Three hydrometer tests taken at one hou...

Page 414: ...turer of the battery charger for details on how to bypass the polarity sensing circuitry 3 Battery chargers vary in the amount of voltage and current they provide The amount of time required for a ba...

Page 415: ...ully charged battery the battery must be load tested Refer to Standard Procedures for the proper battery load test procedures Black or Dark Indicates 0 to 75 battery state of charge The battery is ina...

Page 416: ...clock electronically tuned radio and other modules which may vary with the vehicle equipment A vehicle that has not been operated for approxi mately twenty days may discharge the battery to an inadequ...

Page 417: ...e appropriate wiring information in this service manual for complete Inte grated Power Module fuse circuit breaker and cir cuit identification This will isolate each circuit and identify the circuit t...

Page 418: ...at tery retest the battery using the OUT OF VEHICLE test before replacing 6 While viewing the battery test result press the CODE button and the tester will prompt you for the last 4 digits of the VIN...

Page 419: ...AL 1 Loosen and remove the battery hold down retaining bolt 2 Remove the battery hold down bracket from the battery case INSTALLATION 1 Clean and inspect the battery hold down hard ware Refer to 8 ELE...

Page 420: ...OWER DISTRIBUTION CENTER PDC REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT THE ENGINE F...

Page 421: ...ignition switch in the Start position Observe the voltmeter If the reading is above 0 2 volt clean and tighten the battery negative cable eyelet terminal connection to the engine block Repeat the test...

Page 422: ...and stabilize the battery in the engine compartment which prevents battery movement during even the most extreme vehicle operation Unrestrained battery movement during vehicle operation could result i...

Page 423: ...2 Connect the left front fender ground wire 3 Install the purge solenoid on its mounting bracket 4 Install the battery temperature sensor in the battery tray Refer to 8 ELECTRICAL CHARGING BATTERY TE...

Page 424: ...connected in series with the second rotor field terminal and ground A battery temperature sensor located in the bat tery tray housing is used to sense battery tempera ture This temperature data along...

Page 425: ...Distribution Center PDC for tightness in receptacles They should be properly installed and tight Repair or replace as required 4 Inspect generator mounting bolts for tightness Replace or tighten bolt...

Page 426: ...tion voltage at the PCM increases The BTS is also used for OBD II diagnostics Cer tain faults and OBD II monitors are either enabled or disabled depending upon BTS input for example disable purge and...

Page 427: ...ection at the back of this group for amperage ratings and part numbers Noise emitting from the generator may be caused by worn loose or defective bearings a loose or defec tive drive pulley incorrect...

Page 428: ...URY OR DAMAGE TO ELECTRICAL SYSTEM 1 Disconnect both negative battery cables at both batteries 2 Remove generator drive belt Refer to 7 Cool ing System for procedure 3 Unsnap plastic insulator cap fro...

Page 429: ...AGE TO ELECTRICAL SYSTEM 1 Disconnect negative battery cable at battery 2 Remove generator drive belt Refer to 7 Cool ing System for procedure 3 Unsnap plastic insulator cap from B output terminal 4 R...

Page 430: ...engine and install 2 mounting bolts 2 Tighten bolts Refer to Torque Specifications 3 Position support bracket to front of generator and install bolt and nuts Tighten bolt nuts Refer to Torque Specifi...

Page 431: ...ns CAUTION Never force a belt over a pulley rim using a screwdriver The synthetic fiber of the belt can be damaged CAUTION When installing a serpentine accessory drive belt the belt MUST be routed cor...

Page 432: ...ngth of the rotor magnetic field The EVR circuitry monitors system line voltage B and battery temperature refer to Battery Temperature Sensor for more information It then determines a target charging...

Page 433: ...uce a Diagnostic Trouble Code DTC Refer to Diagnostic Trouble Codes in Emission Control for a list of codes OPERATION The starting system components form two separate circuits A high amperage feed cir...

Page 434: ...n 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 For c...

Page 435: ...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 equipped with manual transmiss...

Page 436: ...nector at starter solenoid If you probe positive battery terminal post and cable connector at starter solenoid you are reading com bined voltage drop in positive battery cable clamp to terminal post c...

Page 437: ...still above 0 2 volt replace faulty negative battery cable Note Certain diesel equipped mod els use dual batteries If equipped with dual battery system this procedure must be per formed twice once fo...

Page 438: ...h manual transmission refer to Clutch Pedal Position Switch in 6 Clutch Park Neutral Position Switch If equipped with automatic transmission refer to Park Neutral Position Switch in 21 Transmission Wi...

Page 439: ...ile load of tester to obtain free running test voltage Refer to Specifications for starter motor free running test voltage specifications 6 Note reading on ammeter and compare reading to free running...

Page 440: ...lower starter mounting bolt 4 Remove 2 mounting bolts Fig 11 5 Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing Always support starter motor d...

Page 441: ...etween front axle and side of transmission Remove 2 support bracket bolts at transmission Pry support bracket slightly to gain access to lower starter mounting bolt 4 Remove nut and lock washer securi...

Page 442: ...pped with automatic transmission slide cooler tube bracket into position 5 Install and tighten both mounting bolts Refer to Torque Specifications 6 Lower vehicle 7 Connect negative battery cable 5 9L...

Page 443: ...nce between terminals 85 and 86 elec tromagnet should be 75 5 ohms If OK go to Step 4 If not OK replace faulty relay 4 Connect 12V battery to terminals 85 and 86 There should now be continuity between...

Page 444: ...h in 21 Transmission REMOVAL The starter relay is located in the Power Distribu tion Center PDC Fig 16 Refer to label on PDC cover for relay location 1 Disconnect and isolate negative battery cable 2...

Page 445: ......

Page 446: ...cludes the following major components The heated mirror switch including the heated mirror system solid state electronic control logic and timer circuitry the heated mirror relay and the heated mirror...

Page 447: ...PER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY The operation of the heated mirror system can be confirmed in one of the following manners 1 Turn the igniti...

Page 448: ...Heat Interface Module SHIM this module con tains the solid state electronic control and diagnostic logic circuitry for the heated seat system One heated seat module is used per vehicle and is mounted...

Page 449: ...heated seat module will automatically turn off the heated seat elements if it detects a short or open in the heated seat ele ment circuit or a heated seat sensor value that is out of range DIAGNOSIS A...

Page 450: ...headlamps or park lamps turned On refer to the Instrument Cluster section of the service manual for the location of cluster illumination lamp diagnosis and testing procedures If the heated seat switc...

Page 451: ...cushion and seat back heating elements and sensor are located on the right side of the seat near the edge of the seat cushion frame The proper connector can be identified by the foam wrapping NOTE Wh...

Page 452: ...r seat in the full rearward position 2 Unclip the heated seat module from the bottom of the drivers seat cushion pan 3 Back probe the heated seat module wire har ness connector do not disconnect Check...

Page 453: ...seat heater OFF The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output run circuit when the ignition switch is in the On positi...

Page 454: ...If OK refer to Step 6 If not OK replace the faulty heated seat switch HEATED SEAT SWITCH CONTINUITY Switch Position Continuity Between Resistance Neutral 4 6 2 2 Kilohms Low 4 6 415 Kilohms High 4 6...

Page 455: ......

Page 456: ...res details of wire harness routing and retention connector pin out information and location views for the various wire harness connectors splices and grounds In most cases any problem involving conti...

Page 457: ...iagnose the horn system requires the use of a DRBIIIt scan tool and the proper Diag nostic Procedures manual The DRBIIIt scan tool can provide confirmation that the PCI data bus is functional that all...

Page 458: ...IBUTOR ROTOR DIAGNOSIS AND TESTING DISTRIBUTOR ROTOR 5 9L V 8 19 IGNITION COIL DESCRIPTION 19 OPERATION 20 REMOVAL 23 INSTALLATION 24 KNOCK SENSOR DESCRIPTION 25 OPERATION 25 REMOVAL 25 INSTALLATION 2...

Page 459: ...also equipped with a sec ond output terminal This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank A separate pri mary electrical connec...

Page 460: ...osition Sensor 5 7L V 8 Engine 12 9 105 Camshaft Position Sensor 8 0L V 10 Engine 6 50 Crankshaft Position Sensor 3 7L V 6 Engine 28 21 205 Crankshaft Position Sensor 4 7L V 8 Engine 28 21 205 Cranksh...

Page 461: ...om to keep them separated This loom is clipped to the intake manifold To prevent a miss match of cables a corresponding spark plug coil number is displayed on each plug cable 1 6 2 3 4 7 and 5 8 These...

Page 462: ...Foot 12 000 Ohms Per Foot SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 3 7L V 6 ZFR6F 11G NGK 1 1 0 042 in 4 7L V 8 RC12MCC4 1 01 mm 040 in 5 7L V 8 Champion RE14MCC4 1 14 mm 045 in 5 9L V 8 RC12LC4 1 0...

Page 463: ...bel on PDC cover for relay location OPERATION OPERATION PCM OUTPUT The ASD relay supplies battery voltage 12 volts to the fuel injectors and ignition coil s With certain emissions packages it also sup...

Page 464: ...continuity between terminals 30 and 87A 4 Connect the ohmmeter between terminals 87 and 30 The ohmmeter should not show continuity at this time 5 Connect one end of a jumper wire 16 gauge or smaller...

Page 465: ...Sensor CMP sensor on the 3 7L V 6 engine contains a hall effect device referred to as a sync signal generator A rotating target wheel tonewheel for the CMP is located at the front of the camshaft for...

Page 466: ...sition from both the camshaft position sensor and crankshaft position sensor The tonewheel is located at the front of the cam shaft Fig 8 As the tonewheel rotates notches Fig 8 pass through the sync s...

Page 467: ...approximately 5 volts When the trailing edge of the tonewheel notch passes the tip of the CMP the following occurs The change of the magnetic field causes the signal voltage to switch low to 0 volts...

Page 468: ...head 4 Check condition of sensor o ring 4 7L V 8 The Camshaft Position Sensor CMP on the 4 7L V 8 engine is bolted to the front top of the right cyl inder head Fig 13 1 Raise and support vehicle 2 Dis...

Page 469: ...gear cover 4 Check condition of sensor o ring 5 9L V 8 Gas The Camshaft Position Sensor CMP is located inside the distributor Fig 17 Distributor removal is not necessary to remove camshaft position s...

Page 470: ...is to be removed and installed such as when servicing the timing chain timing gears or timing chain cover use this procedure 1 Disconnect sensor harness connector from sen sor 2 Remove sensor mounting...

Page 471: ...head 2 Apply a small amount of engine oil to sensor o ring 3 Install sensor into cylinder head with a slight rocking action Do not twist sensor into position as damage to o ring may result CAUTION Bef...

Page 472: ...g on the timing gear cover Fig 22 6 If the dimension is approximately 1 818 inches it is OK to install sensor Proceed to step Step 9 7 If the dimension is approximately 2 018 inches the cam gear will...

Page 473: ...r air gap DISTRIBUTOR DESCRIPTION All 5 9L V 8 engines are equipped with a camshaft driven mechanical distributor Fig 23 containing a shaft driven distributor rotor All distributors are equipped with...

Page 474: ...aft vibration damper is aligned to 0 degree TDC mark on timing chain cover Fig 24 8 The distributor rotor should now be aligned to the CYL NO 1 alignment mark stamped into the camshaft position sensor...

Page 475: ...T WEAR LOOSE CLOTHING 1 Connect DRB scan tool to data link connector The data link connector is located in passenger com partment below and to left of steering column 2 Gain access to SET SYNC screen...

Page 476: ...hat displays any of these adverse conditions IGNITION COIL DESCRIPTION 3 7L V 6 The 3 7L V 6 engine uses 6 dedicated and individ ually fired coil for each spark plug Fig 30 Each coil is mounted direct...

Page 477: ...pendent epoxy filled coils The rear coil pack contains two indepen dent epoxy filled coils OPERATION 3 7L V 6 Battery voltage is supplied to the 6 individual igni tion coils from the ASD relay The Pow...

Page 478: ...OSITE CYLINDER BANK IGNITION COIL Fig 35 IGNITION COIL LOCATION 5 9L V 8 EXCEPT HDC 1 ACCESSORY DRIVE BELT TENSIONER 2 COIL CONNECTOR 3 IGNITION COIL 4 COIL MOUNTING BOLTS Fig 36 IGNITION COIL LOCATIO...

Page 479: ...s indicating the ignition key is ON but the engine is not running it will shut down the ASD circuit Base ignition timing is not adjustable on the 5 7L V 8 engine By controlling the coil ground cir cui...

Page 480: ...e or intake box may need to be removed to gain access to coil 2 Disconnect electrical connector Fig 32 from coil by pushing downward on release lock on top of connector and pull connector from coil 3...

Page 481: ...und top of spark plug 2 Check condition of coil o ring and replace as necessary To aid in coil installation apply silicone to coil o ring 3 Position ignition coil into cylinder head opening and push o...

Page 482: ...exceeds a specified value knock retard is allowed Knock retard uses its own short term and long term memory program Long term memory stores previous detonation information in its battery backed RAM T...

Page 483: ...6 4 7L V 8 NOTE The left sensor is identified by an identifica tion tag LEFT It is also identified by a larger bolt head The Powertrain Control Module PCM must have and know the correct sensor left r...

Page 484: ...ng spark plugs Incorrect torque can distort the spark plug and change plug gap It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head Remove the spark pl...

Page 485: ...chamber ELECTRODE GAP BRIDGING Electrode gap bridging may be traced to loose deposits in the combustion chamber These deposits accumulate on the spark plugs during continuous stop and go driving When...

Page 486: ...at ing temperature of a particular type spark plug Spark plugs are designed to operate within specific temperature ranges This depends upon the thick ness and length of the center electrodes porcelain...

Page 487: ...cess to spark plug Refer to Ignition Coil Removal Installation and observe all CAUTIONS and WARN INGS Before removing or disconnecting any spark plug cables note their original position Remove cables...

Page 488: ...plugs Metallic deposits will remain on spark plug insulator and will cause plug misfire Adjust spark plug gap with a gap gauging tool Fig 51 INSTALLATION 3 7L V 6 Special care should be taken when in...

Page 489: ...s 5 9L V 8 Special care should be taken when installing spark plugs into the cylinder head spark plug wells Be sure the plugs do not drop into the plug wells as elec trodes can be damaged Always tight...

Page 490: ...G CABLES Cable routing is important on certain engines To prevent possible ignition crossfire be sure the cables are clipped into the plastic routing looms Refer to Spark Plug Cable Removal for adddit...

Page 491: ...cable from dis tributor cap tower and connect ohmmeter to the ter minal ends of cable If resistance is not within specifications as found in the SPARK PLUG CABLE RESISTANCE chart replace the cable Tes...

Page 492: ...iners Failure to route the cables properly may cause the radio to reproduce ignition noise It could also cause cross ignition of the plugs or may short circuit the cables to ground When installing new...

Page 493: ......

Page 494: ...ERATION 26 GEAR SELECTOR INDICATOR DESCRIPTION 26 OPERATION 27 HIGH BEAM INDICATOR DESCRIPTION 27 OPERATION 28 LAMP OUT INDICATOR DESCRIPTION 28 OPERATION 28 LOW FUEL INDICATOR DESCRIPTION 29 OPERATIO...

Page 495: ...trip odometer switch button protrudes through dedicated holes in the cluster mask and the cluster lens located near the lower edge of the cluster just to the left of the tachometer The molded plastic...

Page 496: ...echanical relay is also soldered onto the circuit board to pro duce audible clicks that emulate the sound of a con ventional turn signal or hazard warning flasher Refer to 8 ELECTRICAL CHIME BUZZER DE...

Page 497: ...luding CHMSL Panel Lamps Dimming Control The EMIC provides a hard wired 12 volt Pulse Width Modulated PWM output that synchronizes the dimming level of all panel lamps dimmer controlled lamps with tha...

Page 498: ...tor Indicator with Automatic Transmission only High Beam Indicator Lamp Out Indicator Low Fuel Indicator Malfunction Indicator Lamp MIL Overdrive Off Indicator with Automatic Transmission only Seatbel...

Page 499: ...strument panel so that all of these monitors can be easily viewed by the vehicle operator when driving while still allow ing relative ease of access for service The micropro cessor based EMIC hardware...

Page 500: ...IC to provide some features regardless of the ignition switch posi tion while other features will operate only with the ignition switch in the On or Start positions The EMIC circuitry is grounded thro...

Page 501: ...ni tion switch is in the Off or Accessory positions The illumination intensity of the VFD units is con trolled by the EMIC circuitry based upon an input from the headlamp switch and a dimming level in...

Page 502: ...DIAGNOSIS AND TESTING Proper testing of the PCI data bus and the electronic message inputs to the EMIC that control an indicator requires the use of a DRBIIIt scan tool Refer to the appropriate diagno...

Page 503: ...Unlock Driver with Power Locks Transfer Case Switch Illumination Driver with Four Wheel Drive Refer to the appropriate wiring information for additional details GROUNDS The EMIC receives and supplies...

Page 504: ...verdrive off indicator the service four wheel drive indicator the transmission overtemp indicator the upshift indicator the secu rity indicator or the gear selector indicator discon nect and isolate t...

Page 505: ...position but do not start the engine 4 Release the odometer trip odometer switch but ton 5 The instrument cluster will simultaneously illuminate all of the operational segments in both VFD units perfo...

Page 506: ...mation 64 Driver door lock switch input circuit open Refer to the appropriate diagnostic information 65 Driver door lock switch input circuit stuck Refer to the appropriate diagnostic information 66 A...

Page 507: ...TE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RE...

Page 508: ...ster from the instru ment panel Refer to 8 ELECTRICAL INSTRU MENT CLUSTER REMOVAL 3 Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board Fig 6 4 Pull the b...

Page 509: ...tery negative cable CLUSTER LENS HOOD AND MASK 1 Position the cluster lens hood and mask unit over the face of the instrument cluster Fig 7 Be certain that the odometer trip odometer switch but ton is...

Page 510: ...ver the Programmable Communications Interface PCI data bus The ABS indicator Light Emitting Diode LED is completely controlled by the instru ment cluster logic circuit and that logic will only allow t...

Page 511: ...dicator will be illuminated The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp off message from the ACM whichever is longer Communication Error If the clus...

Page 512: ...released or until the ignition switch is turned to the Off position whichever occurs first Actuator Test Each time the instrument clus ter is put through the actuator test the brake indi cator will b...

Page 513: ...rake switch sense circuit between the park brake switch and the instrument cluster as required CARGO LAMP INDICATOR DESCRIPTION A cargo lamp indicator is standard equipment on all instrument clusters...

Page 514: ...the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module PCM on vehicles equipped with a gasoline engine o...

Page 515: ...appears in a blue green color and at the same lighting level as the gear selector indicator information when it is illuminated by the instrument cluster electronic circuit board The cruise indicator...

Page 516: ...ion switch is 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...

Page 517: ...ed to the Off position whichever occurs first The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate en...

Page 518: ...confirm the functionality of the LED and the cluster control circuitry The actuator test illumination of the ETC indicator is a function of the PCM The PCM continually monitors the ETC system cir cuit...

Page 519: ...n Empty Percent Tank Full Mes sage Each time the cluster receives a message from the PCM or ECM indicating the percent tank full is less than empty the gauge needle is moved to the far left end of the...

Page 520: ...is open and no electronic messages are received from the TCM within two seconds the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until th...

Page 521: ...er then sends the proper low beam and high beam lamp on and lamp off messages to the Front Control Module FCM over the Programmable Communications Interface PCI data bus and turns the high beam indica...

Page 522: ...ntrol Module PCM on vehicles equipped with a gasoline engine or from the Engine Control Module ECM on vehicles equipped with a diesel engine over the Programmable Communications Interface PCI data bus...

Page 523: ...ions Interface PCI data bus The MIL Light Emitting Diode LED is completely con trolled by the instrument cluster logic circuit and that logic will only allow this indicator to operate when the instrum...

Page 524: ...nufactured and cannot be changed Engine hours are displayed in the format hr9999 The cluster will accumulate values up to 9 999 hours before the display rolls over to zero The odometer has a Rental Ca...

Page 525: ...ter controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left to right from L or Low to H or High for gasoline engines On vehicles with a diesel...

Page 526: ...overdrive off indicator consists of the words O D OFF which appear in the lower portion of the odom eter trip odometer indicator Vacuum Fluorescent Dis play VFD unit The VFD is soldered onto the clus...

Page 527: ...un start circuit the indica tor will be illuminated as a seatbelt reminder for about six seconds or until the ignition switch is turned to the Off position whichever occurs first This reminder functio...

Page 528: ...e the clus ter receives a lamp on message from the SKIM the security indicator will be illuminated The indicator can be flashed on and off or illuminated solid as dic tated by the SKIM message The ind...

Page 529: ...uring the VFD por tion of the test to confirm the functionality of the VFD and the cluster control circuitry The TCCM continually monitors the electronic transfer case switch and circuits to determine...

Page 530: ...uge dial face that reads left to right from 0 to 7 for gasoline engines On vehicles with a diesel engine the scale reads from 0 to 5 The text RPM X 1000 imprinted on the cluster overlay directly below...

Page 531: ...n clus ter programming and electronic messages received by the cluster from the Powertrain Control Module PCM over the Programmable Communications Interface PCI data bus The transmission over tem pera...

Page 532: ...rd switch mux circuit the requested turn signal lamps and turn signal indicator will be flashed on and off and an electromechanical relay soldered onto the cluster electronic circuit board will produc...

Page 533: ...i cator will always be off when the ignition switch is in any position except On or Start The indicator only illuminates when it is switched to ground by the instrument cluster circuitry The instrumen...

Page 534: ...ssage from the PCM or ECM indicating the electrical sys tem voltage is greater than about 9 5 volts but less than about 15 5 volts or until the ignition switch is turned to the Off position whichever...

Page 535: ...a wait to start lamp off message until the ECM detects that the engine is running or until the ignition switch is turned to the Off position whichever occurs first Actuator Test Each time the cluster...

Page 536: ...r fluid indicator a DRBIIIt scan tool is required Refer to the appro priate diagnostic information WATER IN FUEL INDICATOR DESCRIPTION A water in fuel indicator is only found in the instrument cluster...

Page 537: ...on then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry The ECM continually monitors the water in fuel sensor to determine...

Page 538: ...BRAKE LAMP SWITCH 9 REMOVAL 9 INSTALLATION 10 CENTER HIGH MOUNTED STOP LAMP REMOVAL 10 INSTALLATION 10 CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL 10 INSTALLATION 10 CAB CLEARANCE LAMP REMOVAL 10 INSTA...

Page 539: ...he electrical system of the vehicle Refer to the appropriate wiring information OPERATION DAYTIME RUNNING LAMPS Power is reduced using pulse width modulation to the high beams where by the power is sw...

Page 540: ...g shut off DIAGNOSIS AND TESTING LAMPS LIGHTING EXTERIOR WARNING EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS PER SONAL INJURY CAN RESULT CAUTION Do not touch the glass of halogen bul...

Page 541: ...rroded terminals or splices in circuit 2 Inspect and repair all connectors and splices Refer to Electrical Wiring Information HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output...

Page 542: ...s Communication 3 Verify messages being transmitted by Instrument Cluster and received by FCM 4 Front Control Module Malfunction 4 Refer to appropriate ICM FCM diagnostics FOG LAMP DIAGNOSIS CONDITION...

Page 543: ...ed from Instrument Cluster and received by FCM FOG LAMPS DO NOT ILLUMINATE 1 Blown fuse for fog lamp 1 Replace fuse Refer to Electrical Wiring Information 2 No ground at fog lamps 2 Repair circuit gro...

Page 544: ...al 3157 Side Marker Tail Gate Cab Clearance 168 SPECIAL TOOLS HEADLAMP ALIGNMENT BACKUP LAMP REMOVAL 1 Remove and isolate the negitive battery cable 2 Remove the taillamp unit Refer to 8 ELEC TRICAL L...

Page 545: ...e INSTALLATION 1 Install the bulb into the back plate 2 Install the bulb back plate to the tail lamp unit 3 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INS...

Page 546: ...the brake lamps The brake lamp switch can only be adjusted once That is at the initial installation of the switch If the switch is not adjusted properly or has been removed a new switch must be insta...

Page 547: ...turn clockwise 4 Install the CHMSL Refer to Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR CENTER HIGH MOUNTED STOP LAMP UN INSTALLATION 5 Connect the battery negative cable CENTER HIGH MOUNTED STOP L...

Page 548: ...or 4 Connect the battery negative cable 5 Check for proper operation and beam align ment FOG LAMP RELAY DESCRIPTION The front fog lamp relay is located in the Power Distribution Center PDC in the engi...

Page 549: ...trol output of the Front Control Module FCM through a front fog lamp relay control circuit The FCM controls front fog lamp oper ation by controlling a ground path through this cir cuit Coil Battery Te...

Page 550: ...EMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCI DENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Position the front fog lamp relay to the proper receptacle...

Page 551: ...R INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTH...

Page 552: ...to side three times to allow suspension to stabilize 5 Jounce front suspension three times by pushing downward on front bumper and releasing 6 Measure the distance from the center of head lamp lens to...

Page 553: ...Fig 12 4 Separate license plate lamp from vehicle INSTALLATION 1 Position license plate lamp on the bumper 2 Install the clip 3 Reconnect the harness connector 4 Connect the battery negative cable MA...

Page 554: ...ch is a resistive MUX switch that is monitored by the Instrument Cluster The turn signals are actuated with the lever on Multi Function Switch The signals are automatically turned off by a canceling c...

Page 555: ...UNCTION SWITCH TESTS table MULTI FUNCTION SWITCH TESTS EXTERIOR LIGHTING FUNCTIONS SWITCH POSITION CONNECTOR PINS RESISTANCE OHMS Off 1 2 Open Headlamp High Beams On 1 2 518 575 Hazard 3 2 115 128 Opt...

Page 556: ...at uses a low current input from the Front Control Module FCM to control a high current out put to the park lamps The movable common feed contact point is held against the fixed normally closed contac...

Page 557: ...YSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCI DENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the park lamp relay from the PDC 2 A relay in the de energized position...

Page 558: ...EXTERIOR HEAD LAMP UNIT REMOVAL 3 Seperate the socket from the headlamp unit 4 Release the bulb socket locking tabs and seper ate the bulb from the socket Fig 18 INSTALLATION 1 Install the bulb into t...

Page 559: ...the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION 4 Connect the negative battery cable UNDERHOOD LAMP REMOVAL 1 Disconnect and isolate the battery negative...

Page 560: ...the attaching screw through the lamp and into the hood panel Fig 23 Tighten the screw securely 5 Fold lamp housing over and firmly press onto base to snap into place 6 Connect the wire harness connec...

Page 561: ...rs the door ajar switches When a door is open the instrument cluster grounds the low side drivers to turn on the lamp Upon closing all doors the instrument cluster ini tiates a 30 second timer If any...

Page 562: ...VE BOX REMOVAL for the procedures 3 Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box...

Page 563: ...e lamps off The instrument cluster monitors the door ajar switches When a door is open the instrument cluster grounds the low side drivers to turn on the lamps Upon closing all doors the instrument cl...

Page 564: ...S 12 STANDARD PROCEDURE SETTING TRANSMITTER CODES 12 REMOVAL 13 OVERHEAD CONSOLE DESCRIPTION Two different overhead consoles are available on DR models The Electronic Vehicle Information Cen ter EVIC...

Page 565: ...IAGNOSIS AND TESTING OVERHEAD CONSOLE If the problem with the overhead console is an inaccurate or scrambled display refer to SELF DI AGNOSTIC TEST later in this text If the problem with the overhead...

Page 566: ...e residual magnetic fields from the vehicle Refer to Compass Demagnetizing in the Standard Procedures section of this group STANDARD PROCEDURE STANDARD PROCEDURE READING COURTESY LAMP REPLACEMENT 1 Op...

Page 567: ...nits must be rated as continuous duty for 110 115 volts and 60 Hz They must also have a field strength of over 350 gauss at 7 millimeters 0 25 inch beyond the tip of the probe To demagnetize the roof...

Page 568: ...VIC CMTC module memory 7 Confirm that the correct directions are now indicated by the compass REMOVAL OVERHEAD CONSOLE REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the overhead...

Page 569: ...TC consists of a electronic module that displays compass trip computer and temperature features Actuating the STEP push button will cause the CMTC to change mode of operation when the ignition is ON E...

Page 570: ...verhead console 2 Install the screws holding the compass mini trip computer module in the overhead console 3 Connect the module electrical connector 4 Install the overhead console on the headlin er Re...

Page 571: ...eset push button twice within three seconds will perform a global reset and all of the trip computer information that can be reset will be reset to zero With the ignition switch in the On position and...

Page 572: ...lock when the driver door is opened if the vehicle is stopped and the transmission gear selector is in Park or Neutral The Auto Door Unlock event will only occur once follow ing each Auto Door Lock ev...

Page 573: ...dures section of this group for the procedures AMBIENT TEMP SENSOR DESCRIPTION Ambient air temperature is monitored by the over head console The ambient temperature messages are received from the Fron...

Page 574: ...nsor return or signal circuit as required 4 Remove the jumper wire from the ambient tem perature sensor wire harness connector Check for continuity between the sensor return circuit cavity of the Fron...

Page 575: ...normally see the owner s manual in the vehicle glove box for instructions on training the Transmit ter Retrain the Transmitter with a known good transmitter as instructed in the owner s manual and te...

Page 576: ...tons repeat Step 3 and Step 4 Be sure to keep your hand held transmitter in case you need to retrain the uni versal transmitter REMOVAL 1 For universal transmitter removal and installa tion procedure...

Page 577: ......

Page 578: ...RKE TRANSMITTER PROGRAMING 10 SPECIFICATIONS REMOTE KEYLESS ENTRY TRANSMITTER 10 POWER LOCKS DESCRIPTION POWER LOCKS A power operated door lock system is available fac tory installed equipment on thi...

Page 579: ...ter will arm the VTSS when the Lock button is depressed and disarm the VTSS when the Unlock button is depressed The RKE system includes two transmitters when the vehicle is shipped from the factory bu...

Page 580: ...ANIC button sounds the horns at half second intervals flashes the exterior lamps and turns ON the interior lamps The panic alarm will remain on for three minutes or until the PANIC button is actuated...

Page 581: ...rative check for battery current at the switch with the ignition switch in the On position If OK replace the faulty switch Refer to the appropriate wiring information The wiring information includes w...

Page 582: ...ws the vehicle operator to lock out the power window switches on each passenger door so that the passen ger door power windows may be operated only from the master switches in the DDM Power Window Swi...

Page 583: ...nal but tons is depressed to move the selected mirror Up Down Right or Left The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four two in each mirror h...

Page 584: ...iver door module from the trim panel bezel INSTALLATION 1 Install driver door module to trim panel bezel 2 Install door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION 3 Connect battery...

Page 585: ...and grounds Refer to the proper Body Diagnostic Procedures Manual for test ing the Remote Keyless Entry system using a DRB IIIt scan tool REMOVAL 1 Disconnect and isolate the battery negative cable 2...

Page 586: ...urn the ignition ON or wait 60 seconds 7 Test the horn chirp feature by pressing the LOCK button If a chime is not heard program mode was can celed before the feature could be disabled If neces sary r...

Page 587: ...grammed transmitter for 4 to 10 seconds Within the 4 to 10 seconds with the UNLOCK button still depressed press the PANIC button for one second When a single chime is heard release both button s The...

Page 588: ...tional When the automatic day night mirror is turned on the mirror switch is lighted by an integral Light Emitting Diode LED The mirror will auto matically disable its self dimming feature whenever th...

Page 589: ...rear view mirror housing and detects the ambient light levels outside of the vehicle The headlamp photocell sensor is located inside the rear view mirror housing behind the mirror glass and faces rear...

Page 590: ...battery negative cable Turn the ignition switch to the On position Place the transmission gear selector lever in the Neutral position Place the mirror switch in the On the LED in the mirror switch is...

Page 591: ...lumbar support in the seat back The power lumbar support allows the user to inflate or deflate a bladder located in the lower seat back to achieve optimum comfort and support in the lower lumbar regio...

Page 592: ...ttery feed and ground path to the motor are reversed through the switch contacts This causes the adjuster motor to run in the opposite direction No power seat switch should be held applied in any dire...

Page 593: ...ctrical connector 3 Install the seat cushion side shield on the seat Refer to the Body section of the service manual for the procedure 4 If equipped install the screw that secures the recliner lever t...

Page 594: ...T SWITCH For circuit descriptions and diagrams refer to Wir ing 1 Disconnect and isolate the battery negative cable 2 Remove the power seat switch from the power seat 3 Use an ohmmeter to test the con...

Page 595: ...sible electric motors that are secured to the upper half of the track unit Each motor moves the seat adjuster through a combination of worm drive gearboxes and screw type drive units The front and rea...

Page 596: ...ON The power lumbar seat option includes an electri cally operated lumbar support mechanism A single two way momentary power lumbar switch is integral with the power seat switches The power lumbar swi...

Page 597: ...If the power lumbar adjuster fails to operate in only one direction Test the appropriate power seat switch as described in this group If the power lumbar adjuster fails to operate in either direction...

Page 598: ...ocedures details of wire harness routing and retention connector pin out information and location views for the various wire harness connectors splices and grounds DIAGNOSIS AND TESTING POWER WINDOWS...

Page 599: ...f the LEDs are inoperative the power window and lock switch units with the inoperative LED s is faulty and must be replaced For complete circuit dia grams refer to the appropriate wiring information T...

Page 600: ...trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 3 Gently pry switch from door trim panel INSTALLATION FRONT PASSENGER 1 Insert switch to trim panel bezel 2 Install door trim panel Refer to 2...

Page 601: ......

Page 602: ...TER SEAT BELT RETRACTOR REMOVAL 25 INSTALLATION 26 FRONT CENTER SEAT BELT REMOVAL 26 INSTALLATION 27 FRONT OUTBOARD SEAT BELT RETRACTOR REMOVAL REMOVAL STANDARD CAB 28 REMOVAL QUAD CAB 29 INSTALLATION...

Page 603: ...nt seat belt sys tems The outboard seating position belts employ a lower C pillar mounted inertia latch type emergency locking retractor a fixed position upper C pillar mounted turning loop and a fixe...

Page 604: ...SRS AIRBAG logo located on the headliner above each B pillar Fig 2 The supplemental restraint system includes the following major components which are described in further detail elsewhere in this ser...

Page 605: ...rd wired circuitry connects the supplemental restraint system components to each other through the electrical system of the vehicle These hard wired circuits are integral to several wire harnesses whi...

Page 606: ...bout 40 milliseconds Within one to two seconds from the moment of impact the airbags are almost entirely deflated The times cited for these events are approx imations which apply only to a barrier imp...

Page 607: ...FASTENER IS NEEDED REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG WARNING WHEN A STEERING COLUMN HAS AN AIRBAG UNIT ATTAC...

Page 608: ...rtain airbag has been deployed the complete airbag unit the headliner as well as the upper A B and C pillar trim must be replaced These components are not intended for reuse and will be damaged or wea...

Page 609: ...RVICE DISCON NECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO...

Page 610: ...rther service 2 Using a trim stick or another suitable wide flat bladed tool gently pry each side of the ACM cover away from the instrument panel at each side of the center bracket on the floor panel...

Page 611: ...RBIIIt scan tool using the Programma ble Communications Interface PCI data bus net work This method of communication is used for control of the airbag indicator in the ElectroMechani cal Instrument Cl...

Page 612: ...e mental restraint system protection and based upon the status of the passenger airbag on off switch input and the severity of the monitored impact determines what combination of seat belt tensioner a...

Page 613: ...N VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIRBAG SEAT BELT TENSIONER SIDE CURTAIN AIRBAG...

Page 614: ...ny supplemental restraint system compo nent Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE VERIFICATION TEST AUTOMATIC LOCKING RETRACTOR DESCRIPTION The seat belt retractors used in all seating p...

Page 615: ...ed and the belt will remain tight around whatever it is restraining The retractor is returned to standard emergency locking mode by unbuckling the combination lap and shoulder belt buckle and allowing...

Page 616: ...ether anchors cannot be adjusted or repaired and if faulty or dam aged they must be replaced as a unit with the upper cab back panel reinforcement The upper tether anchor trim covers and bezels are se...

Page 617: ...EPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT ALWAYS REPLACE DAMAGED OR F...

Page 618: ...child restraint anchors used in other models and locations are integral to other components and cannot be serviced separately WARNING DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERV...

Page 619: ...tor case The locking pin secures the centered clock spring rotor to the clockspring case during shipment but the locking pin must be removed from the clock spring after it is installed on the steering...

Page 620: ...TS CLOCK SPRING STANDARD PROCEDURE CLOCK SPRING CENTERING STANDARD PROCEDURE CLOCKSPRING CENTERING The clockspring is designed to wind and unwind when the steering wheel is rotated but is only designe...

Page 621: ...cles CAUTION Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature with out passing through the steering wheel and dam...

Page 622: ...Fig 20 2 Install and tighten the two screws that secure the clockspring to the multi function switch mount ing housing Tighten the screws to 2 N m 20 in lbs 3 Reconnect the two instrument panel wire...

Page 623: ...cover receptacle an integral metal hook inserted through a window in the vertical wall of the trim cover receptacle at each side and by three aluminum blind rivets This combination of fasteners locks...

Page 624: ...irbag If the airbag is faulty or damaged but not deployed review the rec ommended procedures for handling non deployed supplemental restraints Refer to 8 ELECTRICAL RESTRAINTS STANDARD PROCEDURE HAN D...

Page 625: ...TTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT S...

Page 626: ...HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED NEVER ATTEMPT TO REPAIR A SEAT BELT OR CH...

Page 627: ...ighten the two screws that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforce ment Tighten the screws to 20 N m 15 ft lbs 5 Reinstall the t...

Page 628: ...buckle from the front seat INSTALLATION A fixed position front center seat belt buckle is located on the left side of the front center seat sec tion 20 percent used on all models Standard cab models a...

Page 629: ...not deployed review the recommended procedures for handling non de ployed supplemental restraints Refer to 8 ELEC TRICAL RESTRAINTS STANDARD PROCEDURE HANDLING NON DEPLOYED SUPPLEMENTAL RESTRAINTS If...

Page 630: ...e the front outboard seat belt and retractor from the retractor mounting hole in the lower inner B pillar REMOVAL QUAD CAB The following procedure is for replacement of a faulty or damaged front outbo...

Page 631: ...LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG 1 Move the front seat to its most forward position for easiest access to the lower seat belt anchor and the B pillar trim 2 Disconnect and isolate the...

Page 632: ...PROCEDURE SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN D...

Page 633: ...witchable automatic locking mechanism Refer to 8 ELECTRICAL RE STRAINTS AUTOMATIC LOCKING RETRACTOR DESCRIPTION If the seat belt or retractor is faulty or damaged but the seat belt tensioner is not de...

Page 634: ...percent used on all models The seat belt buckle on the driver s side front seat for all mod els also includes a seat belt switch Refer to 8 ELECTRICAL RESTRAINTS SEAT BELT SWITCH DESCRIPTION WARNING D...

Page 635: ...29 2 From behind the front seat install and tighten the screw that secures the front outboard seat belt buckle lower anchor to the bracket on the inboard seat track Tighten the screw to 25 N m 18 ft l...

Page 636: ...ion is used The airbag inflator is a non azide pyrotechnic type unit that is secured to and sealed within the air bag housing The inflator initiator is connected to the vehicle electrical system throu...

Page 637: ...wo screws that secure the mount ing tabs of the two panel outlet housings to the upper glove box opening reinforcement Fig 32 4 Remove the six screws that secure the inboard and lower flanges of the p...

Page 638: ...ESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOY MENT WARNING THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED REPLACEMENT PASSENGER AIRBAG UNITS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS PAINT MAY C...

Page 639: ...modate 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 enable or dis...

Page 640: ...GER AIRBAG SEAT BELT TENSIONER SIDE CURTAIN AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCON NECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAP...

Page 641: ...elt bracket Fig 37 4 Remove the bezel from the webbing of the rear center seat belt 5 Lift the rear center seat belt cover off of the belt bracket at the top of the cab back panel and remove the cover...

Page 642: ...r seat belt to the body bracket Tighten the screws to 20 N m 15 ft lbs 5 Lift the webbing of the rear center seat belt and slide the cover over the belt bracket at the top of the cab back panel until...

Page 643: ...r as it is not intended for reuse 5 Remove the screw that secures the seat belt turning loop to the C pillar 6 Remove the seat belt turning loop from the upper inner C pillar 7 Remove the upper and lo...

Page 644: ...r until it snaps into place 10 Position the lower seat belt anchor to the base of the inner C pillar 11 Install and tighten the screw that secures the lower seat belt anchor to the base of the inner C...

Page 645: ...ion key or a small screwdriver to depress the small white release button on the anchor buckle 2 Remove the rear seat from the vehicle On models with the optional 60 40 split rear bench only the 60 per...

Page 646: ...ar floor panel or onto the rear seat mounting bracket near the base of the cab back panel Fig 40 On models with the optional 60 40 split rear bench the screw that secures the buckle unit also secures...

Page 647: ...tch plate to the unique black keyed lower anchor buckle SEAT BELT SWITCH DESCRIPTION The seat belt switch is a small normally open sin gle pole single throw leaf contact momentary switch Only one seat...

Page 648: ...t switch sense circuit cavity of the seat wire har ness connector for the seat belt switch and a good ground There should be no continuity If OK go to Step 4 If not OK repair the shorted seat belt swi...

Page 649: ...not only keeps the occupant properly positioned for an airbag deployment following a frontal impact of the vehicle but also helps to reduce injuries that the occupant might experience in these situat...

Page 650: ...FORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AIRBAG PASSENGER AIRBAG SEAT BELT TENSIONER SIDE CURTAIN AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCON NECT AND ISOLATE THE...

Page 651: ...ight adjuster from the slot in the sheet metal and remove the adjuster from the inner B pillar INSTALLATION WARNING DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE CAREFULLY INSPE...

Page 652: ...ed to the base of the A pillar near the belt line with a screw The hybrid type inflator for each airbag is secured to the roof rail at the rear of the airbag unit behind the B pillar standard cab or C...

Page 653: ...IAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJ...

Page 654: ...AG OR BECOMING ENTRAPPED BETWEEN THE SIDE CURTAIN AIRBAG CUSHION AND THE HEADLINER FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT 1 Position the side curtain...

Page 655: ...ness If the SIACM detects a monitored system fault it sets an active and stored Diagnostic Trouble Code DTC and sends electronic messages to the ACM over the PCI data bus The ACM will respond by sendi...

Page 656: ...rvice 3 Remove the front outboard seat belt and retrac tor from the inside of the B pillar Refer to 8 ELECTRICAL RESTRAINTS FRONT OUTBOARD SEAT BELT RETRACTOR REMOVAL STAN DARD CAB 4 Remove the four s...

Page 657: ...from the B pillar as a unit INSTALLATION INSTALLATION WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER...

Page 658: ...G CONTROL MODULE CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS NEVER STRIKE OR DROP THE SIDE IMPACT AIRBAG CONTROL MODULE AS IT CAN DAMAGE THE IMPACT SENSOR OR...

Page 659: ......

Page 660: ...N ROADS THAT ARE WINDING ICY SNOW COVERED OR SLIP PERY 5 7L Gas The speed control system is fully electronically con trolled by the Powertrain Control Module PCM A cable and a vacuum controlled servo...

Page 661: ...y depress the COAST switch For each switch activa tion speed will be lowered approximately 1 mph DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING VACUUM SUPPLY TEST 3 7L 4 7L 5 9L 8 0L Gas Powered Engines...

Page 662: ...attachment of both ends of the speed con trol servo cable if used Smooth operation of throttle linkage if used and throttle body air valve Failed speed control servo if used Do the servo vacuum test...

Page 663: ...bracket Fig 4 7 Remove servo cable from servo Refer to Servo Removal Installation 5 9L Gas 1 Disconnect negative battery cable at battery 2 Remove air intake tube at top of throttle body 3 Using fing...

Page 664: ...oken 3 Squeeze 2 tabs on sides of speed control cable at throttle body mounting bracket locking plate and push out of bracket Fig 6 SERVO CABLE AT THROTTLE BODY 8 0L V 10 ENGINE 1 THROTTLE CABLE 2 THR...

Page 665: ...perate accelerator pedal to check for any binding 5 9L 8 0L Gas 1 Install end of cable to speed control servo Refer to Speed Control Servo Removal Installation 2 Install cable into throttle body mount...

Page 666: ...mph to set and the RES ACCEL switch has been depressed ground for the vent and vacuum circuits is restored REMOVAL The speed control servo assembly is attached to the bottom of the battery tray Fig 8...

Page 667: ...d control can be disengaged also by any of the 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...

Page 668: ...servoir is a plastic storage tank con nected to an engine vacuum source by vacuum lines A vacuum reservoir is not used with diesel engines or the 5 7L gas powered engine OPERATION The vacuum reservoir...

Page 669: ...ing lost replace one way check valve c Connect a hand operated vacuum pump to vacuum source end of check valve Apply vacuum Vacuum should flow through valve If vacuum is not flowing replace one way ch...

Page 670: ...nd the Powertrain Control Module PCM The SKIM is installed on the steering column near the ignition lock cylinder The transponder is located under the molded rubber cap on the head of the igni tion ke...

Page 671: ...d with a unique Secret Key code and a security code The SKIM keeps the Secret Key code in memory The SKIM also sends the Secret Key code to each of the programmed Sentry Key tran sponders The security...

Page 672: ...ULES SENTRY KEY IMMOBILIZER MODULE REMOVAL for SKIM replacement STANDARD PROCEDURE CONFIGURING A NEW MODULE SWITCH OPERATING MODES To configure a new module or to switch operating modes a DRBIIIt sca...

Page 673: ...y return to normal system operation following exit from the Customer Learn programming mode 7 Repeat this process for each additional Sentry Key transponder blank to be programmed If any of the above...

Page 674: ...test the SKIM sends a PCI bus messages to keep the LED off for 1 second Then the SKIM sends messages to the instrument cluster to turn the LED off based upon the results if the SKIS self test If the i...

Page 675: ......

Page 676: ...SCRIPTION 20 OPERATION 20 DIAGNOSIS AND TESTING WIPER HIGH LOW RELAY 21 REMOVAL 21 INSTALLATION 21 WIPER MODULE DESCRIPTION 22 OPERATION 23 REMOVAL 23 INSTALLATION 23 WIPER ON OFF RELAY DESCRIPTION 25...

Page 677: ...l Switch The washer fluid level switch is located in a dedicated hole on the out board side of the washer reservoir in the engine com partment Washer Nozzle Two fluidic washer nozzles are secured with...

Page 678: ...ams proper wire and connector repair procedures further details on wire harness routing and reten tion as well as pin out and location views for the various wire harness connectors splices and grounds...

Page 679: ...ule FCM over the Programmable Com munications Interface PCI data bus requesting the appropriate wiper and washer system operating modes Wiper and washer system operation are completely controlled by t...

Page 680: ...ut sixteen kilometers per hour ten miles per hour or less PULSE WIPE MODE When the control knob on the control stalk of the multi function switch is depressed to the momentary Wash position for less t...

Page 681: ...tool Refer to the appropriate diagnostic information WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN DRIVER AI...

Page 682: ...has comparatively lower spring tension as evi denced by a lower scale reading 4 Inspect the wiper blades and squeegees for any indications of damage contamination or rubber dete rioration Fig 2 If th...

Page 683: ...is water could subsequently freeze and plug the nozzle while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns In addition the check valve preven...

Page 684: ...ward the float from the switch nipple formation A small magnet is secured within the end of the float nearest the switch nipple formation and a reed switch is con cealed within the nipple A diagnostic...

Page 685: ...e washer fluid indicator requires the use of a DRBIIIt scan tool Refer to the appropriate diagnostic information REMOVAL The washer fluid level switch can be removed from the washer reservoir without...

Page 686: ...right side of the radiator The engine compartment washer hose is contained within the right headlamp and dash wire harness which is routed through the engine compartment along the top of the right fro...

Page 687: ...cleaned REMOVAL 1 Remove both wiper arms from the wiper pivots Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARM REMOVAL 2 Unlatch and open the hood 3 Remove the cowl plenum cover grille panel from over...

Page 688: ...ctric motor The motor is con nected to the vehicle electrical system through a sin gle take out and two cavity connector of the right except V 10 or diesel engine or left V 10 or diesel engine only he...

Page 689: ...et nipple from the rubber grom met seal in the reservoir 8 Disconnect the reservoir washer hose from the washer pump motor unit outlet nipple 9 Remove washer pump motor unit from the back of the washe...

Page 690: ...at the bottom and one at the top The two bottom tabs are inserted into two slots near the bottom of the shroud while the upper tab slides into an integral channel like slot near the top of the shroud...

Page 691: ...Grasp the bottom of the washer reservoir firmly with both hands and pull the unit sharply upward to disengage the locking feature on the washer reservoir from the depression in the radiator shroud 8...

Page 692: ...ine fitting at the engine com partment washer hose in the right headlamp and dash wire harness 7 Reposition the coolant recovery container or the coolant pressure container to the top of the cooling m...

Page 693: ...nd of the spring is hooked through the small hole in the steel strap The entire wiper arm has a satin black finish applied to all of its visible surfaces A wiper arm cannot be adjusted or repaired If...

Page 694: ...claws of the superstructure All models have two 60 00 centimeter 23 62 inch long wiper blades with non replaceable rubber ele ments squeegees The wiper blades cannot be adjusted or repaired If faulty...

Page 695: ...l Standards Organization ISO micro relay Fig 22 Relays conforming to the ISO specifications have common physical dimensions current capacities terminal patterns and terminal functions The relay is con...

Page 696: ...ow relay operation requires the use of a DRBIIIt scan tool Refer to the appropriate diagnostic information DIAGNOSIS AND TESTING WIPER HIGH LOW RELAY The wiper high low relay Fig 23 is located in the...

Page 697: ...o the drive end Linkage Two stamped steel drive links con nect the wiper motor crank arm to the wiper pivot lever arms The left side drive link has a plastic sock et type bushing on each end The right...

Page 698: ...Off and to park the wiper blades in the lowest portion of the wipe pattern The automatic resetting circuit breaker protects the motor from overloads The wiper motor crank arm the two wiper linkage mem...

Page 699: ...NUM WASHER HOSE 2 PLASTIC FASTENER 6 3 SCREW 2 4 WIPER ARM BLADE 2 5 COWL PLENUM COVER GRILLE PANEL 6 WIPER MODULE 7 WIRE HARNESS CONNECTOR 8 PLENUM PANEL 9 SCREW 4 10 ENGINE COMPARTMENT WASHER HOSE 8...

Page 700: ...relay include Common Feed Terminal The common feed terminal 30 is connected to the common feed termi nal of the wiper high low relay at all times through the wiper on off relay output circuit Coil Gr...

Page 701: ...form further testing Refer to the appropriate diagnostic information REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the cover from the Integrated Power Module IPM Fig 29 3 Remove...

Page 702: ...OCK BRAKES 8W 35 1 VEHICLE THEFT SECURITY SYSTEM 8W 39 1 INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 AUD...

Page 703: ......

Page 704: ...iring content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics Diagr...

Page 705: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION DR WIRING DIAGRAM INFORMATION Continued...

Page 706: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 DR 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued...

Page 707: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION DR WIRING DIAGRAM INFORMATION Continued...

Page 708: ...t Vehicles Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and c...

Page 709: ...r group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can howev...

Page 710: ...general warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER...

Page 711: ...for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify...

Page 712: ...r lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with...

Page 713: ...round has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 1 Connect the positive lead of the voltmeter to the side of the circuit closest to the battery Fig 9 2 Connect the other lead of t...

Page 714: ...moved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pi...

Page 715: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION DR CONNECTOR Continued...

Page 716: ...APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPE...

Page 717: ...ected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire fr...

Page 718: ...of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION...

Page 719: ......

Page 720: ...W 40 Door Lock Motor Ajar Switches 8W 40 61 Door Lock Switch Passenger 8W 61 Driver Door Module 8W 60 61 62 Electric Brake Provision 8W 33 54 Component Page Electronic Throttle Control Module 8W 30 En...

Page 721: ...bilizer Module 8W 39 Spare Relay 8W 10 Speakers 8W 47 Component Page Speed Control Servo 8W 33 Speed Control Switches 8W 33 Starter Motor Relay 8W 21 Starter Motor 8W 21 21 3 Tail Stop Lamps 8W 52 Tai...

Page 722: ...4 45 Fuse 32 8W 10 16 36 Fuse 33 8W 10 16 36 Component Page Fuse 34 8W 10 16 36 Fuse 35 8W 10 48 Fuse 36 8W 10 47 58 Fuse 37 8W 10 48 Fuse 38 8W 10 47 48 Fuse 40 8W 10 14 15 34 Fuse 41 8W 10 15 38 Fus...

Page 723: ......

Page 724: ......

Page 725: ......

Page 726: ......

Page 727: ......

Page 728: ......

Page 729: ......

Page 730: ......

Page 731: ......

Page 732: ......

Page 733: ......

Page 734: ......

Page 735: ......

Page 736: ......

Page 737: ......

Page 738: ......

Page 739: ......

Page 740: ......

Page 741: ......

Page 742: ......

Page 743: ......

Page 744: ......

Page 745: ......

Page 746: ......

Page 747: ......

Page 748: ......

Page 749: ......

Page 750: ......

Page 751: ......

Page 752: ......

Page 753: ......

Page 754: ......

Page 755: ......

Page 756: ......

Page 757: ......

Page 758: ......

Page 759: ......

Page 760: ......

Page 761: ......

Page 762: ......

Page 763: ......

Page 764: ......

Page 765: ......

Page 766: ......

Page 767: ......

Page 768: ......

Page 769: ......

Page 770: ......

Page 771: ......

Page 772: ......

Page 773: ......

Page 774: ......

Page 775: ......

Page 776: ......

Page 777: ......

Page 778: ......

Page 779: ......

Page 780: ...06 8W 15 4 G107 8W 15 8 9 10 G108 8W 15 7 G109 8W 15 7 G114 8W 15 11 G117 8W 15 11 Component Page G120 8W 15 11 G201 8W 15 12 13 G202 8W 15 14 15 G203 8W 15 17 G204 8W 15 18 G301 8W 15 20 G302 8W 15 2...

Page 781: ......

Page 782: ......

Page 783: ......

Page 784: ......

Page 785: ......

Page 786: ......

Page 787: ......

Page 788: ......

Page 789: ......

Page 790: ......

Page 791: ......

Page 792: ......

Page 793: ......

Page 794: ......

Page 795: ......

Page 796: ......

Page 797: ......

Page 798: ......

Page 799: ......

Page 800: ......

Page 801: ......

Page 802: ...rake 8W 18 5 6 Data Link Connector 8W 18 2 3 4 Data Link Connector Engine 8W 18 3 Engine Control Module 8W 18 3 Component Page Front Control Module 8W 18 5 6 Fuse 51 8W 18 2 3 G120 8W 18 3 G201 8W 18...

Page 803: ......

Page 804: ......

Page 805: ......

Page 806: ......

Page 807: ......

Page 808: ...ink 8W 20 2 3 4 G100 8W 20 2 3 G101 8W 20 2 3 G102 8W 20 2 3 G107 8W 20 2 G108 8W 20 3 Component Page G109 8W 20 3 G120 8W 20 3 Generator 8W 20 2 3 Integrated Power Module 8W 20 2 3 4 Leak Detection P...

Page 809: ......

Page 810: ......

Page 811: ......

Page 812: ...103 8W 21 4 G104 8W 21 4 Ignition Switch 8W 21 2 3 Integrated Power Module 8W 21 2 3 4 Component Page Powertrain Control Module 8W 21 2 4 Starter Motor 8W 21 2 3 Starter Motor Relay 8W 21 2 3 Transfer...

Page 813: ......

Page 814: ......

Page 815: ......

Page 816: ...30 87 Fuse 49 8W 30 4 31 Fuse 50 8W 30 28 88 Component Page Fusible Link 8W 30 77 G103 8W 30 3 25 30 35 G104 8W 30 3 25 30 35 G105 8W 30 81 86 G106 8W 30 85 G107 8W 30 2 16 24 29 34 40 42 45 47 50 54...

Page 817: ......

Page 818: ......

Page 819: ......

Page 820: ......

Page 821: ......

Page 822: ......

Page 823: ......

Page 824: ......

Page 825: ......

Page 826: ......

Page 827: ......

Page 828: ......

Page 829: ......

Page 830: ......

Page 831: ......

Page 832: ......

Page 833: ......

Page 834: ......

Page 835: ......

Page 836: ......

Page 837: ......

Page 838: ......

Page 839: ......

Page 840: ......

Page 841: ......

Page 842: ......

Page 843: ......

Page 844: ......

Page 845: ......

Page 846: ......

Page 847: ......

Page 848: ......

Page 849: ......

Page 850: ......

Page 851: ......

Page 852: ......

Page 853: ......

Page 854: ......

Page 855: ......

Page 856: ......

Page 857: ......

Page 858: ......

Page 859: ......

Page 860: ......

Page 861: ......

Page 862: ......

Page 863: ......

Page 864: ......

Page 865: ......

Page 866: ......

Page 867: ......

Page 868: ......

Page 869: ......

Page 870: ......

Page 871: ......

Page 872: ......

Page 873: ......

Page 874: ......

Page 875: ......

Page 876: ......

Page 877: ......

Page 878: ......

Page 879: ......

Page 880: ......

Page 881: ......

Page 882: ......

Page 883: ......

Page 884: ......

Page 885: ......

Page 886: ......

Page 887: ......

Page 888: ......

Page 889: ......

Page 890: ......

Page 891: ......

Page 892: ......

Page 893: ......

Page 894: ......

Page 895: ......

Page 896: ......

Page 897: ......

Page 898: ......

Page 899: ......

Page 900: ......

Page 901: ......

Page 902: ......

Page 903: ......

Page 904: ......

Page 905: ......

Page 906: ......

Page 907: ......

Page 908: ...tput Speed Sensor 8W 31 6 13 14 16 Component Page Overdrive Switch 8W 31 9 11 19 Powertrain Control Module 8W 31 3 5 8 9 10 11 12 13 14 15 16 17 18 19 Speed Control Servo 8W 31 17 Speed Control Switch...

Page 909: ......

Page 910: ......

Page 911: ......

Page 912: ......

Page 913: ......

Page 914: ......

Page 915: ......

Page 916: ......

Page 917: ......

Page 918: ......

Page 919: ......

Page 920: ......

Page 921: ......

Page 922: ......

Page 923: ......

Page 924: ......

Page 925: ......

Page 926: ......

Page 927: ......

Page 928: ......

Page 929: ......

Page 930: ......

Page 931: ......

Page 932: ......

Page 933: ......

Page 934: ...pring 8W 33 3 4 Controller Antilock Brake 8W 33 6 Electric Brake Provision 8W 33 6 Fuse 24 8W 33 6 Component Page G104 8W 33 2 G201 8W 33 6 Instrument Cluster 8W 33 6 Integrated Power Module 8W 33 6 P...

Page 935: ......

Page 936: ......

Page 937: ......

Page 938: ......

Page 939: ......

Page 940: ...ink Connector 8W 34 2 Fuse 6 8W 34 2 Fuse 35 8W 34 2 G106 8W 34 2 G201 8W 34 3 Component Page Integrated Power Module 8W 34 2 Powertrain Control Module 8W 34 2 3 Red Brake Warning Indicator Switch 8W...

Page 941: ......

Page 942: ......

Page 943: ......

Page 944: ...se 35 8W 35 2 G106 8W 35 2 G201 8W 35 3 Integrated Power Module 8W 35 2 Component Page Powertrain Control Module 8W 35 2 3 Red Brake Warning Indicator Switch 8W 35 2 Transmission Control Module 8W 35...

Page 945: ......

Page 946: ......

Page 947: ......

Page 948: ...nger 8W 39 4 Door Lock Motor Ajar Switch Right Rear 8W 39 4 Front Control Module 8W 39 3 Fuse 15 8W 39 3 Fuse 19 8W 39 2 Fuse 22 8W 39 2 Fuse 45 8W 39 3 G105 8W 39 3 Component Page G106 8W 39 3 G201 8...

Page 949: ......

Page 950: ......

Page 951: ......

Page 952: ......

Page 953: ......

Page 954: ...Door Module 8W 40 8 Fog Lamp Relay 8W 40 3 Fog Lamp Left 8W 40 3 Fog Lamp Right 8W 40 3 Fuse 18 8W 40 5 Fuse 22 8W 40 5 Component Page Fuse 41 8W 40 3 G201 8W 40 3 11 G202 8W 40 10 G301 8W 40 2 6 7 1...

Page 955: ......

Page 956: ......

Page 957: ......

Page 958: ......

Page 959: ......

Page 960: ......

Page 961: ......

Page 962: ......

Page 963: ......

Page 964: ......

Page 965: ......

Page 966: ......

Page 967: ......

Page 968: ...se 25 8W 41 3 Fuse 29 8W 41 3 Fuse 42 8W 41 3 Fuse 45 8W 41 2 G106 8W 41 2 G203 8W 41 3 Component Page G302 8W 41 4 Horn Relay 8W 41 2 Horn Switch 8W 41 4 Horn High Note 8W 41 2 Horn Low Note 8W 41 2...

Page 969: ......

Page 970: ......

Page 971: ......

Page 972: ...W 42 5 Engine Control Module 8W 42 7 9 Evaporator Temperature Sensor 8W 42 4 Fuse 12 8W 42 10 Fuse 16 8W 42 7 Fuse 36 8W 42 3 Fuse 36 8W 42 4 Component Page G107 8W 42 7 G120 8W 42 7 G202 8W 42 3 G202...

Page 973: ......

Page 974: ......

Page 975: ......

Page 976: ......

Page 977: ......

Page 978: ......

Page 979: ......

Page 980: ......

Page 981: ......

Page 982: ...43 3 Airbag Left Curtain 8W 43 4 Airbag Passenger 8W 43 3 Airbag Right Curtain 8W 43 4 Clockspring 8W 43 3 Data Link Connector 8W 43 2 4 Component Page Fuse 52 8W 43 2 Fuse 53 8W 43 2 4 G204 8W 43 2...

Page 983: ......

Page 984: ......

Page 985: ......

Page 986: ...oor Lock Motor Ajar Switch Driver 8W 44 3 Door Lock Motor Ajar Switch Left Rear 8W 44 3 Door Lock Motor Ajar Switch Passenger 8W 44 4 Door Lock Motor Ajar Switch Right Rear 8W 44 4 Component Page Fuse...

Page 987: ......

Page 988: ......

Page 989: ......

Page 990: ...ower Module 8W 47 5 Radio 8W 47 2 3 4 7 Remote Radio Switch Left 8W 47 7 Component Page Remote Radio Switch Right 8W 47 7 Speaker Center Instrument Panel 8W 47 4 Speaker Left Front Door 8W 47 3 6 Spea...

Page 991: ......

Page 992: ......

Page 993: ......

Page 994: ......

Page 995: ......

Page 996: ......

Page 997: ......

Page 998: ...ta Link Connector 8W 49 2 Dome Lamp 8W 49 3 Front Control Module 8W 49 3 Fuse 17 8W 49 2 3 Fuse 28 8W 49 2 Component Page G202 8W 49 2 Instrument Cluster 8W 49 3 Integrated Power Module 8W 49 2 3 Over...

Page 999: ......

Page 1000: ......

Page 1001: ......

Page 1002: ...l Module 8W 50 2 3 4 5 Fuse 15 8W 50 4 Fuse 32 8W 50 4 Fuse 34 8W 50 4 Fuse 41 8W 50 5 G103 8W 50 3 4 5 Component Page G104 8W 50 3 4 5 G105 8W 50 3 4 G201 8W 50 5 G203 8W 50 6 Headlamp Switch 8W 50 2...

Page 1003: ......

Page 1004: ......

Page 1005: ......

Page 1006: ......

Page 1007: ......

Page 1008: ...33 8W 51 7 Fuse 34 8W 51 2 Fuse 38 8W 51 3 Component Page G103 8W 51 2 3 5 6 G104 8W 51 2 3 5 6 G202 8W 51 7 Integrated Power Module 8W 51 2 3 5 6 7 License Lamp Left 8W 51 2 License Lamp Right 8W 51...

Page 1009: ......

Page 1010: ......

Page 1011: ......

Page 1012: ......

Page 1013: ......

Page 1014: ......

Page 1015: ......

Page 1016: ...e 8W 52 2 3 4 5 6 Multi Function Switch 8W 52 2 Component Page Park Lamp Relay 8W 52 3 Park Turn Signal Lamp Left Front 8W 52 3 Park Turn Signal Lamp Right Front 8W 52 3 Tail Stop Lamp 8W 52 4 5 Tail...

Page 1017: ......

Page 1018: ......

Page 1019: ......

Page 1020: ......

Page 1021: ......

Page 1022: ...4 G105 8W 53 4 G106 8W 53 3 4 Instrument Cluster 8W 53 2 Integrated Power Module 8W 53 2 3 4 Component Page Multi Function Switch 8W 53 2 Washer Fluid Level Switch 8W 53 4 Washer Pump Motor Front 8W...

Page 1023: ......

Page 1024: ......

Page 1025: ......

Page 1026: ...use 33 8W 54 2 3 Fuse 46 8W 54 2 3 Fuse 47 8W 54 2 3 G103 8W 54 3 4 Component Page G104 8W 54 3 4 5 G106 8W 54 5 Integrated Power Module 8W 54 2 3 5 Park Lamp Relay 8W 54 2 3 PTC No 5 8W 54 2 3 Traile...

Page 1027: ......

Page 1028: ......

Page 1029: ......

Page 1030: ......

Page 1031: ......

Page 1032: ...ow Circuit Breaker 8W 60 2 4 Power Window Motor Driver 8W 60 2 4 Power Window Motor Left Rear 8W 60 7 Component Page Power Window Motor Passenger 8W 60 3 5 Power Window Motor Right Rear 8W 60 6 Power...

Page 1033: ......

Page 1034: ......

Page 1035: ......

Page 1036: ......

Page 1037: ......

Page 1038: ......

Page 1039: ......

Page 1040: ...ock Motor Ajar Switch Left Rear 8W 61 5 Door Lock Motor Ajar Switch Passenger 8W 61 3 4 Door Lock Motor Ajar Switch Right Rear 8W 61 4 Component Page Door Lock Switch Passenger 8W 61 3 4 Driver Door M...

Page 1041: ......

Page 1042: ......

Page 1043: ......

Page 1044: ......

Page 1045: ......

Page 1046: ...3 Driver Door Module 8W 62 2 3 Fuse 17 8W 62 2 Fuse 27 8W 62 3 Fuse 36 8W 62 3 G302 8W 62 2 3 Component Page Heated Mirror Relay 8W 62 3 Integrated Power Module 8W 62 2 3 Power Mirror Left 8W 62 2 3...

Page 1047: ......

Page 1048: ......

Page 1049: ......

Page 1050: ...tor Driver 8W 63 2 Lumbar Motor Passenger 8W 63 3 4 Passenger Lumbar Switch 8W 63 3 Component Page Power Seat Motor Driver Front Vertical 8W 63 2 Power Seat Motor Driver Horizontal 8W 63 2 Power Seat...

Page 1051: ......

Page 1052: ......

Page 1053: ......

Page 1054: ......

Page 1055: ......

Page 1056: ...72 8W 70 12 S173 8W 70 11 68 S174 8W 30 69 S175 8W 30 69 S176 8W 15 11 S178 8W 30 17 S179 8W 31 9 S181 8W 30 16 Component Page S182 8W 10 25 S183 8W 15 9 16 S184 8W 30 16 S186 8W 10 44 S191 8W 10 49 S...

Page 1057: ......

Page 1058: ......

Page 1059: ......

Page 1060: ......

Page 1061: ......

Page 1062: ......

Page 1063: ......

Page 1064: ......

Page 1065: ......

Page 1066: ......

Page 1067: ......

Page 1068: ...id 8W 80 12 C100 Diesel 8W 80 12 C100 Diesel 8W 80 13 C100 Gas 8W 80 13 C100 Gas 8W 80 13 C106 5 7L 8W 80 14 C106 5 7L 8W 80 14 C107 5 7L 8W 80 15 C107 5 7L 8W 80 15 C108 Diesel 8W 80 15 C108 Diesel 8...

Page 1069: ...51 Door Lock Motor Ajar Switch Driver Except Base 8W 80 51 Component Page Door Lock Motor Ajar Switch Left Rear Except Base 8W 80 51 Door Lock Motor Ajar Switch Passenger Except Base 8W 80 51 Door Loc...

Page 1070: ...esel 8W 80 78 Component Page Overdrive Switch 8W 80 78 Overhead Map Reading Lamp Except Base 8W 80 78 Oxygen Sensor 1 1 Upstream 8W 80 78 Oxygen Sensor 1 2 Downstream 8W 80 79 Oxygen Sensor 2 1 Upstre...

Page 1071: ...de Sensor 8W 80 102 Transfer Case Position Sensor 4 7L 5 9L 8W 80 103 Transfer Case Selector Switch 8W 80 103 Transfer Case Shift Motor 8W 80 103 Transmission Control Module 8W 80 104 Component Page T...

Page 1072: ...UTPUT 2 Z359 18BK BR GROUND A C PRESSURE TRANSDUCER BLACK 4 WAY CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND 2 K6 18VT WT EXCEPT NGC 5 VOLT SUPPLY 2 K7 18OR NGC 5 VOLT SUPPLY 3 C18 18DB A C PRESSUR...

Page 1073: ...PASSENGER BLEND DOOR DRIVER 14 15 C16 20LB YL HEATED MIRROR RELAY CONTROL 16 D25 20VT LG PCI BUS A C HEATER CONTROL C2 BLACK 10 WAY CAV CIRCUIT FUNCTION 1 2 C4 16TN BLOWER MOTOR LOW DRIVER 3 C6 14LB...

Page 1074: ...GROUND 5 R45 18DG LB DRIVER SQUIB 1 LINE 2 6 R43 18BK LB DRIVER SQUIB 1 LINE 1 7 R42 18BK YL PASSENGER SQUIB 1 LINE 1 8 R44 18DG YL PASSENGER SQUIB 1 LINE 2 9 R53 18LG YL RIGHT SEAT BELT TENSIONER LIN...

Page 1075: ...ELLOW 8 WAY CAV CIRCUIT FUNCTION 1 F14 18LG YL FUSED IGNITION SWITCH OUTPUT RUN START 2 3 R76 18LB WT RIGHT CURTAIN SQUIB 1 LINE 2 4 R74 18LB YL RIGHT CURTAIN SQUIB 1 LINE 1 5 Z29 18BK PK GROUND 6 7 8...

Page 1076: ...NAL 1 G31 20VT LG AMBIENT TEMPERATURE SENSOR SIGNAL 2 Y137 20VT LB SENSOR GROUND 2 K4 20VT LB NGC SENSOR GROUND AMPLIFIER AUDIO C1 GRAY 12 WAY CAV CIRCUIT FUNCTION 1 X53 20DG LEFT FRONT SPEAKER 2 X55...

Page 1077: ...X94 18TN VT RIGHT REAR SPEAKER 15 X80 18LB BK RIGHT FRONT DOOR SPEAKER 16 X85 18LG DG LEFT FRONT DOOR SPEAKER 17 X86 18OR RD RIGHT INSTRUMENT PANEL SPEAKER 18 X81 18YL BK LEFT INSTRUMENT PANEL SPEAKE...

Page 1078: ...TION 1 C7 10BK TN BLOWER MOTOR HIGH DRIVER 2 C1 10DG BLOWER MOTOR FEED BLOWER MOTOR RESISTOR BLOCK BLACK 4 WAY CAV CIRCUIT FUNCTION 1 C5 16LG BLOWER MOTOR M1 DRIVER 2 C7 12BK TN BLOWER MOTOR HIGH DRIV...

Page 1079: ...PEED CONTROL SUPPLY 4 V32 20YL RD 5 7L BRAKE SWITCH NO 2 SIGNAL 5 Z241 20BK VT GROUND 6 K29 20WT PK BRAKE SWITCH SENSE 6 K29 20WT PK NGC BRAKE SWITCH NO 1 SIGNAL BRAKE TRANSMISSION SHIFT INTERLOCK SOL...

Page 1080: ...BLACK DASH TO ENGINE CAV CIRCUIT 1 V10 20BR EXCEPT 8 0L 2 B6 20WT DB 3 B7 20WT 4 G29 20BK TN EXCEPT 8 0L 5 Y137 20VT LB EXCEPT 8 0L 6 Y169 18WT TN 7 Y168 18WT LB 8 L60 18LG TN 9 L7 18BK YL 10 C100 GA...

Page 1081: ...N OR L K94 18TN LG M K95 18TN DG N K96 18TN LB O K97 18BR P K98 18LB C106 5 7L BLACK ENGINE TO TRANSMISSION CAV CIRCUIT A K11 18WT DB B K12 18TN C K13 18YL WT D K14 18LB BR E K38 18GY F K58 18BR DB G...

Page 1082: ...TO TRANSMISSION CAV CIRCUIT 1 K4 18BK LB 2 K1 18DG RD 3 K21 18BK RD 4 K101 18WT 5 K6 18VT WT 6 K888 18BR PK 7 A142 16DG OR 8 K7 18OR 9 K2 18TN BK 10 K122 18DB GY 11 K22 18OR DB 12 13 F855 18OR PK 14...

Page 1083: ...14 C110 DIESEL CAV CIRCUIT 1 C3 18DB BK 2 K29 18WT PK 3 K4 18BK LB 4 V37 18RD LG 5 V37 18RD LG 6 Y1 18LG 7 Y5 18OR 8 Y3 18WT 9 D20 18LG 10 D21 18PK 11 Y135 18LG BK 12 13 14 C110 DIESEL ENGINE TO TRAN...

Page 1084: ...14RD BK 3 K69 18BR LB 4 K68 18BR LG C115 DIESEL CAV CIRCUIT 1 K91 14TN RD 2 K12 14YL WT 3 K91 14TN RD 4 K11 14WT DB C115 DIESEL INJECTOR SIDE CAV CIRCUIT 1 K91 14TN RD 2 K12 14YL WT 3 K91 14TN RD 4 K1...

Page 1085: ...GC A4 A5 A6 B1 V35 20LG RD EXCEPT 5 7L EXCEPT 8 0L B2 V32 20YL RD B3 K51 20DB YL EXCEPT DIESEL B3 K914 20VT BR DIESEL B4 Y169 18WT TN B5 B6 20WT DB ABS B6 K118 18PK YL B7 L1 18VT BK C1 A14 20RD WT C2...

Page 1086: ...8DG WT EXCEPT 5 7L EXCEPT 4 7L J7 K255 20WT DG 5 7L K1 V36 20TN RD EXCEPT 5 7L K2 C13 20DB OR K3 Y193 20YL RD 3 7 5 9L 8 0L K4 Y128 20DG GY 3 7L 5 9L8 0L K5 A42 18DG 8 0L 3 7L 5 9L K5 K981 20BR DG 5 7...

Page 1087: ...L 8 0L C7 G29 18BK TN 3 7L 4 7L C7 F15 20DB DIESEL C7 G29 20BK TN 5 9L 5 7L D1 B7 20WT D2 D15 18WT DG 3 7L A T 4 7L A T 5 7L A T DIESEL D3 K29 20WT PK 5 7L D3 K29 18WT PK EXCEPT 5 7L D4 L10 18BR LG D5...

Page 1088: ...3 7L A T 4 7L A T 5 7L A T K7 Y137 20VT LB 5 7L 5 9L K7 Y137 18VT LB 3 7L 4 7L L1 K223 18PK DB 5 7L L2 T24 18BR YL NGC L3 L4 L5 L6 G31 18VT LG NGC L7 K7 18OR 5 7L M1 D20 20LG 5 7L DIESEL M1 D20 18LG E...

Page 1089: ...CAV CIRCUIT 1 C7 10BK TN 2 C34 20DB WT 3 C4 16TN 4 C32 20GY DB 5 C6 14LB 6 C5 16LG 7 C1 10DG 8 C33 20DB RD 9 C12 20LG BK A C ONLY 10 C57 20DB GY A C ONLY 11 C62 20DB PK 12 C46 20YL LG DUAL ZONE 13 C3...

Page 1090: ...CEPT BASE 7 8 M3 20PK DB 9 M20 20BR 10 M11 20PK LB 11 L1 18VT BK 12 F32 18RD YL C202 DASH TO FOG LAMPS CAV CIRCUIT 1 L39 18LB 2 Z144 BK OR C202 BLACK FOG LAMPS TO DASH CAV CIRCUIT 1 L39 18LB 2 Z144 18...

Page 1091: ...8BK YL C216 CHASSIS TO DASH CAV CIRCUIT 1 B113 18RD VT 2 B114 18WT VT 3 L76 18BK OR 4 L24 18WT LG 5 L62 18BR RD 6 K4 18BK LB 7 G8 18LB BK 8 L7 18BK YL C217 CHASSIS TO DASH CAV CIRCUIT 1 Y141 18YL PK 2...

Page 1092: ...DG RD 12 L1 18VT BK 13 Y140 18 WT PK 14 Z13 16BK C218 WHITE DASH TO BODY CAV CIRCUIT 1 2 Y148 18YL RD 3 F121 16TN BK 4 F235 18RD 5 6 7 8 F14 18LG YL 9 F37 12 RD LB 10 11 12 C218 BODY TO DASH CAV CIRCU...

Page 1093: ...0VT RD 21 V32 20YL RD 22 23 A22 16BK OR 24 G11 20WT LG 25 V30 20DB RD EXCEPT 5 7L 25 Y135 18LG BK 5 7L 25 Z10 20BK TN DIESEL 26 M1 18PK 27 L1 18VT BK 28 D25 20VT OR EXCEPT 4 7L 29 D25 20VT BK 30 K4 18...

Page 1094: ...20YL DB 5 7L ETC 51 52 53 Y124 16DG VT ETC 54 Y112 20YL BR ETC 55 F32 20RD YL 56 F23 18DB YL 57 T24 20BR YL 5 7L ETC 58 Y116 20YL GY 5 7L ETC 59 60 Y131 14RD WT 61 A31 14BK WT 62 63 64 65 66 A38 16OR...

Page 1095: ...22 23 A22 16BK OR 24 G11 20WT LG 25 V30 20DB RD 26 M1 18PK 27 L1 18VT BR 28 D25 20VT OR 29 D25 20VT BK 30 K4 20BK LB 31 E1 20TN 32 F15 20DB 33 F35 18RD 34 D25 20VT BR 35 36 F30 18RD 37 38 A21 16DB 39...

Page 1096: ...0YL WT SLT 72 D25 20VT PK 73 Y105 20BR RD 74 Y114 20YL VT SLT C220 WHITE I P TO BODY CAV CIRCUIT 1 Y105 20BR RD 2 X91 18WT BK 3 F32 20RD YL 4 X87 18LG RD 5 G75 20TN 6 G77 20VT OR 7 X85 18LG DG 8 G10 2...

Page 1097: ...4 15 16 Z11 18 BK WT 17 Y157 18TN PK EXCEPT BASE 18 P97 20WT DG EXCEPT BASE 19 20 P55 18DB EXCEPT BASE 21 22 F21 12TN EXCEPT BASE 23 R56 18LB DG 24 R54 18LB YL C301 WHITE BODY TO PASSENGER DOOR CAV CI...

Page 1098: ...R CAV CIRCUIT 1 Y107 20VT RD 2 3 4 Y156 18TN WT 5 6 P96 20WT LG 7 Q16 14BR WT 8 Q26 14VT WT 9 G72 20DG OR 10 Y200 18TN VT 11 Z311 20BK LB 12 13 F121 18TN BK 14 C302 BLACK PASSENGER DOOR TO BODY CAV CI...

Page 1099: ...20BK LG C304 WHITE DRIVER DOOR TO BODY CAV CIRCUIT 1 G75 20TN 2 P76 20OR YL 3 P72 20YL BK 4 X87 18LG RD 5 X85 18LG DG 6 P74 20DB 7 F21 14TN 8 Q1 14YL 9 F32 18RD YL 10 Z314 20BK LG C305 BLACK BODY TO D...

Page 1100: ...HITE BODY TO LEFT REAR DOOR CAV CIRCUIT 1 Z75 20BK 2 G77 20TN OR 3 Y157 18TN PK 4 Y201 18TN OR 5 Q1 14YL 6 Q17 14DB WT 7 Q27 14RD BK 8 X91 18WT BK 9 X93 18WT RD 10 C306 WHITE LEFT REAR DOOR TO BODY CA...

Page 1101: ...YL 2 3 Z151 18BK 4 L22 18WT LG 5 L62 18DG RD 6 L1 18VT BK C308 BODY TO I P CAV CIRCUIT 1 G74 20TN RD 2 G72 20DG OR EXCEPT BASE 3 4 X80 18LB BK 5 P96 20WT LG EXCEPT BASE 6 G76 20TN YL 7 8 Y200 18TN VY...

Page 1102: ...G YL 12 R55 18LG DG 13 14 X94 18TN VT 15 X92 18TN BK 16 17 18 19 X82 18LB VT C309 WHITE I P TO BODY CAV CIRCUIT 1 2 P133 20TN DG 3 P137 20VT DG 4 5 P140 20VT BK 6 P134 20TN LG 7 P138 20VT LG 8 P139 20...

Page 1103: ...CHASSIS CAV CIRCUIT 1 Y174 18PK VT 2 3 Z150 18BK 4 L24 18WT LG 5 L63 18DG RD 6 L1 18VT BK C311 EXCEPT SLT SEAT TO BODY CAV CIRCUIT 1 Z238 14BK 2 F37 12RD LB 3 G10 20LG RD 4 Y148 16BR YL 5 Z237 20BK O...

Page 1104: ...2 G76 20VT OR 3 Y200 18TN OR EXCEPT BASE 4 Y156 18TN PK EXCEPT BASE 5 Q1 14YL EXCEPT BASE 6 Q18 14DB WT EXCEPT BASE 7 Q28 14RD BK EXCEPT BASE 8 X92 18WT BK 9 X94 18WT RD 10 C313 DK GRAY JUMPER TO DRI...

Page 1105: ...12YL LB 11 P21 12RD LG 12 P19 12YL LG C314 DK GRAY DRIVER SEAT TO JUMPER CAV CIRCUIT 1 Y148 16BR YL 2 Z300 16BK WT C314 JUMPER TO DRIVER SEAT CAV CIRCUIT 1 Y148 16BR YL 2 Z300 16BK WT C315 HEATED POW...

Page 1106: ...20BK LG 5 P86 20PK BK 6 Z238 14BK C316 PASSENGER SEAT TO JUMPER CAV CIRCUIT 1 Z121 20BK WT 2 P142 18TN DB 3 F37 12RD LB 4 P144 20BK LG 5 P86 20PK BK 6 Z238 14BK C317 PASSENGER SEAT TO SEAT SWITCH CAV...

Page 1107: ...DRIVER SEAT 3 G10 20LG RD DRIVER POWER MANUAL SEAT 3 P133 20TN DG SLT HEATED POWER DRIVER SEAT 4 G10 20 LG RD SLT HEATED POWER DRIVER SEAT 4 Y148 16BR YL POWER DRIVER SEAT DRIVER MANUAL SEAT WITH POWE...

Page 1108: ...P134 20TN LG 10 P140 20VT BK 11 Z237 20BK OR 12 Z121 20BK LG 13 14 Y148 16YL RD C323 JUMPER TO PASSENGER LUMBAR CAV CIRCUIT 1 Z238 18BK 2 P105 12LG DB 3 F37 12RD LB 4 P104 12YL LB 5 Z238 18BK 6 C323 P...

Page 1109: ...R DIESEL 3 WAY CAV CIRCUIT FUNCTION 1 K72 18DG OR 5 VOLTS SUPPLY 2 K55 18LB WT MASS AIR FLOW SENSOR SIGNAL 3 K53 18DB RD MASS AIR FLOW SENSOR SIGNAL RETURN CAMSHAFT POSITION SENSOR GAS GRAY 3 WAY CAV...

Page 1110: ...L50 18WT TN BRAKE LAMP SWITCH OUTPUT CIGAR LIGHTER OUTLET RED 3 WAY CAV CIRCUIT FUNCTION 1 F30 18RD FUSED IGNITION SWITCH OUTPUT RUN ACC 2 3 Z301 18TN BK GROUND CLEARANCE LAMP NO 1 HEAVY DUTY 2 WAY CA...

Page 1111: ...CIRCUIT FUNCTION 1 L7 20BK YL HEADLAMP SWITCH OUTPUT 2 Z253 20BK RD GROUND CLOCKSPRING C1 6 WAY CAV CIRCUIT FUNCTION 1 Z5 20BK LB GROUND 2 X20 20GY WT RADIO CONTROL MUX 3 V38 20VT OR 5 7L S C SWITCH S...

Page 1112: ...WAY CAV CIRCUIT FUNCTION 1 Z5 22BK LB GROUND 2 X20 22GY WITHOUT ETC RADIO CONTROL MUX 2 X20 22RD BK WITH ETC RADIO CONTROL MUX CLUTCH INTERLOCK BRAKE SWITCH DK GREEN 2 WAY CAV CIRCUIT FUNCTION 1 T24 2...

Page 1113: ...2 A142 16DG OR AUTO SHUT DOWN RELAY OUTPUT 2 K93 18TN OR NGC COIL CONTROL NO 3 3 COIL ON PLUG NO 4 3 7L 4 7L 5 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K94 18TN LG COIL ON PLUG DRIVER NO 4 1 A142 16DG O...

Page 1114: ...Y OUTPUT 2 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K97 18BR 5 7L COIL CONTROL NO 7 3 COIL ON PLUG NO 8 4 7L 5 7L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K98 18LB RD COIL CONTROL NO 8 1 A142 16DG OR...

Page 1115: ...8 B114 20WT VT REAR WHEEL SPEED SENSOR 9 K29 20WT PK BRAKE SWITCH SENSE 10 11 G9 20GY BK BRAKE FLUID LEVEL SWITCH SENSE 12 G7 20WT OR EXCEPT 4 7L ABS 5 7L ABS VEHICLE SPEED SIGNAL NO 1 12 B22 20DG YL...

Page 1116: ...REMIUM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G73 20LG OR DRIVER CYLINDER LOCK SWITCH MUX 2 Z70 20BK LG GROUND CYLINDER LOCK SWITCH PASSENGER PREMIUM LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 G72 20DG OR PASSE...

Page 1117: ...DOOR AJAR SWITCH DRIVER BASE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G75 20TN DRIVER DOOR AJAR SWITCH SENSE 2 Z314 20BK LG GROUND DOOR AJAR SWITCH LEFT REAR BASE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G77 20VT...

Page 1118: ...LOCK DRIVER LEFT DOORS DOOR LOCK MOTOR AJAR SWITCH LEFT REAR EXCEPT BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G77 20VT OR LEFT REAR DOOR AJAR SWITCH SENSE 2 Z75 20BK GROUND 3 Y201 18TN OR DOOR UNLOCK DR...

Page 1119: ...H MUX 2 Y107 20VT RD FUSED IGNITION SWITCH OUTPUT RUN START 3 4 5 Z74 20BK LG GROUND 6 DOOR WINDOW LOCK SWITCH PASSENGER BLUE 6 WAY CAV CIRCUIT FUNCTION 1 Q12 14BR RIGHT FRONT WINDOW DRIVER UP 2 Q26 1...

Page 1120: ...R MODULE C2 BLUE 8 WAY CAV CIRCUIT FUNCTION 1 P71 20YL LEFT MIRROR UP DRIVER 2 P76 20OR YL LEFT MIRROR COMMON DRIVER RIGHT DOWN 3 F32 18RD YL FUSED B 4 P74 20DB RIGHT MIRROR LEFT DRIVER 5 Z239 20BK GR...

Page 1121: ...S SIGNAL 15 K21 18BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 17 K2 18TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 18 19 K31 18BR FUEL PUMP RELAY CONTROL 20 21 22 G17 18WT TN SPEEDOMETER SIGNAL 23...

Page 1122: ...R NO 2 58 59 K91 16TN RD COIL ON PLUG DRIVER NO 1 60 ENGINE CONTROL MODULE C2 DIESEL 50 WAY CAV CIRCUIT FUNCTION 1 K22 18DR DB THROTTLE POSITION SENSOR SIGNAL 2 K24 18WT DG CRANKSHAFT POSITION SENSOR...

Page 1123: ...Y1 18LG PARK LOCKOUT SOLENOID CONTROL 44 45 46 V37 18RD YL S C SWITCH SIGNAL 47 K118 18PK YL BATTERY TEMPERATURE SENSOR SIGNAL 48 49 Z816 16BK TN GROUND 50 Z816 16BK TN GROUND ENGINE COOLANT TEMPERATU...

Page 1124: ...EVAPORATIVE SOLENOID CONTROL 2 Y134 20GY RD FUSED IGNITION SWITCH OUTPUT RUN START EVAP PURGE SOLENOID NGC BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K108 18WT TN EVAP PURGE RETURN 2 K52 18PK BK EVAP PURGE C...

Page 1125: ...RELAY OUTPUT 2 Z57 18BK GROUND FENDER LAMP REAR LEFT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Y174 18PK VT FUSED PARK LAMP RELAY OUTPUT 2 Z57 18BK GROUND FENDER LAMP REAR RIGHT BLACK 2 WAY CAV CIRCUIT FUNC...

Page 1126: ...DIESEL 2 WAY CAV CIRCUIT FUNCTION A A93 14RD BK FUEL HEATER RELAY OUTPUT B Z378 14BK GROUND FUEL INJECTOR NO 1 DIESEL 2 WAY CAV CIRCUIT FUNCTION 1 K91 14TN RD COMMON INJECTOR DRIVER 2 K11 14WT DB FUEL...

Page 1127: ...N RELAY OUTPUT FUEL INJECTOR NO 3 DIESEL 2 WAY CAV CIRCUIT FUNCTION 1 K91 14TNRD COMMON INJECTOR DRIVER 2 K13 14TN FUEL INJECTOR NO 3 CONTROL FUEL INJECTOR NO 3 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K13...

Page 1128: ...CK 2 WAY CAV CIRCUIT FUNCTION 1 K38 18GY FUEL INJECTOR NO 5 DRIVER 1 K38 18GY NGC INJECTOR CONTROL NO 5 2 A142 16DG OR NGC ASD RELAY OUTPUT 2 A142 16DG OR AUTO SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO...

Page 1129: ...UIT FUNCTION 1 K28 18GY LB FUEL INJECTOR NO 8 DRIVER 1 K28 18GY LB NGC INJECTOR CONTROL NO 8 2 A142 16DG OR NGC ASD RELAY OUTPUT 2 A142 16DG OR AUTO SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 9 8 0L BLAC...

Page 1130: ...18WT DB JTEC DIESEL GENERATOR SOURCE 1 K20 18DG NGC GEN FIELD CONTROL 2 K20 18DG JTEC DIESEL GENERATOR FIELD CONTROL GLOVE BOX LAMP AND SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M11 20PK LB COURTESY L...

Page 1131: ...WAY CAV CIRCUIT FUNCTION 1 P142 20TN DB PASSENGER SEAT TEMPERATURE SENSOR INPUT 2 Z121 20BK WT GROUND 3 P144 20BK LG PASSENGER SEAT TEMPERATURE 5 VOLT SUPPLY 4 P86 20PK BK SEAT HEATER DRIVER HEATED S...

Page 1132: ...CTION 1 X3 20BK RD HORN SWITCH SENSE 2 HORN HIGH NOTE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X2 18DG RD HORN RELAY OUTPUT 2 Z307 18BK WT GROUND HORN LOW NOTE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X2 18DG RD...

Page 1133: ...NO 1 DRIVER IGNITION COIL LEFT 8 0L 3 WAY CAV CIRCUIT FUNCTION 1 K17 18DB TN IGNITION COIL NO 8 DRIVER 2 A142 14DG OR AUTO SHUT DOWN RELAY OUTPUT 3 K32 18YL GY IGNITION COIL NO 4 DRIVER IGNITION COIL...

Page 1134: ...N ACC 11 Y131 14RD WT FUSED B 12 A30 10CK WT FUSED B 13 A41 16YL FUSED IGNITION SWITCH OUTPUT RUN START 14 A38 16OR FUSED IGNITION SWITCH OUTPUT RUN INLET AIR TEMPERATURE PRESSURE SENSOR DIESEL 4 WAY...

Page 1135: ...ENSE 21 G74 20TN RD PASSENGER DOOR AJAR SWITCH SENSE 22 23 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 24 G26 20LB KEY IN IGNITION SWITCH SENSE 25 P55 18DB DOOR UNLOCK DRIVER LEFT FRONT 26 INSTRUMENT CLUSTER...

Page 1136: ...FEED 17 Y161 20OR RD ELECTRIC 4X4 PANEL LAMPS FEED 18 Y163 20OR WT HEADLAMP SWITCH ILLUMINATION CONTROL 19 Y166 20OR DB PANEL LAMPS DRIVER 20 21 D25 20VT YL PCI BUS 22 G11 20WT LG PARK BRAKE SWITCH S...

Page 1137: ...15 A64 16DG WT EXCEPT 4 7L FUEL PUMP RELAY OUTPUT 16 A108 18TN RD FUSED B 17 L76 18BK OR FUSED PARK LAMP RELAY OUTPUT 18 F32 18RD YL FUSED B 19 Y174 18PK VT FUSED PARK LAMP RELAY OUTPUT 20 21 22 23 Y...

Page 1138: ...18WT LG LEFT STOP LAMP DRIVER 18 L63 18DG RD LEFT REAR TURN LAMP DRIVER 19 L60 18LG TN RIGHT FRONT TURN LAMP DRIVER 20 Y137 20VT LB SENSOR GROUND INTEGRATED POWER MODULE C4 BLACK 20 WAY CAV CIRCUIT F...

Page 1139: ...16 K30 18PK TRANSMISSION CONTROL RELAY CONTROL 17 F121 16TN BK HEATED MIRROR RELAY OUTPUT 18 C3 18DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 19 20 21 C16 20LB YL HEATED MIRROR RELAY CONTROL 22 V4 16RD...

Page 1140: ...CONTROL 13 14 15 Y170 18WT LG LEFT HIGH BEAM DRIVER 16 Y153 18DB RD ADJUSTABLE PEDAL RELAY OUTPUT 17 18 19 K31 20BR 20 L39 18LB FOG LAMPS FOG LAMP RELAY OUTPUT 21 A41 16YL FUSED IGNITION SWITCH OUTPUT...

Page 1141: ...CTION PUMP NGC BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z54 18BK PK GROUND 2 K107 18OR NVLD SWITCH SIGNAL 3 K106 18WT DG NVLD SOLENOID CONTROL LEAK DETECTION PUMP BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 K125 1...

Page 1142: ...MP FEED 2 Z11 18BK WT GROUND LINE PRESSURE SENSOR 3 7L 5 7L BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z113 18BK GROUND 2 T39 18GY LB 5 VOLT SUPPLY 3 T38 18VT TN LINE PRESSURE SENSOR SIGNAL 4 LINE PRESSURE SE...

Page 1143: ...IRCUIT FUNCTION 1 K1 18DG RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL 2 K4 18BK LB SENSOR GROUND 2 K4 20BK LB NGC SENSOR GROUND 3 K7 18OR 5 VOLT SUPPLY 3 K6 18VT WT NGC 5 VOLT SUPPLY MANIFOLD ABSOLUTE...

Page 1144: ...FUNCTION 1 Y109 20VT OR WASH BEAM SELECT SWITCH SIGNAL 2 Y108 20VT BR WIPER TURN BEAM SELECT SWITCH RETURN 3 Y110 20WT VT TURN LAMPS SWITCH SIGNAL 4 V8 20VT INTERMITTENT WIPER SWITCH SIGNAL OUTPUT SP...

Page 1145: ...CUIT FUNCTION 1 M11 20PK LB COURTESY LAMP GROUND 2 F32 18RD YL FUSED B 3 M20 20BR COURTESY LAMP DRIVER OXYGEN SENSOR 1 1 UPSTREAM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A141 18DG WT FUSED AUTO SHUT DOWN R...

Page 1146: ...ALIFORNIA 5 9L 4 WAY CAV CIRCUIT FUNCTION 1 A141 18DG WT FUSED AUTO SHUT DOWN RELAY OUTPUT 1 K299 18BR WT NGC O2 2 1 HEATER CONTROL 2 Z193 18BK DG NGC GROUND 2 K299 18BR WT OXYGEN SENSOR 2 1 HEATER CO...

Page 1147: ...L ZONE 2 WAY CAV CIRCUIT FUNCTION 1 C34 20DB WT COMMON DOOR DRIVER 2 C46 20YL LG PASSENGER BLEND DOOR DRIVER PASSENGER LUMBAR SWITCH 5 WAY CAV CIRCUIT FUNCTION 1 Z238 18BK GROUND 2 P104 12YL LB LUMBAR...

Page 1148: ...P DRIVER 5 Z311 20BK LB GROUND 6 7 8 POWER OUTLET RED 3 WAY CAV CIRCUIT FUNCTION 1 A12 18RD TN FUSED B 2 3 Z300 18BK LB GROUND POWER OUTLET CONSOLE EXCEPT BASE 3 WAY CAV CIRCUIT FUNCTION 1 Y148 18BR Y...

Page 1149: ...K LB GROUND 7 F37 12RD LB FUSED B 8 P11 12YL WT LEFT SEAT REAR UP 9 P17 12RD LB LEFT SEAT HORIZONTAL REARWARD 10 P15 12YL LB LEFT SEAT HORIZONTAL FORWARD 11 P21 12RD LG LEFT SEAT FRONT DOWN 12 P19 12Y...

Page 1150: ...WINDOW MOTOR LEFT REAR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q23 14RD WT DRIVER REAR WINDOW DRIVER DOWN 2 Q13 14DB DRIVER REAR WINDOW DRIVER UP POWER WINDOW MOTOR PASSENGER BLACK 2 WAY CAV CIRCUIT FUNCT...

Page 1151: ...DRIVER UP 5 Q24 14RD WT PASSENGER REAR WINDOW DRIVER DOWN 6 Q1 14YL POWER WINDOW SWITCH FEED POWER WINDOW CIRCUIT BREAKER GRAY 2 WAY CAV CIRCUIT FUNCTION 1 F1 10DB IGNITION SWITCH OUTPUT RUN ACC 2 F21...

Page 1152: ...88 18VT WT GOVERNOR PRESSURE SOLENOID CONTROL 9 10 11 K54 18OR BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL 12 13 14 15 16 17 18 19 20 21 T60 18BR 3 4 SHIFT SOLENOID CONTROL 22 23 24 25 T13 18DB BK SPE...

Page 1153: ...OL 6 7 8 9 10 11 V32 18YL RD SPEED CONTROL SUPPLY 12 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT 13 T6 18OR WT OVERDRIVE OFF SWITCH SENSE 14 15 16 17 18 19 20 21 22 23 24 K29 18WT PK BRAKE SWITCH SENSE...

Page 1154: ...O 2 DRIVER 12 S28 18YL BK 3 7L POWER STEERING PRESSURE SWITCH SIGNAL 13 G113 18OR 5 9L PTO SWITCH SENSE 13 A41 14YL 3 7L FUSED IGNITION SWITCH OUTPUT RUN START 14 K77 18BR WT 5 9L MANUAL TRANSFER CASE...

Page 1155: ...H OUTPUT 13 B22 20DG YL 5 7L VEHICLE SPEED SIGNAL NO 1 13 G7 18WT OR 4 7L VEHICLE SPEED SIGNAL 14 15 16 17 18 Z82 16BK TN GROUND 19 20 G60 18GY YL OIL PRESSURE SIGNAL 21 C18 18DB A C PRESSURE SIGNAL 2...

Page 1156: ...LENOID CONTROL 12 K58 18BR DB FUEL INJECTOR NO 6 DRIVER 13 K28 18GY LB 5 9L 8 0L FUEL INJECTOR NO 8 DRIVER 14 K116 18WT DB 8 0L FUEL INJECTOR NO 10 DRIVER 15 K12 18TN FUEL INJECTOR NO 2 DRIVER 16 K14...

Page 1157: ...TROL 18 K41 18DK DG O2 1 1 HEATER CONTROL 19 K20 18DG GEN FIELD CONTROL 20 K2 18TN BK ECT SIGNAL 21 K22 18OR DB TP NO 1 SIGNAL 22 23 K1 18DG RD MAP SIGNAL 24 Y205 18BR WT 5 7L KNOCK SENSOR NO 1 RETURN...

Page 1158: ...18OR WT 5 9L OVERDRIVE OFF SWITCH SENSE 13 T10 18YL DG 5 9L DIESEL TORQUE MANAGEMENT REQUEST SENSE 14 K107 18OR LEAK DETECTION PUMP SOLENOID CONTROL 15 K118 18PK YL BATTERY TEMPERATURE SENSOR SIGNAL 1...

Page 1159: ...K DB 5 7L APPS NO 1 RETURN 17 K981 18BR DG 5 7L APPS NO 2 RETURN 18 V38 20VT OR 5 7L S C SWITCH NO 2 SIGNAL 19 A142 16DG OR ASD RELAY OUTPUT 20 K108 18WT TN EVAP PURGE SOL SIGNAL 21 T24 20BR YL TRS T2...

Page 1160: ...T1 SENSE 16 T3 18VT 4 7L TRS T3 SENSE 17 T6 18OR WT 4 7L OVERDRIVE OFF SWITCH SENSE 18 K30 18PK 4 7L TRANSMISSION CONTROL RELAY CONTROL 19 T16 16RD 4 7L TRANSMISSION CONTROL RELAY OUTPUT 20 T48 18DB 4...

Page 1161: ...N BK RIGHT REAR SPEAKER 21 X94 18TN VT RIGHT REAR SPEAKER 22 Z9 18BK DG GROUND RADIO PREMIUM GRAY 22 WAY CAV CIRCUIT FUNCTION 1 M1 18PK FUSED B 2 Y105 20BR RD FUSED IGNITION SWITCH OUTPUT RUN ACC 3 Y1...

Page 1162: ...14 WAY CAV CIRCUIT FUNCTION 1 P133 20TN DG DRIVER SEAT HEATER MUX SWITCH 2 P86 20PK BK SEAT HEATER DRIVER 3 P142 18TN DB PASSENGER SEAT TEMPERATURE SENSOR INPUT 4 F235 18RD FUSED B 5 P141 18TN LB DRI...

Page 1163: ...EAKER 2 X84 20OR BK RIGHT INSTRUMENT PANEL SPEAKER SPEAKER LEFT FRONT DOOR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X85 18LG DG LEFT FRONT DOOR SPEAKER 2 3 X87 18LG RD LEFT FRONT DOOR SPEAKER SPEAKER LEFT I...

Page 1164: ...PEAKER RIGHT REAR WHITE 3 WAY CAV CIRCUIT FUNCTION 1 X94 18TN VT RIGHT REAR SPEAKER 2 3 X92 18TN BK RIGHT REAR SPEAKER SPEED CONTROL SERVO BLACK 4 WAY CAV CIRCUIT FUNCTION 1 V36 20TN RD SPEED CONTROL...

Page 1165: ...20BK LB SENSOR GROUND SPEED CONTROL SWITCH RIGHT ETC WHITE 3 WAY CAV CIRCUIT FUNCTION 1 V38 20VT OR S C SWITCH NO 2 SIGNAL 2 Y215 20BK LB S C SWITCH RETURN 3 V37 20RD LG S C SWITCH NO 1 SIGNAL SPEED C...

Page 1166: ...ELAY OUTPUT 2 3 Z150 18BK GROUND 4 L24 18WT LG LEFT STOP LAMP FEED 5 L63 18DG RD LEFT REAR TURN LAMP DRIVER 6 L1 18VT BK BACK UP LAMP FEED TAIL STOP TURN SIGNAL LAMP RIGHT BLACK 6 WAY CAV CIRCUIT FUNC...

Page 1167: ...OSITION SENSOR NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 K7 18OR 5 VOLT SUPPLY 2 K22 18OR DB 4 7L 5 9L TP NO 1 SIGNAL 2 K4 18BK LB 3 7L SENSOR GROUND 3 K4 18BK LB 4 7L 5 9L SENSOR GROUND 3 K22 18OR DB 3 7L...

Page 1168: ...8BK OR PARK LAMP RELAY OUTPUT 6 7 B40 14LB TRAILER TOW BRAKE B 8 Z52 14BK GROUND 9 Z52 14BK GROUND 10 Y141 18YL PK TRAILER TOW LEFT TURN RELAY OUTPUT TRANSFER CASE CONTROL MODULE C1 BLACK 16 WAY CAV C...

Page 1169: ...LB 5 VOLT SELECTOR SWITCH SUPPLY TRANSFER CASE CONTROL MODULE C3 4 WAY CAV CIRCUIT FUNCTION A Z21 16BK LG GROUND B A34 16LB RD FUSED B C Y124 16DG VT SHIFT MOTOR CONTROL A D Y125 16DG WT SHIFT MOTOR...

Page 1170: ...2 Y187 20RD 2WD AWD INDICATOR 3 4 Y121 20YL LG NEUTRAL INDICATOR 5 Y120 20YL DG MODE SELECT 6 Y189 20OR BK PANEL LAMPS FEED 7 Y107 20VT RD FUSED IGNITION SWITCH OUTPUT RUN 8 Y122 20DG BR 4WD LOW INDIC...

Page 1171: ...NSMISSION CONTROL RELAY OUTPUT 18 T118 18YL DB PRESSURE CONTROL SOLENOID CONTROL 19 T119 18WT DB 2C SOLENOID CONTROL 20 T120 18LG LR SOLENOID CONTROL 21 22 23 24 25 26 27 28 B22 20DG YL 5 7L VEHICLE S...

Page 1172: ...N 2 Y193 20YL RD TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX 3 4 L1 18VT BK BACKUP LAMP FEED 5 Y128 20DG GY TRANS RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY 6 T24 20BR YL PARK NEUTRAL POSITION SWITCH...

Page 1173: ...3 T4 18PK OR TRS T2 SENSE 14 T50 18DG LOW REVERSE PRESSURE SWITCH SENSE 15 T147 18LB 2C PRESSURE SWITCH SENSE 16 T9 18OR BK OVERDRIVE PRESSURE SWITCH SENSE 17 T59 18PK UNDERDRIVE SOLENOID CONTROL 18 T...

Page 1174: ...18WT SENSOR SUPPLY 6 F15 20DB FUSED IGNTION SWITCH OUTPUT RUN WASHER FLUID LEVEL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Y137 20VT LB EXCEPT 8 0L DIESEL SENSOR GROUND 2 G29 20BK TN WASHER FLUID SWIT...

Page 1175: ...2 B113 18RD VT REAR WHEEL SPEED SENSOR WHEEL SPEED SENSOR RIGHT FRONT ABS GRAY 2 WAY CAV CIRCUIT FUNCTION 1 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR 2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR WIPER MOT...

Page 1176: ...FUNCTION 1 Z216 20BK VT GROUND 2 V10 20BR WASHER PUMP MOTOR CONTROL WATER IN FUEL SENSOR DIESEL 2 WAY CAV CIRCUIT FUNCTION 1 K104 18RD WT SENSOR GROUND 2 G20 18VT YL IGNITION SWITCH SENSE WHEEL SPEED...

Page 1177: ...RAY 2 WAY CAV CIRCUIT FUNCTION 1 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR 2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR WIPER MOTOR FRONT BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 V5 20DG WIPER PARK SWITCH SEN...

Page 1178: ...l C2 BK Center of Instrument Panel 36 37 Adjustable Pedal Motor WT Left of Instrument Panel 33 Adjustable Pedal Switch BL Left of Instrument Panel 37 39 Airbag Control Module YL Lower Center of Instru...

Page 1179: ...anel Speaker 37 39 C205 BK Left Rear Side of Engine Compartment N S C206 BK Right Instrument Panel 37 40 46 C216 BK Middle Left Frame 26 28 48 C217 BK Middle Left Frame 26 28 37 48 C218 WT Left Side o...

Page 1180: ...Side of Intake Manifold 4 Coil On Plug No 2 BK Right Top Side of Intake Manifold 3 Coil On Plug No 3 BK Left Top Side of Intake Manifold 4 Coil On Plug No 4 BK Right Top Side of Intake Manifold 3 Coil...

Page 1181: ...Generator 4 7 9 Engine Oil Pressure Sensor BK Lower Left Side of Engine 4 6 8 9 11 Evap Purge Solenoid BK Left Fender Side Shield 26 28 Evaporator Temperature Sensor BK Right Side of HVAC N S Fog Lam...

Page 1182: ...Compartment 2 Intake Air Temperature Manifold Absolute Temperature Sensor Diesel BK Left rear Engine N S Intake Air Temperature Sensor BK On Intake Manifold 4 7 9 Integrated Power Module C1 BK Left F...

Page 1183: ...ght Side of Instrument Panel 35 37 40 Passenger Blend Door Actuator Dual Zone BK Right Side of HVAC N S Passenger Lumbar Switch At Passenger Seat N S Power Mirror Left BK At Mirror 42 Power Mirror Rig...

Page 1184: ...l Wheels BK Front of Left Rear Fender 50 Side Marker Left Rear Dual Wheels BK Rear of Left Rear Fender 50 Side Marker Right Front Dual Wheels BK Front of Right Rear Fender 50 Side Marker Right Rear Du...

Page 1185: ...anel 35 37 38 Transfer Case Shift Motor BK Left Rear of Transmission 20 Transmission Control Module BK Left Rear of Engine Compartment 21 Transmission Range Sensor BK Left side of Transmission 11 12 T...

Page 1186: ...r 26 S103 Left Rear of Engine Compartment 26 S104 Front Facia N S S105 Front Facia N S S106 Left Rear of Engine Compartment 26 S107 Left Front Fender 26 S108 Headlamp and Dash Left Side 26 28 S109 Lef...

Page 1187: ...er 26 S146 Left Front Fender 26 S147 Right Rear of Engine 7 S148 Top Front of Transmission 3 14 16 17 22 23 24 S149 Left Rear of Engine 3 4 14 S150 Top Center of Engine 3 5 8 S153 Rear Engine Compartm...

Page 1188: ...Instrument Panel 37 40 S218 Left Side of Instrument Panel 39 S219 Center of Instrument Panel N S S220 Center of Instrument Panel N S S221 Center of Instrument Panel 37 38 S222 Center of Instrument Pa...

Page 1189: ...49 S325 Left Rear Chassis 48 49 S326 Left Rear Chassis 48 49 S327 Left Rear Chassis 48 49 S328 At Driver Seat N S S329 At Driver Seat N S S330 Center Rear of Chassis 49 S331 Center Rear of Chassis 49...

Page 1190: ...Fig 1 RIGHT SIDE FRONT LIGHTING Fig 2 LEFT FRONT BUMPER AND RIGHT BATTERY TRAY DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 13 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1191: ...Fig 3 RIGHT SIDE ENGINE 4 7L 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1192: ...Fig 4 LEFT SIDE ENGINE 4 7L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1193: ...Fig 5 LEFT SIDE ENGINE 5 7L 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1194: ...Fig 6 RIGHT SIDE ENGINE 5 7L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1195: ...Fig 7 RIGHT SIDE ENGINE 5 9L 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1196: ...Fig 8 LEFT SIDE ENGINE 5 9L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1197: ...Fig 9 ENGINE 8 0L 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1198: ...Fig 10 ENGINE DIESEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1199: ...Fig 11 LEFT SIDE ENGINE AND TRANSMISSION 5 9L 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1200: ...Fig 12 LEFT SIDE ENGINE AND TRANSMISSION 8 0L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1201: ...Fig 13 LEAK DETECTION PUMP 8 0L 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1202: ...Fig 14 TRANSMISSION 45RFE 4X4 DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1203: ...Fig 15 TRANSMISSION 45RFE 4X4 5 7L 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1204: ...Fig 16 MANUAL TRANSMISSION 4X4 DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1205: ...Fig 17 TRANSMISSION 4 7L 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1206: ...Fig 18 TRANSMISSION 45RFE AUTO 5 7L HEAVY DUTY MANUAL SIMILAR DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1207: ...Fig 19 45RFE TRANSMISSION 5 7L LIGHT DUTY 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1208: ...Fig 20 LEFT FRONT TRANSFER CASE DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1209: ...Fig 21 REAR ENGINE COMPARTMENT 4 7L 5 7L 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1210: ...Fig 22 REAR ENGINE COMPARTMENT 8 0L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1211: ...Fig 23 REAR ENGINE COMPARTMENT DIESEL 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1212: ...Fig 24 TOP REAR ENGINE COMPARTMENT 5 9L DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1213: ...Fig 25 RIGHT SIDE ENGINE COMPARTMENT 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1214: ...Fig 26 LEFT SIDE ENGINE COMPARTMENT DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1215: ...Fig 27 LEFT SIDE ENGINE COMPARTMENT 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1216: ...Fig 28 LEFT SIDE ENGINE COMPARTMENT DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1217: ...Fig 29 LEFT SIDE ENGINE COMPARTMENT 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1218: ...Fig 30 INTEGRATED POWER MODULE AND FAN DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1219: ...Fig 31 LEFT SIDE ENGINE COMPARTMENT AND HOOD 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1220: ...Fig 32 STEERING COLUMN DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1221: ...Fig 33 LEFT STEERING COLUMN 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1222: ...Fig 34 INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 45 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1223: ...Fig 35 REAR INSTRUMENT PANEL 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1224: ...Fig 36 CENTER INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 47 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1225: ...Fig 37 INSTRUMENT PANEL 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1226: ...Fig 38 CENTER INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 49 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1227: ...Fig 39 LEFT INSTRUMENT PANEL 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1228: ...Fig 40 RIGHT INSTRUMENT PANEL DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 51 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1229: ...Fig 41 STANDARD CAB FRONT BODY 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1230: ...Fig 42 STANDARD CAB LEFT FRONT DOOR PREMIUM DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 53 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1231: ...Fig 43 LEFT REAR DOOR RIGHT SIDE SIMILAR 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1232: ...Fig 44 STANDARD CAB LEFT SIDE BODY DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 55 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1233: ...Fig 45 QUAD CAB LEFT SIDE BODY 8W 91 56 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1234: ...Fig 46 ROOF Fig 47 REAR BODY DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 57 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1235: ...Fig 48 CHASSIS 8W 91 58 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1236: ...Fig 49 REAR CHASSIS DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 59 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1237: ...Fig 50 LEFT REAR FENDER RIGHT SIDE SIMILAR 8W 91 60 8W 91 CONNECTOR GROUND SPLICE LOCATION DR CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1238: ...Fig 51 REAR BUMPER DR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 61 CONNECTOR GROUND SPLICE LOCATION Continued...

Page 1239: ......

Page 1240: ...Wiring Diagrams for complete circuit sche matics The power distribution system also incorporates various types of circuit control and protection fea tures including Automatic resetting circuit breake...

Page 1241: ...to expand Once the spring clips expand far enough to release the heating element the spring loaded housing forces the knob and heat ing element to pop back outward to their relaxed position When the c...

Page 1242: ...laceable components of the integrated power module assembly are broken down into the following components the Power Distribution Center PDC the integrated power module cover the Front Control Module F...

Page 1243: ...nnectors by pushing straight on and rotating the connector arm inboard until the connector is firmly locked in place on the module assembly 4 Grasp the integrated power module with two hands and insta...

Page 1244: ...bus network and all of the electronic modules that provide inputs to or receive outputs from the front control module must be checked All PCI J1850 communication faults must be resolved prior to furth...

Page 1245: ...the vehicle can be loaded unloaded and moved as needed by both vehi cle transportation company and dealer personnel The IOD fuse is disconnected from Integrated Power Module fuse cavity 51 when the v...

Page 1246: ...ery voltage at the insulated con tact located at the back of the power outlet recepta cle If not OK go to Step 5 5 Disconnect and isolate the battery negative cable Remove the power outlet receptacle...

Page 1247: ...losed fixed contact and holds it against the other normally open fixed contact When the electromagnetic coil is de energized spring pressure returns the movable contact to the normally closed position...

Page 1248: ...rom its receptacle A slight back and fourth rocking motion may help the removal process INSTALLATION 1 Position the relay to the proper receptacle 2 Align the relay terminals with the terminal cavitie...

Page 1249: ...ormation 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 various wire harnes...

Page 1250: ...RS 9 STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION 10 REMOVAL 10 INSTALLATION 11 SPECIFICATIONS SPECIFICATIONS 3 7L ENGINE 12 TORQUE 15 SPECIAL TOOLS 16 AIR CLEANER ELEMENT REMOVAL 20 INSTALLAT...

Page 1251: ...PTION 56 OPERATION 56 REMOVAL 56 INSTALLATION 56 FRONT MOUNT REMOVAL 57 INSTALLATION 58 REAR MOUNT REMOVAL 60 INSTALLATION 60 LUBRICATION DESCRIPTION 60 OPERATION 60 DIAGNOSIS AND TESTING DIAGNOSIS AN...

Page 1252: ...f two different components the first component is the cylinder bore and upper block the second component is the bed plate that comprises the lower portion of the cylinder block and houses the lower ha...

Page 1253: ...re Diagnosis Refer to 9 ENGINE CYLINDER HEAD DIAGNO SIS AND TESTING Intake Manifold Leakage Diagnosis Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIA...

Page 1254: ...haust system 7 Inspect and replace as necessary 8 Faulty coil 8 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 9 Incorrect cam timing 9 Refer to Engine TIming in this section 1 ENGINE MI...

Page 1255: ...ISE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or diluted oil 3 Change...

Page 1256: ...NE BLOCK CRANKSHAFT OIL SEAL FRONT REMOVAL 6 Scratched or damaged vibration damper hub 6 Polish or replace damper OIL PRESSURE DROP 1 Low oil level 1 Check and correct oil level 2 Faulty oil pressure...

Page 1257: ...ion 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 combus...

Page 1258: ...l unless specified Bead size continuity and location are of great importance Too thin a bead can result in leakage while too much can result in spill over which can break off and obstruct fluid feed l...

Page 1259: ...evenly over the sealing surfaces Material in an aerosol can should be used on engines with multi layer steel gaskets STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION To ensure engine gasket seali...

Page 1260: ...nd secure out of way NOTE It is necessary to disconnect the front prop shaft for access to the starter and left side exhaust flange 35 Remove the starter 36 Remove the ground straps from the left and...

Page 1261: ...e viscous fan assembly 37 Install the radiator core support bracket 38 Install the air cleaner assembly 39 Refill the engine cooling system 40 Recharge the air conditioning 41 Install the hood 42 Chec...

Page 1262: ...l Diameter 63 488 63 512 mm 2 4996 2 5005 in Bearing Clearance 0 002 0 034 mm Out of Round MAX 0 005 mm 0 0002 in Taper MAX 0 006 mm 0 0004 in DESCRIPTION SPECIFICATION End Play 0 052 0 282 mm 0 0021...

Page 1263: ...Exhaust 390 0 430 0 N 40 12 mm 87 67 96 66 lbs 1 5795 in DESCRIPTION SPECIFICATION Spring Force Valve Open Intake 984 0 1040 0 N 28 12 mm 221 2 233 8 lbs 1 107 in Exhaust 965 0 1055 0 N 28 12 mm 216...

Page 1264: ...nder Head Bolts M11 Bolts Refer To Procedure M8 Bolts Cylinder Head Cover Bolts 12 105 Exhaust Manifold Bolts 25 18 Exhaust Manifold Heat Shield Nuts 8 72 Then loosen 45 DESCRIPTION N m Ft In Lbs Lbs...

Page 1265: ...ter Pins 8346 Front Crankshaft Seal Remover 8511 Front Crankshaft Seal Installer 8348 Handle C 4171 Rear Crankshaft Seal Installer 8349 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 9 1...

Page 1266: ...8512 Puller 1026 Crankshaft Damper Removal Insert 8513 Chain Tensioner Wedge 8379 Chain Tensioner Pins 8514 VALVE SPRING COMPRESSOR 8426 ENGINE LIFTING FIXTURE 8427 CAMSHAFT HOLDER 8428 DR ENGINE 3 7L...

Page 1267: ...ocker Arm 8516 Idler Shaft Remover 8517 Valve Spring Compressor Adapters 8519 INSTALLER REMOVER COUNTER BALANCE SHAFT 8641 Valve Spring Tester C 647 Dial Indicator C 3339 Valve Spring Compressor C 342...

Page 1268: ...Bore Size Indicator C 119 Oil Pressure Gauge C 3292 Piston Ring Compressor C 385 Pressure Tester Kit 7700 Bloc Chek Kit C 3685 A ENGINE SUPPORT FIXTURE 8534 DR ENGINE 3 7L 9 19 ENGINE 3 7L Continued...

Page 1269: ...ir duct to air cleaner cover and tighten hose clamp to 3 N m 30 in lbs torque 5 If any other hose clamps were removed from air intake system tighten them to 3 4 N m 30 in lbs torque 6 If any bolts wer...

Page 1270: ...THOD Combustion leaks into the cooling system can also be checked by using Bloc Chek Kit C 3685 A or equivalent Perform test following the procedures supplied with the tool kit REMOVAL 1 Disconnect th...

Page 1271: ...oner Refer to Timing Chain and Sprockets 19 Remove the cylinder head access plug Fig 8 20 Remove the left side secondary chain guide Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMO...

Page 1272: ...lastic scraper 1 Clean the cylinder head and cylinder block mating surfaces Fig 10 2 Position the new cylinder head gasket on the locating dowels CAUTION When installing cylinder head use care not dam...

Page 1273: ...assembly Refer to 5 BRAKES HYDRAULIC ME CHANICAL POWER BRAKE BOOSTER INSTAL LATION 19 Install the intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 20 Refill the cooling system...

Page 1274: ...emoving the camshaft sprocket bolt and sprocket Fig 13 7 Using Special Tool 8428 Camshaft Wrench gently allow the camshaft to rotate 5 clockwise until the camshaft is in the neutral position no valve...

Page 1275: ...haft sprocket bolt Failure 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 Speci...

Page 1276: ...seats that are worn or burned can be reworked provided that correct angle and seat width are maintained Otherwise the cylinder head must be replaced NOTE When refacing valves and valve seats it is im...

Page 1277: ...ve any burrs from the valve stem before removing the valve from the cylinder head 7 Remove the valve from the cylinder head NOTE The valve stem seals are common between intake and exhaust 8 Remove the...

Page 1278: ...the spring retainer are fully seated 6 lubricate the camshaft journal with clean engine oil then Position the camshaft with the sprocket dowel on the left camshaft at 11 o clock and the right camshaft...

Page 1279: ...ard on the valve spring remove rocker arm Fig 22 INSTALLATION CAUTION Make sure the rocker arms are installed with the concave pocket over the lash adjusters Failure to do so may cause severe damage t...

Page 1280: ...are common between intake and exhaust INSTALLATION NOTE All six valve springs and seals are removed in the same manner this procedure only covers one valve seal and valve spring 1 Apply shop air to t...

Page 1281: ...sprocket using Special Tool 8429 Timing Chain Hold ing Fixture NOTE Mark the secondary timing chain prior to removal to aid in installation 16 Mark the secondary timing chain one link on each side of...

Page 1282: ...lts are tightened using an angle torque procedure however the bolts are not a torque to yield design 6 Tighten the bolts in sequence using the follow ing steps and torque values Step 1 Tighten bolts 1...

Page 1283: ...re machined into the camshaft Camshaft end play is controlled by two thrust walls that border the nose piece journal Engine oil enters the hollow camshafts at the third journal and lubri cates every i...

Page 1284: ...n links Two links marked during remov al 7 Using Special Tool 8428 Camshaft Wrench rotate the camshaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the s...

Page 1285: ...for roller and camshaft lubrication REMOVAL NOTE Disconnect the battery negative cable to pre vent accidental starter engagement 1 Remove the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLIN...

Page 1286: ...and exhaust 3 Install the spring retainer and the spring 4 Using Special Tool 8387 Valve Spring Compres sor compress the valve spring 5 Install the two spring retainer lock halves NOTE the valve spri...

Page 1287: ...CLEANING Thoroughly clean the oil pan and engine block gas ket surfaces Use compressed air to clean out The galley at the oil filter adaptor hole The front and rear oil galley holes The feed holes for...

Page 1288: ...in to a bore formed by the cylinder block and the bedplate assembly REMOVAL NOTE To remove the crankshaft from the engine the engine must be removed from the vehicle 1 Remove the engine Refer to 9 EN...

Page 1289: ...from the cylinder block and bedplate 2 Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores Remove all oil and sealant residue 3 Inspect the bedplate main bearing bo...

Page 1290: ...T Engine RTV sealant prior to installation Failure to do so will cause severe oil leaks NOTE Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contamin...

Page 1291: ...ten bolts 1 8 to 7 N m 5 ft lbs Turn bolts 1 8 an additional 90 Tighten bolts A E 27 N m 20 ft lbs 8 Measure crankshaft end play 9 Install the connecting rods and measure side clearance Refer to 9 ENG...

Page 1292: ...rmine the maximum diameter of the journal with a micrometer Measure at two locations 90 apart at each end of the journal The maximum allowable taper is 0 008mm 0 0004 inch and maximum out of round is...

Page 1293: ...ankshaft 9U9 014 044 mm 0005 0017 in CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Disconnect negative cable from battery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 R...

Page 1294: ...fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 8 Connect negative cable to battery CRANKSHAFT OIL SEAL REAR REMOVAL NOTE This procedure can be performed in vehicle 1 If being preformed in v...

Page 1295: ...h a hammer tap the seal into place Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore 4 Install the flexplate 5 Install the transmission Fig...

Page 1296: ...DESCRIPTION CAUTION Do not use a metal stamp to mark con necting rods as damage may result instead use ink or a scratch awl The pistons are made of a high strength aluminum alloy The connecting rods...

Page 1297: ...ing insert in connect ing rod Fig 47 3 Use piston ring compressor and Guide Pins Special Tool 8507 Fig 48 to install the rod and pis ton assemblies The oil slinger slots in the rods must face front of...

Page 1298: ...on 8 If bearing to journal clearance exceeds the specification determin which services bearing set to use the bearing sizes are as follows Bearing Mark SIZE USED WITH JOURNAL SIZE 025 US 025 mm 57 883...

Page 1299: ...Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY To correctly select the proper size pis ton a cylinder bore gauge capable of reading in 0 003 mm 0001 i...

Page 1300: ...devise to clean the pistons or con necting rods The pistons have a Moly coating this coating must not be damaged 1 Using a suitable cleaning solvent clean the pis tons in warm water and towel dry 2 Us...

Page 1301: ...inder head s Refer to 9 ENGINE CYLIN DER HEAD INSTALLATION Timing chain and cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION Cylinder head covers Refer to 9 ENGINE CYLINDER...

Page 1302: ...n 0 004 in Oil Control Ring 019 229mm 25mm Steel Rails 0007 0090 in 0 010 in Ring Position Ring Gap Wear Limit Upper Ring 0 20 0 36mm 0 43mm 0 0079 0 0142 in 0 0017 in Intermediate Ring 0 37 0 63mm 0...

Page 1303: ...rection VIBRATION DAMPER REMOVAL 1 Disconnect negative cable from battery 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Drain cooling system Refer to 7 COOLING...

Page 1304: ...d severe damage to either the tool or the crankshaft 2 Assemble Special Tool 8512 A as follows The nut is threaded onto the shaft first Then the roller bearing is placed onto the threaded rod The hard...

Page 1305: ...structural cover Fig 64 in the sequence shown 5 Pivot the exhaust pipe downward and remove the structural cover INSTALLATION CAUTION The structural cover must be installed as described in the followin...

Page 1306: ...le to remove the left and right engine mounts 13 Remove the 8 mount to engine attaching bolts 14 Remove the engine mounts 4WD 1 Disconnect the negative cable from the battery CAUTION Remove the viscou...

Page 1307: ...tall the oil drain trough 6 Install the engine oil filter 7 Lower the vehicle 8 Install the viscous fan Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 9 Reconnect the negative battery cabl...

Page 1308: ...the front axle to the left engine bracket to 101 N m 75 ft lbs 9 Install the oil drain trough 10 Install the engine oil filter 11 Install the front crossmember 12 Install the skid plate 13 Lower the v...

Page 1309: ...on system is a full flow filtration pres sure feed type OPERATION Oil from the oil pan is pumped by a gerotor type oil pump directly mounted to the crankshaft nose Oil pressure is controlled by a reli...

Page 1310: ...ubrication Flow Chart Cylinder Heads Table 2 The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads ENGINE LUBRICATION FLOW CHART CYLINDER HEADS TABLE 2 FROM TO Cyl...

Page 1311: ...FLOW TO BOTH SECONDARY TENSIONERS 5 OIL FLOW TO LEFT CYLINDER HEAD 6 OIL PRESSURE SENSOR LOCATION 7 OIL FLOW TO COUNTER BALANCE SHAFT 8 OIL PUMP OUTLET TO CYLINDER BLOCK 9 OIL PUMP 10 OIL FLOW TO CRA...

Page 1312: ...Inspection for Rear Seal Area Leak 6 If no leaks are detected turn off the air supply and remove the air hose and all plugs and caps Install the PCV valve and breather cap hose 7 Clean the oil off the...

Page 1313: ...g cap to cylinder block mating sur faces See Engine for proper repair procedures of these items 4 If no leaks are detected pressurized the crank case as outlined in the section Inspection Engine oil L...

Page 1314: ...gine enough to provide clearance for oil pan removal Check for proper clearance at fan shroud to fan and cowl to intake manifold 7 Raise engine using special tool 8534 to pro vide clearance to remove...

Page 1315: ...LATION 12 Fill engine oil 13 Reconnect the negative battery cable 14 Start engine and check for leaks OIL PRESSURE SENSOR SWITCH DESCRIPTION The 3 wire solid state engine oil pressure sensor sending u...

Page 1316: ...pump cover is scratched or grooved the oil pump assembly should be replaced 2 Lay a straight edge across the pump cover sur face Fig 77 If a 0 025 mm 0 001 in feeler gauge can be inserted between the...

Page 1317: ...pressure loss INSTALLATION 1 Position the oil pump onto the crankshaft and install one oil pump retaining bolts 2 Position the primary timing chain tensioner and install three retaining bolts 3 Tighte...

Page 1318: ...nch loosen filter 3 Rotate the oil filter counterclockwise Fig 84 to remove it from the cylinder block oil filter boss 4 When filter separates from cylinder block oil filter boss tip gasket end upward...

Page 1319: ...result API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi fied MOPARt provides engine oils that conform to this service grade SAE VISCOSITY An SAE viscosity grade is used to...

Page 1320: ...a suitable drain pan under crankcase drain 5 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for stretching or other damage Replace drain plug if damaged 6...

Page 1321: ...ove top oil dipstick tube retaining bolt and ground strap 11 Bleed fuel system Refer to FUEL SYSTEM 12 Remove fuel rail 13 Remove throttle body assembly and mounting bracket 14 Drain cooling system be...

Page 1322: ...ili con molybdenum cast iron A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head The exhaust manifolds are cov ered by a three layer laminated heat shiel...

Page 1323: ...ening heat shield fasteners may cause shield to distort and or crack 5 Assemble exhaust pipe to manifold and secure with bolts nuts and retainers Tighten the bolts and nuts to 34 N m 25 ft lbs torque...

Page 1324: ...mary chain receives oil splash lubrication from the secondary chain drive and designed oil pump leak age The idler sprocket assembly connects the pri mary chain drive secondary chain drives and the co...

Page 1325: ...procedure 2 To determine if the secondary timing chains are worn rotate the engine clockwise until maximum tensioner piston extension is obtained Measure the distance between the secondary timing cha...

Page 1326: ...TDC with both camshaft sprocket V6 marks in the 12 o clock posi tion Fig 100 2 Look down the left cylinder head chain cavity The timing dot on the counter balance shaft drive gear should be in the 6...

Page 1327: ...he camshaft drive gear onto the cam shaft 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 retai...

Page 1328: ...counterbal ance shaft into engine 3 Install Counterbalance shaft thrust plate retaining bolt finger tight Do not tighten bolt at this time 4 Position the right side of the thrust plate with the right...

Page 1329: ...ve electric cooling fan and fan shroud assembly 4 Remove fan and fan drive assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 5 Disconnect both heater hoses at timing cover 6 Disconne...

Page 1330: ...y drive belt tensioner assembly Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS INSTALLATION 9 Install radiator upper and lower hoses 10 Install both heater hoses 11 Install electric fan shroud and...

Page 1331: ...R HEAD 2 RIGHT CYLINDER HEAD Fig 108 Engine Top Dead Center 1 TIMING CHAIN COVER 2 CRANKSHAFT TIMING MARKS Fig 109 Cylinder Head Access Plugs 1 RIGHT CYLINDER HEAD ACCESS PLUG 2 LEFT CYLINDER HEAD ACC...

Page 1332: ...aft approximately 5 degrees clockwise to a neutral posi tion 15 While holding the right camshaft steel tube with Special Tool 8428 Camshaft Wrench remove the right camshaft sprocket 16 Remove idler sp...

Page 1333: ...left side chain tensioner arm and Torxt bolt Tighten Torxt bolt to 28 N m 250 in lbs 6 Install the right side chain guide Tighten the bolts to 28 N m 250 in lbs 7 Install both secondary chains onto t...

Page 1334: ...ess oil from bolts then Install sprocket bolts but do not tighten at this time 14 Verify that all plated links are aligned with the marks on all sprockets and the V6 marks on camshaft sprockets are at...

Page 1335: ...overs Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION NOTE Before installing threaded plug in right cylin der head the plug must be coated with sealant to prevent leaks 23 Coat the...

Page 1336: ...ON RIGHT CYLINDER HEAD 111 CAMSHAFT S LEFT DESCRIPTION 113 REMOVAL 113 INSTALLATION 114 CAMSHAFT S RIGHT DESCRIPTION 117 REMOVAL 117 INSTALLATION 118 CYLINDER HEAD COVER S DESCRIPTION 121 REMOVAL REMO...

Page 1337: ...51 OIL FILTER REMOVAL 152 INSTALLATION 153 OIL PAN REMOVAL 153 INSTALLATION 153 OIL PRESSURE SENSOR SWITCH DESCRIPTION DESCRIPTION 154 DESCRIPTION 154 OPERATION OPERATION 154 OPERATION 154 REMOVAL 154...

Page 1338: ...p relay or wiring 7 Repair or replace as necessary ENGINE STALLS OR ROUGH IDLE 1 Idle speed set to low 1 Refer to 14 FUEL SYSTEM FUEL INJECTION IDLE AIR CONTROL MOTOR REMOVAL 2 Idle mixture too lean o...

Page 1339: ...ly gapped 1 Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CLEANING 2 Dirt in fuel system 2 Clean fuel system 3 Burned warped or pitted valves 3 Replcae as necessary 4 Faulty coil 4 Refer to 8 ELEC...

Page 1340: ...ISE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or diluted oil 3 Change...

Page 1341: ...structions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 psi recom mended 7 Perform the test procedures on each cylinder according to...

Page 1342: ...lines A continuous bead of the proper width is essential to obtain a leak free gasket There are numerous types of form in place gasket materials that are used in the engine area Mopart Engine RTV GEN...

Page 1343: ...h bolt retaining nut and bolt from both the left and right side engine mounts 7 4X4 vehicles Remove locknut from left and right side engine mount brackets 8 Disconnect two ground straps from the lower...

Page 1344: ...r steering pump and position out of the way 34 Install Special Tools 8400 Lifting Studs into the cylinder heads 35 Install Engine Lifting Fixture Special Tool 8347 Fig 4 following these steps Holding...

Page 1345: ...5 Remove Special Tools 8400 Lifting Studs 6 Position generator wiring behind the oil dip stick tube then install the oil dipstick tube upper mounting bolt 7 Connect both left and right side body grou...

Page 1346: ...OM PRESSOR INSTALLATION 20 Install both breathers Connect tube to both crankcase breathers Fig 2 21 Connect throttle and speed control cables 22 Install throttle body resonator assembly and air inlet...

Page 1347: ...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 1348: ...17 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 49...

Page 1349: ...73 0 0911 in Guide Bore Diameter Std 6 975 7 00 mm 0 2747 0 2756 in Cylinder Head Warpage Flatness 0 0508 mm 0 002 in DESCRIPTION SPECIFICATION OIL PUMP Clearance Over Rotors End Face MAX 095 mm 0 003...

Page 1350: ...Transmission Bolts 46 34 Generator Mounting Bolts M10 Bolts 54 40 M8 Bolts 28 250 Intake Manifold Bolts 12 105 Refer to Procedure for Tightening Sequence DESCRIPTION N m Ft In Lbs Lbs Oil Pan Bolts 1...

Page 1351: ...6958 Adapter Pins 8346 Engine Lifting Studs 8400 Engine Lift Fixture 8347 Front Crankshaft Seal Remover 8511 Front Crankshaft Seal Installer 8348 Handle C 4171 Rear Crankshaft Seal Installer 8349 9 1...

Page 1352: ...Connecting Rod Guides 8507 Crankshaft Damper Installer 8512 Puller 1026 Crankshaft Damper Removal Insert 8513 Chain Tensioner Wedge 8350 Chain Tensioner Pins 8514 Secondary Chain Holder 8515 DR ENGINE...

Page 1353: ...r 8387 Idler Shaft Remover 8517 Valve Spring Compressor Adapters 8519 Valve Spring Tester C 647 Dial Indicator C 3339 Valve Spring Compressor C 3422 B Bore Size Indicator C 119 Oil Pressure Gauge C 32...

Page 1354: ...nt filter from hous ing 5 Clean inside of housing before replacing ele ment Housing Assembly 1 Loosen clamp Fig 7 and disconnect air duct at air cleaner cover 2 Lift entire housing assembly from 4 loc...

Page 1355: ...nd acceptable limits replace the cylinder heads REMOVAL REMOVAL LEFT CYLINDER HEAD 1 Disconnect the negative cable from the battery 2 Raise the vehicle on a hoist 3 Disconnect the exhaust pipe at the...

Page 1356: ...to 9 ENGINE VALVE TIMING TIM ING BELT CHAIN AND SPROCKETS REMOVAL 19 Remove the cylinder head access plug Fig 12 20 Remove the left side secondary chain guide Refer to 9 ENGINE VALVE TIMING TIMING BEL...

Page 1357: ...he crankshaft until the damper timing mark is aligned with TDC indicator mark Fig 13 12 Verify the V8 mark on the camshaft sprocket is at the 12 o clock position Fig 14 Rotate the crankshaft one turn...

Page 1358: ...l for any reason A damaged target wheel can result in a vehicle no start condition Fig 14 Camshaft Sprocket V8 Marks 1 LEFT CYLINDER HEAD 2 RIGHT CYLINDER HEAD Fig 15 Using Special Tool 8515 to Hold C...

Page 1359: ...threads are necked down the bolts should be replaced Necking can be checked by holding a straight edge against the threads If all the threads do not contact the scale the bolt should be replaced Fig 1...

Page 1360: ...COUS CLUTCH INSTALLATION 17 Install the cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 18 Reinstall the master cylinder and booster assembly Refer to section 5...

Page 1361: ...N m 35 ft lbs Tighten bolts 11 14 25 N m 18 ft lbs Step 3 Tighten bolts 1 10 90 degrees Tighten bolts 11 14 30 N m 22 ft lbs 7 Position the secondary chain onto the camshaft drive gear making sure on...

Page 1362: ...cylinder heads are still installed DO NOT force fully rotate the camshafts or crankshaft indepen dently of each other Severe valve and or piston damage can occur CAUTION When removing the cam sprocke...

Page 1363: ...may slide downward mark the rocker arms before removing camshaft 9 Remove the camshaft bearing caps and the camshaft INSTALLATION 1 Lubricate camshaft journals with clean engine oil NOTE Position the...

Page 1364: ...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 28 NOTE When gripping the camshaft place the pliers...

Page 1365: ...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 chain wedge...

Page 1366: ...hydraulic tensioner ratchet over exten sion Requiring timing chain cover removal to re set the tensioner ratchet 1 Remove the cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S...

Page 1367: ...side working inward loosen the camshaft bearing cap retaining bolts 1 2 turn at a time Repeat until all load is off the bearing caps CAUTION DO NOT STAMP OR STRIKE THE CAM SHAFT BEARING CAPS SEVERE DA...

Page 1368: ...or the sprocket areas 7 Using the adjustable pliers rotate the cam shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket Install the sprocket onto the camshaft Fig...

Page 1369: ...g 37 Camshaft Sprocket Installation 1 ADJUSTABLE PLIERS 2 CAMSHAFT DOWEL Fig 38 Tightening Right Side Cam Sprocket Retaining Bolt 1 TORQUE WRENCH 2 SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 LEFT CAMS...

Page 1370: ...jector harness in front of cylinder 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 ga...

Page 1371: ...rness retaining clips 6 Install the resonator and air inlet hose 7 Connect negative cable to battery INTAKE EXHAUST VALVES SEATS DESCRIPTION The valves are made of heat resistant steel and have chrome...

Page 1372: ...Ping is heard Take reading on torque wrench at this instant Multiply this reading by two This will give the spring load at test length Fractional measurements are indicated on the table for finer adj...

Page 1373: ...juster a Check lash adjusters for sponginess while installed in cylinder head and cam on camshaft at base circle Depress part of rocker arm over adjuster Normal adjusters should feel very firm Spongy...

Page 1374: ...VAL 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 hydraulic lash adjusters...

Page 1375: ...VH an enhanced compacted graphite 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...

Page 1376: ...use a dial bore gauge to measure each cylinder bore diameter To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in INCRE MENTS is required If a bore...

Page 1377: ...of the engine The F s near the piston wrist pin bore should point to the front of the engine 4 Install the lower bearing insert in the bearing cap The lower insert must be dry Place strip of Plas tig...

Page 1378: ...he proper 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 flang...

Page 1379: ...ankshaft from the engine the engine must be removed from the vehicle 1 Remove the engine Refer to 9 ENGINE REMOVAL 2 Remove the engine oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL CAUTION D...

Page 1380: ...BLOCK CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE for proper bearing selections 1 Lubricate upper main bearing halves with clean engine oil CAUTION When installing crankshaft use care not to damage be...

Page 1381: ...to 9 ENGINE ENGINE BLOCK CRANKSHAFT STAN DARD PROCEDURE 9 Install the connecting rods and measure side clearance Refer to 9 ENGINE ENGINE BLOCK CONNECTING ROD BEARINGS STANDARD PROCEDURE 10 Position t...

Page 1382: ...target wheel is mounted to the number 8 counter weight on the crankshaft NOTE Service main bearings are coded These codes identify what size grade the bearing is MAIN BEARING SELECTION CHART 4 7L GRAD...

Page 1383: ...8511 remove crankshaft front seal Fig 65 INSTALLATION CAUTION To prevent severe damage to the Crank shaft Damper or Special Tool 8512 thoroughly clean the damper bore and the crankshaft nose before in...

Page 1384: ...eal surface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth CAUTION Use extreme caution when crankshaft polishing is necessary...

Page 1385: ...a hammer tap the seal into place Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore 4 Install the flexplate 5 Install the transmission Fig...

Page 1386: ...r of the cylinder bore at a point 38 0 mm 1 5 inches below top of bore Start perpendicular across or at 90 degrees to the axis of the crankshaft at point A and then take an additional bore reading 90...

Page 1387: ...onnecting rod cap Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed Remove piston from cylinder bore Repeat this procedure for each piston being removed CAUTION Car...

Page 1388: ...anks The connect ing rod oil slinger slot faces the front of the engine Fig 75 6 Wipe cylinder bore clean and lubricate with engine oil 7 Rotate crankshaft until connecting rod journal is on the cente...

Page 1389: ...inch from bottom of cylinder bore 3 Using a piston to ensure that the ring is squared in the cylinder bore slide the ring downward into the cylinder 4 Using a feeler gauge check the ring end gap Fig 7...

Page 1390: ...ring groove and the expander ring Hold end firmly and press down the portion to be installed until side rail is in position Repeat this step for the lower side rail 10 Install No 2 intermediate piston...

Page 1391: ...threaded onto the shaft first Then the roller bearing is placed onto the threaded rod The hard ened bearing surface of the bearing MUST face the nut Then the hardened washer slides onto the threaded r...

Page 1392: ...e the left hand exhaust pipe from exhaust manifold 3 Loosen the right hand exhaust manifold to ex haust pipe retaining bolts 4 Remove the eight bolts retaining structural cover Fig 85 in the sequence...

Page 1393: ...2 Raise the engine far enough to be able to remove the left and right engine mounts 13 Remove the 8 mount to engine attaching bolts 14 Remove the engine mounts 4WD 1 Disconnect the negative cable from...

Page 1394: ...the front axle Torque nuts to 94 N m 70 ft lbs 2 Raise the front axle into the frame and install the left and right side through bolts Torque nuts to 94 N m 70 ft lbs 3 Insert the two upper through bo...

Page 1395: ...t attach the front axle to the left engine bracket to 101 N m 75 ft lbs 9 Install the oil drain trough 10 Install the engine oil filter 11 Install the front crossmember 12 Install the skid plate 13 Lo...

Page 1396: ...pound must be applied to the bolts before installation 1 Install the two bolts that attach the transmis sion mount to the transmission bracket 2 Torque the bolts to 61N m 45 ft lbs torque 3 Lower the...

Page 1397: ...alve mounted inside the oil pump housing For lubrication flow refer to Fig 92 Fig 92 Engine Oil Lubrication System 1 LEFT CYLINDER HEAD OIL GALLERY 2 OIL PRESSURE SENSOR LOCATION 3 TO LEFT CYLINDER HE...

Page 1398: ...ery Block Main Oil Gallery 1 Crankshaft Main Journal 2 Left Cylinder Head 3 Right Cylinder Head Crankshaft Main Journals Crankshaft Rod Journals Crankshaft Number One Main Journal 1 Front Timing Chain...

Page 1399: ...ead cover Cap or plug the PCV valve grommet 3 Attach an air hose with pressure gauge and regulator to the dipstick tube CAUTION Do not subject the engine assembly to more than 20 6 kPa 3 PSI of test p...

Page 1400: ...ED ENGINE OIL PROPERLY ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API SERVICE GRADE CERTIFI...

Page 1401: ...vehicle on safety stands 3 Remove oil fill cap 4 Place a suitable drain pan under crankcase drain 5 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for str...

Page 1402: ...sing special tool 8534 to pro vide clearance to remove oil pan NOTE Do not pry on oil pan or oil pan gasket Gas ket is integral to engine windage tray and does not come out with oil pan 9 Remove the o...

Page 1403: ...ATION The oil pressure sensor uses two circuits They are A signal to the PCM relating to engine oil pres sure A sensor ground through the PCM s sensor return The oil pressure sensor returns a voltage...

Page 1404: ...r If the outer rotor diameter measures at 85 925 mm 3 382 in or less the oil pump assembly must be replaced 5 Measure the thickness of the inner rotor Fig 103 If the inner rotor thickness measures at...

Page 1405: ...otor cavity with engine oil 5 If oil pressure is low and pump is within spec ifications inspect for worn engine bearings or other causes for oil pressure loss Fig 103 Measuring Inner Rotor Thickness F...

Page 1406: ...LTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water at the suspected leak area 3 If a change in RPM is observed the area of the suspected leak has been found 4...

Page 1407: ...r straps 5 Install throttle body assembly 6 Install throttle cable bracket 7 Connect throttle cable and speed control cable to throttle body 8 Install fuel rail Refer to 14 FUEL SYSTEM FUEL DELIVERY F...

Page 1408: ...e air cleaner assembly resonator assem bly and air inlet hose 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove A C compressor Refer to 24 HEAT ING AIR COND...

Page 1409: ...d Right ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE 1 Stud Qty 2 25 N m 18 ft lbs 4 Nut Qty 2 8 N m 72 in lbs then loosen 45 degrees 2 Bolt Qty 4 5 Nut Qty 2 3 Stud Qty 2 9 160 ENGINE 4 7L DR EXHA...

Page 1410: ...gine compartment CLEANING 1 Clean the exhaust manifold using a suitable cleaning solvent then allow to air dry 2 Clean all gasket residue from the manifold mating surface INSPECTION 1 Inspect the exha...

Page 1411: ...then loosen 45 degrees 5 Install starter and fasteners 6 Connect exhaust pipe to manifold 7 Connect heater hoses at engine 8 Install fastener attaching A C accumulator 9 Install A C compressor and fas...

Page 1412: ...25 N m 18 ft lbs CAUTION Over tightening heat shield fasteners may cause shield to distort and or crack 4 Install exhaust manifold heat shield Fig 113 Tighten fasteners to 8 N m 72 in lbs then loosen...

Page 1413: ...ntegral thirty tooth sprockets and a fifty tooth sprocket that is splined to the assembly The spline joint is a non serviceable press fit anti rattle type The idler sprocket assembly spins on a statio...

Page 1414: ...ine clockwise until maximum tensioner piston extension is obtained Measure the distance between the secondary timing chain ten sioner housing and the step ledge on the piston Fig 115 The measurement a...

Page 1415: ...position the engine is at TDC cylinder 1 on the compression stroke 4 If both of the camshaft drive gears are off in the same or opposite directions the primary chain or both secondary chains are at f...

Page 1416: ...or the sprocket areas 5 Using a suitable pair of adjustable pliers rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear Fig 119 CAUTION Rem...

Page 1417: ...ISCOUS CLUTCH REMOVAL 4 Disconnect both heater hoses at timing cover 5 Disconnect lower radiator hose at engine 6 Remove crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 7 Rem...

Page 1418: ...system Refer to 7 COOLING STANDARD PROCEDURE 11 Connect the battery negative cable TIMING BELT CHAIN AND SPROCKETS REMOVAL 1 Disconnect negative cable from battery 2 Drain cooling system Refer to 7 C...

Page 1419: ...loosening or tightening camshaft sprocket Do not place the target wheel near a magnetic source of any kind A damaged or magnetized tar get wheel could cause a vehicle no start condition Fig 125 Camsh...

Page 1420: ...ly 45 degrees counterclockwise to a neu tral position 16 Remove idler sprocket assembly bolt 17 Slide the idler sprocket assembly and crank sprocket forward simultaneously to remove the pri mary and s...

Page 1421: ...ensioner While continuing to hold pawl back Push ratchet device to approximately 2 mm from the tensioner body Install Special Tool 8514 lock pin into hole on front of tensioner Slowly open vise to tra...

Page 1422: ...n engine oil 10 Install all chains crankshaft sprocket and idler sprocket as an assembly Fig 134 After guid ing both secondary chains through the block and cyl inder head openings affix chains with a...

Page 1423: ...ks are at 12 o clock Fig 131 20 Lubricate all three chains with engine oil 21 After installing all chains it is recommended that the idler gear end play be checked Fig 137 The end play must be within...

Page 1424: ...4 Using Special Tool 8517 Slide Hammer remove the idler shaft INSTALLATION 1 Thoroughly clean the idler shaft bore 2 Position the idler shaft in the bore NOTE The two lubrication holes in the idler sh...

Page 1425: ...LINDER HEAD COVER S REMOVAL 196 INSTALLATION 196 INTAKE EXHAUST VALVES SEATS DESCRIPTION DESCRIPTION VALVE GUIDES 197 DESCRIPTION 197 STANDARD PROCEDURE REFACING 197 REMOVAL 198 INSTALLATION 198 ROCKE...

Page 1426: ...L STANDARD PROCEDURE ENGINE OIL SERVICE 215 OIL FILTER REMOVAL 216 INSTALLATION 217 OIL PAN REMOVAL 217 INSTALLATION 217 OIL PUMP REMOVAL 218 CLEANING 218 INSPECTION 218 INSTALLATION 219 INTAKE MANIFO...

Page 1427: ...plugs The cyl inders are numbered from front to rear 1 3 5 7 on the left bank and 2 4 6 8 on the right bank The firing order is 1 8 4 3 6 5 7 2 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAG...

Page 1428: ...NGINE DIAGNOSIS PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1 Weak battery 1 Charge or replace as necessary 2 Corroded or loose battery connections 2 Clean and tighten batter...

Page 1429: ...nspect and replace as necessary 8 Faulty coil 8 Refer to 8 ELECTRICAL IGNITION CONTROL IGNITION COIL REMOVAL 1 ENGINE MISSES ON ACCELERATION 1 Spark plugs dirty or incorrectly gapped 1 Refer to 8 ELEC...

Page 1430: ...SE 1 Insufficient oil supply 1 Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 2 Low oil pressure 2 Check oil pump if Ok check rod and main bearings for excessive wear 3 Thin or diluted oil 3 Change o...

Page 1431: ...structions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 psi recom mended 7 Perform the test procedures on each cylinder according to...

Page 1432: ...orrect oil level 2 Faulty oil pressure sending unit 2 Replace sending unit 3 Low oil pressure 3 Check pump and bearing clearance 4 Clogged oil filter 4 Replace oil filter 5 Worn oil pump 5 Replace as...

Page 1433: ...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 en...

Page 1434: ...nspect oil pickup tube and pump 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 fast...

Page 1435: ...g to 34 N m 25 ft lbs torque 13 Install a new oil filter 14 Fill engine crankcase with the specified amount and grade of oil Refer to LUBRICATION MAINTENANCE SPECIFICATIONS 15 Connect the negative cab...

Page 1436: ...COVER INSTALLATION 10 Install the starter and connect the starter wires Refer to 8 ELECTRICAL STARTING STARTER MOTOR INSTALLATION 11 Install exhaust pipe to manifold 12 Lower the vehicle 13 Remove eng...

Page 1437: ...Bearing to Journal Clearance Standard No 1 0 040 0 080 mm 0015 003 in No 2 0 050 0 090 mm 0 0019 0035 in No 3 0 040 0 080 mm 0015 003 in No 4 0 050 0 090 mm 0 0019 0035 in No 5 0 040 0 080 mm 0015 00...

Page 1438: ...0 460 in Stem Diameter Intake 7 935 7 953 mm 0 312 0 313 in DESCRIPTION SPECIFICATION Exhaust 7 905 7 925 mm 0 311 0 312 in Guide Bore 7 975 8 000 mm 0 313 0 314 on Stem to Guide Clearance Intake 0 0...

Page 1439: ...TON PINS Clearance in Piston 0 009 0 018 mm 0 00035 0 00070 in Diameter 24 0 24 003 mm 0 9448 0 9449 in Length 69 75 70 25 mm 2 74 2 76 in PISTON RINGS Ring Gap Compression Ring Top 0 23 0 38 mm 0 009...

Page 1440: ...nting Bolt 55 40 Intake Manifold Bolts Refer to Procedure DESCRIPTION N m Ft In Oil Pan Bolts 12 105 Oil Dipstick Tube 12 105 Oil Pan Drain Plug 34 25 Oil Pump Attaching Bolts 28 250 Oil Pump Pickup T...

Page 1441: ...A Bore Size Indicator C 119 Puller 8454 Crankshaft Damper Installer 8512 Crankshaft Damper Removal Insert 8513 A Dial Indicator C 3339 Handle C 4171 Oil Pressure Gauge C 3292 Piston Ring Compressor C...

Page 1442: ...r Crankshaft Seal Remover 8506 Valve Spring Compressor C 3422 B Valve Spring Tester C 647 Adapter Valve Spring Compressor Off vehicle 8464 ENGINE SUPPORT FIXTURE 8534 ENGINE LIFT FIXTURE 8984 REAR CAM...

Page 1443: ...rque 5 If any other hose clamps were removed from air intake system tighten them to 3 4 N m 30 in lbs torque 6 If any bolts were removed from air resonator housing or air intake tubing tighten them to...

Page 1444: ...llowing the procedures supplied with the tool kit REMOVAL 1 Disconnect the battery negative cable 2 Drain cooling system 3 Remove the air cleaner resonator and duct work 4 Remove the generator 5 Remov...

Page 1445: ...ps in those locations only 3 Remove cylinder head cover retaining bolts and ground straps 4 Remove cylinder head cover NOTE The gasket may be used again provided no cuts tears or deformation has occur...

Page 1446: ...ly a small amount of Prussian blue to the valve seat insert the valve into the cylinder head while applying light pressure on the valve rotate the valve Remove the valve and examine the valve face If...

Page 1447: ...sequence Center center left center right left right CAUTION The rocker shaft assemblies are not interchangeable between intake and exhaust The intake rocker arms are marked with an I 3 Remove the roc...

Page 1448: ...ease air charge in cylinder 5 Remove spring compressor tool 9065 CAUTION Verify that the pushrods are fully seated into lifter and rocker arm Recheck after rocker arm shaft has been torqued to specifi...

Page 1449: ...t steps above 6 Determine out of roundness by comparing the difference between each measurement 7 If cylinder bore taper does not exceed 0 025 mm 0 001 inch and out of roundness does not exceed 0 025...

Page 1450: ...er reused must be installed in the same position from which it was removed When camshaft is replaced all of the lifters must be replaced 8 Install lifters and retainer assembly 9 Install both left and...

Page 1451: ...LT CHAIN AND SPROCKETS INSTALLATION 11 Install oil pump and pickup Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TION 12 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHA...

Page 1452: ...shroud attaching fasteners 6 Remove radiator cooling fan and shroud Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 7 Remove crankshaft damper bolt 8 Remove damper using Special Tools 8513A Insert and...

Page 1453: ...no further inspection can be done until dis assembled Refer to 9 ENGINE DIAGNOSIS AND TESTING under the Oil Leak row for components inspections on possible causes and corrections 7 After the oil leak...

Page 1454: ...rrectly select the proper size piston a cyl inder bore gauge capable of reading in 0 003 mm 0001 in INCREMENTS is required If a bore gauge is not available do not use an inside micrometer 2 Measure th...

Page 1455: ...or each piston being removed CAUTION Care must be taken not to nick crank shaft journals as engine damage may occur 6 Immediately after piston and connecting rod removal install bearing cap on the mat...

Page 1456: ...r bore using a ham mer handle While at the same time guide connect ing rod into position on rod journal CAUTION Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused Always replace the...

Page 1457: ...0 5455 0 6245mm 0 10mm 0 0214 0 0245 in 0 004 in Ring Position Ring Gap Wear Limit Upper Ring 0 23 0 38mm 0 43mm 0 0090 0 0149 in 0 017 in Intermediate Ring 0 35 0 60mm 0 74mm 0 0137 0 0236 in 0 029 i...

Page 1458: ...5 Remove upper fan shroud 6 Using Special Tools 6958 Spanner with Adapter Pins 8346 loosen fan and viscous assembly from water pump 7 Remove fan and viscous assembly 8 Remove crankshaft damper bolt 9...

Page 1459: ...s retaining structural cover 3 Remove the structural cover INSTALLATION CAUTION The structural cover must be installed as described in the following steps Failure to do so will cause severe damage to...

Page 1460: ...e 11 Remove the 6 through bolts 12 Raise the engine far enough to be able to remove the left and right engine mounts 13 Remove the engine mounts INSTALLATION 2WD 1 Install insulator on the engine Fig...

Page 1461: ...23 5 Loose assemble the 3 bolts that attach the front axle to the left engine bracket 6 Loose assemble the lower through bolts 7 Torque the nuts for the 4 through bolts to 101 N m 75 ft lbs 8 Torque t...

Page 1462: ...smember 6 Remove the mount INSTALLATION NOTE Threadlocking compound must be applied to the bolts before installation 1 Install the two bolts that attach the transmis sion mount to the transmission bra...

Page 1463: ...OSIS AND TESTING DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 1 Remove oil pressure sending unit and install gauge assembly C 3292 2 Run engine until thermostat opens 3 Oil Pressure Curb Idle 25...

Page 1464: ...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 necessary The followi...

Page 1465: ...old engine is not accurate To ensure proper lubrication 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...

Page 1466: ...wl to intake manifold 7 Raise engine using special tool 8534 to pro vide clearance to remove oil pan NOTE Do not pry on oil pan or oil pan gasket Gas ket is integral to engine windage tray and does no...

Page 1467: ...e outer rotor and the body Fig 28 If the measurement is 0 235mm 0 009 in or more the oil pump assembly must be replaced 4 Install the inner rotor in the into the oil pump body Measure the clearance be...

Page 1468: ...tors for the follow ing components Manifold Absolute Pressure MAP Sensor Intake Air Temperature IAT Sensor Throttle Position TPS Sensor Coolant Temperature CTS Sensor 4 Disconnect brake booster hose a...

Page 1469: ...Raise engine enough to remove manifolds CAUTION Do not damage engine harness while raising the engine 7 Remove heat shield 8 Remove manifold bolts 9 Remove manifold and gasket CLEANING Clean mating su...

Page 1470: ...12 Install both heater hoses 13 Install radiator fan shroud 14 Install the fan and fan drive assembly 15 Install the accessory drive belt 16 Install the coolant bottle and washer bottle 17 Install the...

Page 1471: ...venly over their respec tive shafts and check alignment of timing marks 7 Install the camshaft bolt Tighten the bolt to 122 N m 90 ft lbs torque 8 Remove tensioner pin Again verify align ment of timin...

Page 1472: ...RATION CYLINDER HEAD 243 OPERATION CYLINDER HEAD COVER GASKET 243 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET FAILURE 243 REMOVAL 244 CLEANING 244 INSPECTION 244 INSTALLATION 244 CYLINDER HEAD COVER S...

Page 1473: ...MBLY 272 INSPECTION 272 ASSEMBLY 274 INSTALLATION 274 INTAKE MANIFOLD DESCRIPTION 274 OPERATION 274 DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKAGE 274 REMOVAL 275 CLEANING 275 INSPECTION 275 INSTALLATI...

Page 1474: ...diagnosis Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts Information concerning additional tes...

Page 1475: ...test and if necessary inspect fuel injector s and driver circuits Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP DIAGNOSIS AND TESTING 3 Low or no engine compression 3 Perform cylinder compression p...

Page 1476: ...er or replace spark plug cables Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CABLE DIAGNOSIS AND TESTING 6 Faulty coil 6 Test and replace if necessary Refer to 8 ELECTRICAL IGNITION CONTROL IGNIT...

Page 1477: ...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 en...

Page 1478: ...nspect oil pickup tube and pump 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 fast...

Page 1479: ...orrect oil level 2 Faulty oil pressure sending unit 2 Replace sending unit 3 Low oil pressure 3 Check pump and bearing clearance 4 Clogged oil filter 4 Replace oil filter 5 Worn oil pump 5 Replace as...

Page 1480: ...iller cap Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and...

Page 1481: ...t leakage 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 wil...

Page 1482: ...rit stones is the best tool for this job In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring and scratches Usually a few strokes will clean up a b...

Page 1483: ...ct the starter wires Remove starter motor Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 28 Remove the dust shield and transmission inspection cover 29 Remove drive plate to converter bolts Auto...

Page 1484: ...ANS COOLER INSTALLATION 36 Connect the transmission cooler lines 37 If equipped install the condenser Refer to 24 HEATING AIR CONDITIONING PLUMBING A C CONDENSER INSTALLATION 38 Evacuate and charge th...

Page 1485: ...of Round Max 0 127 mm 0 001 in Taper Max 0 0254 mm 0 001 in Bearing Clearance Journal 1 0 013 0 038 mm DESCRIPTION SPECIFICATION 0 0005 0 0015 in Journals 2 5 0 013 0 051 mm 0 0005 0 002 in Service Li...

Page 1486: ...22 962 mm 0 9035 0 9040 in Clearance to bore 0 0279 0 0610 mm DESCRIPTION SPECIFICATION 0 0011 0 0024 in Dry Lash 1 524 5 334 mm 0 060 0 210 in Push Rod Length 175 64 176 15 mm 6 915 6 935 in OIL PRES...

Page 1487: ...60 0 061 in Oil Ring Steel Rails Max 0 447 0 473 mm 0 018 0 019 in VALVE TIMING Exhaust Valve Closes ATDC 33 Opens BBDC 56 Duration 269 DESCRIPTION SPECIFICATION Intake Valve Closes ATDC 62 Opens BBDC...

Page 1488: ...nting Bolt 41 30 Intake Manifold Bolts Refer to Procedure Oil Pan Bolts 24 215 Oil Pan Drain Plug 34 25 Oil Pump Attaching Bolts 41 30 Oil Pump Cover Bolts 11 95 DESCRIPTION N m Ft Lbs In Lbs Rear Ins...

Page 1489: ...Engine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A Adaptor 6633 Adaptor 6716A Valve Guide Sleeve C 3973 Dial Indicator C 3339 Puller C 3688 Puller 1026 Crankshaft Damper Removal Inse...

Page 1490: ...Distributor Bushing Puller C 3052 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 Pressure Tester Kit 7700 Blo...

Page 1491: ...r 2 Lift entire housing assembly from 4 locating pins Fig 5 INSTALLATION 1 Install filter element into housing 2 Position housing cover into housing locating tabs Fig 4 3 Pry up 4 spring clips Fig 4 a...

Page 1492: ...een a cylinder and the adjacent water jacket Possible indications of the cylinder head gasket leaking between adjacent cylinders are Loss of engine power Engine misfiring Poor fuel economy Possible in...

Page 1493: ...OLDS INTAKE MANIFOLD REMOVAL and throttle body as an assembly Dis card the flange side gaskets and the front and rear cross over gaskets 16 Remove exhaust manifolds Refer to 9 ENGINE MANIFOLDS EXHAUST...

Page 1494: ...nstall the air cleaner 23 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 24 Connect the negative cable to the battery 25 Start engine check for leaks CYLINDER HEAD COVER S REMOVAL NOTE A st...

Page 1495: ...cator 2 Attach dial indicator Tool C 3339 to cylinder head and set it at right angles to valve stem being measured Fig 11 3 Move valve to and from the indicator The total dial indicator reading should...

Page 1496: ...Inspect the remaining margin after the valves are refaced Fig 13 Valves with less than 1 190 mm 0 047 in margin should be discarded VALVE SEATS CAUTION DO NOT un shroud valves during valve seat refac...

Page 1497: ...to obtain specified height and allowable tensions Discard the springs that do not meet specifications REMOVAL 1 Remove the cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 2 Compress valve spring...

Page 1498: ...s removed INSTALLATION 1 Rotate the crankshaft until the V8 mark lines up with the TDC mark on the timing chain case cover This mark is located 147 ATDC from the No 1 firing position 2 Install the pus...

Page 1499: ...move timing case cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL and timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 7 Remove rocker arms 8 R...

Page 1500: ...A TION 14 Install the engine cover 15 Install the A C Condenser if equipped 16 Install the radiator Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 17 Start engine check for leaks CONNECTING ROD BEARI...

Page 1501: ...ll allow the crankshaft to fall damaging 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...

Page 1502: ...ION TRANS AXLE CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings Fig 26 are located in the cylinder block One half of the main bearing is located in the crankshaft main bore the other half of the mat...

Page 1503: ...to position Remove Tool C 3059 3 Install the bearing caps Clean and oil the bolts Tighten the capbolts to 115 N m 85 ft lbs torque 4 Install the oil pump Refer to 9 ENGINE LU BRICATION OIL PUMP INSTAL...

Page 1504: ...The crankshaft rear seal is a two piece viton seal One part of the two piece rear seal is located in a slot in the cylinder block oppsite the crankshaft main bearing cap the second part of the two pie...

Page 1505: ...engine 4 Position the crankshaft into the cylinder block 5 Lightly oil the new lower seal lips with engine oil 6 Install the new lower rear bearing oil seal into the bearing cap with the white paint f...

Page 1506: ...lock and oil pan sealing Fig 33 Apply enough sealant until a small amount is squeezed out Withdraw nozzle and wipe excess seal ant off the oil pan seal groove 10 Immediately install the oil pan Refer...

Page 1507: ...AULIC TAPPETS Before disassembling any part of the engine to cor rect tappet noise check the oil pressure If vehicle has no oil pressure gauge install a reliable gauge at the pressure sending unit The...

Page 1508: ...generates a noise very much like a light tappet noise during normal operation Care must be taken to ensure that tappets are mak ing the noise If more than one tappet seems to be noisy it s probably no...

Page 1509: ...NI FOLD INSTALLATION 5 Install rocker arms Refer to 9 ENGINE CYL INDER HEAD ROCKER ARM ADJUSTER ASSY INSTALLATION 6 Install cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S IN...

Page 1510: ...ing rods must be removed from top of cylinder block When removing the assemblies from the engine rotate crankshaft so that the connecting rod is centered in cylinder bore and at BDC Be careful not to...

Page 1511: ...g gap should be between 0 254 0 508 mm 0 010 0 020 in The second compression ring gap should be between 0 508 0 762 mm 0 020 0 030 in The oil ring gap should be 0 254 1 270 mm 0 010 0 050 in c Rings w...

Page 1512: ...lace installing tool part of Puller Tool Set C 3688 in position and press the vibration damper onto the crankshaft Fig 45 3 Install the crankshaft bolt and washer Tighten the bolt to 244 N m 180 ft lb...

Page 1513: ...le to remove the left and right engine mounts 13 Remove the 8 mount to engine attaching bolts 14 Remove the engine mounts 4WD 1 Disconnect the negative cable from the battery CAUTION Remove the viscou...

Page 1514: ...cous fan Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 9 Reconnect the negative battery cable 4WD NOTE For mount to engine block and left engine bracket to front axle bolts apply MoparT L...

Page 1515: ...NGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 15 Reconnect the negative battery cable REAR MOUNT REMOVAL 1 Raise the vehicle on a hoist 2 Using a suitable jack support transmission 3 Remove the nuts from the...

Page 1516: ...e No 1 main bear ing back up to the left side of the block and into the oil gallery on the left side of the engine Galleries extend downward from the main oil gal lery to the upper shell of each main...

Page 1517: ...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 1518: ...essure that provide the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures 10 If the leakage occurs at the rear oil seal a...

Page 1519: ...used 1 Position a drain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss Fig 54...

Page 1520: ...l allow easier installation and removal with a screwdriver Fig 56 5 Install the dowels in the cylinder block Fig 57 6 Apply small amount of Mopart Silicone Rubber Adhesive Sealant or equivalent in the...

Page 1521: ...g 59 4 Wash all parts in a suitable solvent and inspect carefully for damage or wear INSPECTION Mating surface of the oil pump cover should be smooth Replace pump assembly if cover is scratched or gro...

Page 1522: ...0 203 mm 0 008 inch or more replace shaft and both rotors Fig 64 Place a straightedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm 0 004 inch or more can be inserted b...

Page 1523: ...r to 9 ENGINE LU BRICATION OIL PAN INSTALLATION INTAKE MANIFOLD DESCRIPTION The aluminum intake manifold Fig 67 is a single plane design with equal length runners and uses a separate plenum therefore...

Page 1524: ...the engine compartment as an assembly 17 Remove and discard the flange side gaskets and the front and rear end seals 18 Remove the throttle body bolts and lift the throttle body off the intake manifol...

Page 1525: ...12 to 8 N m 72 in lbs Step 3 Check all bolts are torqued to 8 N m 72 in lbs Step 4 Tighten all bolts in sequence to 16 N m 12 ft lbs Step 5 Check all bolts are torqued to 16 N m 12 ft lbs 9 Install c...

Page 1526: ...6 Remove bolts nuts and washers attaching manifold to cylinder head 7 Remove manifold from the cylinder head CLEANING Clean mating surfaces on cylinder head and mani fold Wash with solvent and blow dr...

Page 1527: ...e NOTE Special Tool 6635 must be used to align the front cover and seal with the crankshaft 4 Position the special tool 6635 onto the crank shaft Fig 75 5 Tighten chain case cover bolts to 41 N m 30 f...

Page 1528: ...ion With the cylinder heads removed apply 20 N m 15 ft lbs torque in the reverse direc tion Note the amount of chain movement Fig 77 4 Install a new timing chain if its movement exceeds 3 175 mm 1 8 i...

Page 1529: ...R S REMOVAL REMOVAL CYLINDER HEAD COVER 304 REMOVAL ROCKER HOUSING 304 CLEANING 304 INSPECTION 304 INSTALLATION INSTALLATION CYLINDER HEAD COVER 304 INSTALLATION ROCKER HOUSING 304 INTAKE EXHAUST VALV...

Page 1530: ...TION DESCRIPTION 337 OPERATION 337 DIAGNOSIS AND TESTING ENGINE OIL PRESSURE 338 OIL STANDARD PROCEDURE STANDARD PROCEDURE ENGINE OIL LEVEL 341 STANDARD PROCEDURE ENGINE OIL SERVICE 341 OIL COOLER LIN...

Page 1531: ...d o ring fittings at lubrication oil access points The engine Fig 1 is manufactured with the cylinders being a non sleeved type cylinder However one approved service method is to bore out the cylinder...

Page 1532: ...new bearing Tighten cap to proper torque 10 Worn bearings or wrong bearings installed 10 Inspect and replace connecting rod or main bearings Check and replace directed piston cooling nozzles 11 Direc...

Page 1533: ...gine overloaded 3 Verify the engine load rating is not being exceeded 4 Improperly operating injectors 5 Check and replace misfiring inoperative injectors EXCESSIVE VIBRATION 1 Loose or broken engine...

Page 1534: ...em Check entire air intake system including all hoses and tubes for cracks loose clamps and or holes in rubber ducts Also check intake manifold for loose mounting hardware Diagnostic Trouble Codes DTC...

Page 1535: ...r to Powertrain Diagnostic Procedures Information In very cold ambient temperatures engine block heater is malfunctioning if equipped Refer to 7 COOLING ENGINE ENGINE BLOCK HEATER REMOVAL Engine coola...

Page 1536: ...ning Refer to Powertrain Diagnostic Procedures Information Internal engine damage scuffed cylinder Analyze engine oil and inspect oil filter to locate area of probable damage Restriction in fuel suppl...

Page 1537: ...Tool 9010 to remove the injector and cop per sealing washer 8 Install the exhaust rocker lever and torque to 43 N m 32 ft lbs 9 Cover the remaining rocker levers with clean shop towels to prevent any...

Page 1538: ...etallic surfaces It will not cure if left in the uncovered tube The anaerobic material is for use between two machined surfaces Do not use on flexible metal flanges MOPARt GASKET SEALANT Mopart Gasket...

Page 1539: ...isconnect engine grid heater harness at grid heater relays 3 Disconnect electrical connections from rear of alternator 4 Recover A C refrigerant Refer to 24 HEAT ING AIR CONDITIONING PLUMBING STAN DAR...

Page 1540: ...e cylinder 5 and 6 fuel injector 49 Remove rocker housing 50 Remove two cylinder head bolts in location 4 and 12 according to the diagram below and install Tool 9009 Fig 3 51 Loosen but do not remove...

Page 1541: ...ler mounting bolts to 2 N m 17 in lbs 24 Connect the charge air cooler piping Torque all clamps to 8 N m 72 in lbs 25 Connect the a c refrigerant lines to the a c condenser if equipped 26 Install the...

Page 1542: ...rance Intermediate Min 0 045 mm 0018 inch Max 0 095 mm 0 0037 inch Oil Control Min 0 040 mm 0016 inch Max 0 085 mm 0 0033 inch DESCRIPTION SPECIFICATION Piston Pins Pin Diameter Min 39 990 mm 1 5744 i...

Page 1543: ...Fuel Drain Line Banjo 24 18 Fuel line rail to cylinder head 30 22 Fuel line pump to fuel rail 30 22 Injector fuel line brace 24 18 Fuel rail holddown bolt 24 18 Oil Pan Bolts 28 21 Oil Pan Drain Plug...

Page 1544: ...ngine Support Fixture 8534 TAPPET INSTALLATION TOOL 8502 STEEL BRACKET 8534 A Compression Test Adapter 9007 Engine Lift Bracket 9009 Fuel Injector Remover 9010 DR ENGINE 5 9L DIESEL 9 295 ENGINE 5 9L...

Page 1545: ...FUEL BLOCKOFF PLUG 9011 FUEL TEST FITTING 9013 Fuel Injector Tube Connector Remover 9015 TURBO TEST ADAPTER 9022 9 296 ENGINE 5 9L DIESEL DR ENGINE 5 9L DIESEL Continued...

Page 1546: ...f Filter Minder After engine has been shut off a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element has experienced A drop in air pres...

Page 1547: ...t rub ber hose connection Cap off open ports to prevent intrusion of dirt or foreign material 10 Disconnect turbocharger oil supply line at the turbocharger end Cap off open ports to prevent intrusion...

Page 1548: ...the fuel rail and at the cylinder head c Remove the fuel line bracket bolts at the intake manifold cover 30 Remove the fuel rail as follows a Remove fuel rail pressure sensor connector b Remove banjo...

Page 1549: ...L INJECTOR REMOVAL 41 Remove rocker housing bolts and rocker hous ing and gasket 42 Reinstall the engine lift bracket at the rear of cylinder head Torque to 77 N m 57 ft lbs 43 Remove twenty six 26 cy...

Page 1550: ...to end is 0 305 mm 0 012 inch Fig 13 and maximum overall variation side to side 0 076 mm 003 in DO NOT proceed with the in chassis overhaul if the cylinder head or block surface is damaged or not fla...

Page 1551: ...to 70 N m 52 ft lbs b Back off 360 degrees in sequence c Torque bolts to 105 N m 77 ft lbs d Re check all bolts to 105 N m 77 ft lbs e Tighten all bolts an additional 1 4 turn 90 4 Install push rods...

Page 1552: ...m 18 ft lbs k Torque rail bolts to 24 Nm 18 ft lbs l Connect fuel pressure sensor 20 Install the engine lift bracket at the rear of cylinder head Torque to 77 N m 57 ft lbs 21 Reposition number 6 fuel...

Page 1553: ...ing a suitable solvent Clean and dry gasket mating surfaces on cylinder head and rocker housing Wipe gasket dry and inspect for re use INSPECTION The cylinder head cover gasket rocker hous ing gasket...

Page 1554: ...g compressor mounting base as shown in Fig 22 4 Install the compressor top plate washer and nut Using a suitable wrench tighten the nut clock wise to compress the valve springs Fig 23 and remove the l...

Page 1555: ...diameter Min 7 027 mm 0 2767 in Max 7 077 mm 0 2786 in Installed valve guide depth Intake Min 0 584 mm 0 023 in Max 1 092 mm 0 043 in Exhaust Min 0 965 mm 0 028 in Max 1 473 mm 0 058 in Fig 24 Valve...

Page 1556: ...proce dure on the remaining cylinders 7 Install new o ring and sealing washer on injec tor 8 Lubricate o ring and injector bore 9 Verify sealing washer shim was removed with old injector 10 Install i...

Page 1557: ...falls within these specifications no adjustment reset is necessary Engine operation within these ranges has no adverse affect on performance emissions fuel economy or level of engine noise 5 If adjust...

Page 1558: ...ghten the nut clock wise Fig 35 to compress the valve springs and remove the collets e Rotate the compressor nut counter clockwise to relieve tension on springs Remove spring com pressor f Remove and...

Page 1559: ...estal fasteners Fig 36 and remove rocker arm and pedestal from cylin der head Mark the arms and pedestals so they can be installed in their original position CAUTION When removing the rocker arms the...

Page 1560: ...the socket are pressed into the tube Fig 41 Roll the push rod on a flat work surface with the socket end hanging off the edge Fig 42 Replace any push rod that appears to be bent Fig 37 Rocker Arm Ass...

Page 1561: ...TANDARD PROCEDURE CYLINDER BLOCK REFACING 1 The combustion deck can be refaced twice The first reface should be 0 25 mm 0 0098 inch If addi tional refacing is required an additional 0 25 mm 0 0098 inc...

Page 1562: ...e cylinder bores immediately after de glazing 11 Rinse the bores until the detergent is removed and blow the block dry with compressed air 12 Check the bore cleanliness by wiping with a white lint fre...

Page 1563: ...blow the block dry Check the bore cleanliness by wiping with a white lint free lightly oiled cloth There should be no grit residue present If the block is not to be used right away coat it with a rus...

Page 1564: ...clean the cylinder bores with a strong solution of laundry detergent and hot water After rinsing blow the block dry with compressed air Wipe the bore with a white lint free lightly oiled cloth Make su...

Page 1565: ...ge or excessive wear Measure the cylinder bores Fig 54 If the cylin der bores exceed the limit Refer to 9 ENGINE EN GINE BLOCK STANDARD PROCEDURE BORE SPECIFICATIONS BORE DIAMETER Min 102 000 mm 4 015...

Page 1566: ...radiator out of engine compartment 12 Remove upper radiator support panel 13 If A C equipped disconnect A C condenser refrigerant lines 14 Disconnect charge air cooler piping from the cooler inlet and...

Page 1567: ...bes and bearing journals for cracks pitting scoring or generally excessive wear Replace any camshaft that exceeds the allowable lim its 2 Measure the bearing journals and lobes Fig 58 CAUTION If Camsh...

Page 1568: ...ock Fig 60 Camshaft Gear Inspect the camshaft gear for cracks gear and hub Fig 61 and chipped broken fretted teeth Fig 62 If replacement is necessary camshaft and gear are replaced as an assembly Refe...

Page 1569: ...iv alent CAUTION When installing the camshaft DO NOT push it in farther than it will go with the thrust washer in place 3 Install the camshaft and thrust plate Align the timing marks as shown Fig 64 4...

Page 1570: ...r engine oil and cool ant leaks CONNECTING ROD BEARINGS STANDARD PROCEDURE CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE 1 Measure the connecting rod bore with bearings removed and the bolts...

Page 1571: ...g 1 0 mm 0 039 inch to 1 5 mm 0 059 inch above the crankshaft Fig 67 WARNING WEAR PROTECTIVE GLOVES TO PRE VENT INJURY CAUTION DO NOT heat the gear longer than 45 minutes 3 Heat the crankshaft gear fo...

Page 1572: ...NT REMOVAL 1 Disconnect both battery negative cables 2 Raise vehicle on hoist 3 Partially drain engine coolant into container suitable for re use Refer to 7 COOLING STAN DARD PROCEDURE 4 Lower vehicle...

Page 1573: ...Stud Bearing Mount to the outside diameter of the seal Do not lubricate the inside diameter of the new seal 4 With the cover supported by wood blocks install the seal into the rear of the cover using...

Page 1574: ...ces must be completely dry when the seal is installed Use a soap and water solution on outside diameter of seal to ease assembly 1 Clean the crankshaft journal with a suitable solvent and dry with a c...

Page 1575: ...in the seal service kit install the align ment tool into the retainer and install to the cylinder block Fig 76 using a new gasket Tighten the six 6 mounting bolts by hand 4 The seal alignment tool is...

Page 1576: ...Tappet Replacement Kit 1 Remove camshaft Refer to 9 ENGINE EN GINE BLOCK CAMSHAFT BEARINGS IN BLOCK REMOVAL 2 Insert the trough provided with tool kit the full length of the camshaft bore Fig 79 Make...

Page 1577: ...t stem diameter Replace the tappet if it falls below the minimum size Fig 82 INSTALLATION 1 Insert the trough the full length of the cam shaft bore Again make sure the cap end goes in first and the op...

Page 1578: ...all the camshaft Refer to 9 ENGINE ENGINE BLOCK CAMSHAFT BEARINGS IN BLOCK INSTALLATION PISTON CONNECTING ROD DESCRIPTION PISTONS The piston Fig 87 is constructed of aluminum and is gravity cast free...

Page 1579: ...the same engine STANDARD PROCEDURE HEAD GASKET SELECTION 1 Measure piston protrusion for all six pistons 2 Calculate the average piston protrusion Maxi mum allowable protrusion is 0 516 mm 0 020 inch...

Page 1580: ...ooves skirt and pin bore Measure the piston skirt diameter Fig 90 If the piston is out of limits replace the piston The upper groove only needs to be inspected for damage Use a new piston ring to meas...

Page 1581: ...o be installed is at BDC Bottom Dead Cen ter Fig 96 5 Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the numbers on the rod and cap are or...

Page 1582: ...led If the crankshaft does not rotate freely check the installa tion of the rod bearing and the bearing size 12 Measure the side clearance between the con necting rod and the crankshaft Fig 98 DO NOT...

Page 1583: ...ion the oil ring expander in the oil control ring groove bottom groove 6 Install the oil control ring with the end gap OPPOSITE the ends on the expander Fig 101 7 Install the intermediate piston ring...

Page 1584: ...ON FRONT MOUNT REMOVAL 1 Disconnect the battery negative cables 2 Remove the viscous fan drive assembly Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 3 Raise vehicle on hoist 4 Install engine support...

Page 1585: ...1 Mount 2 Insulator 3 Bolt Fig 107 LH Insulator 1 Bolt 2 Insulator 3 Mount Fig 108 LH Insulator 1 Bolt 2 Insulator 3 Mount Fig 109 RH Insulator 1 Mount 2 Insulator 3 Bolt 9 336 ENGINE 5 9L DIESEL DR F...

Page 1586: ...ESCRIPTION NOTE Refer to Fig 111 and Fig 112 for circuit illustrations A gear driven gerotor type oil pump is mounted behind the front gear cover in the lower right portion on the engine OPERATION A g...

Page 1587: ...t cooling nozzles are used Crankshaft internal cross drillings supply oil to the connecting rod journals Another series of transfer drillings intersecting the main oil rifle supply the valve train com...

Page 1588: ...em Circulation 1 TO FILTER 2 FROM FILTER 3 TO MAIN OIL RIFLE 4 CLOSED 5 OPEN 6 TO COOLER 7 FROM PUMP 8 CLOSED 9 OPEN 10 OIL DRAINS BACK TO THE PUMP 11 OIL DRAIN 12 OIL SUPPLY DR ENGINE 5 9L DIESEL 9 3...

Page 1589: ...Fig 112 Lubrication System Circulation Cont d 9 340 ENGINE 5 9L DIESEL DR LUBRICATION Continued...

Page 1590: ...indication of engine problems that might exist Thin black oil indicates fuel dilution Milky discoloration indicates coolant dilution 4 Clean the area around the oil filter head Remove the filter Refer...

Page 1591: ...pan bolts break the pan to block seal and lower pan slightly and remove oil suction tube fasteners 12 Remove oil pan and suction tube CLEANING Remove all gasket material from the oil pan and cylinder...

Page 1592: ...pres sure OIL PRESSURE SENSOR SWITCH REMOVAL 1 Disconnect the battery negative cables 2 Disconnect the oil pressure switch connector 3 Using a suitable socket remove the oil pres sure switch from the...

Page 1593: ...eplace the pump 7 Measure the clearance of the gerotor drive gerotor planetary to port plate Fig 119 Maximum clearance is 0 127 mm 0 005 inch If the oil pump is out of limits replace the pump 8 Measur...

Page 1594: ...VALVE TIMING GEAR HOUSING COVER INSTALLATION 8 Install the vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION and speed indicator ring 9 Install the fan support hub assembl...

Page 1595: ...and cylinder head sealing surface CLEANING Clean manifold in solvent and blow dry with com pressed air Clean cylinder block gasket surfaces using a suit able solvent The plenum pan rail must be clean...

Page 1596: ...manifold stud Position the tube out of the way 11 Remove heat shield 12 Remove exhaust manifold bolt lockplates 13 Remove the exhaust manifold to cylinder head bolts and spacers Fig 126 14 Remove the...

Page 1597: ...camshaft gear assembly 9 If timing marks alignment is off and no dam age is found at either the crankshaft or camshaft gear keyways realign timing marks as necessary GEAR HOUSING REMOVAL 1 Disconnect...

Page 1598: ...tall the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 20 Install the upper cooling fan and shroud together Refer to 7 COOLING ENGINE RADIA TOR FAN INSTALLATION 21 I...

Page 1599: ...fan support hub assy and tighten bolts to 32 N m 24 ft lbs torque 10 Install power steering pump 11 Install accessory drive belt tensioner Torque bolt to 43 N m 32 ft lbs torque 12 Install the access...

Page 1600: ...ION 372 CYLINDER HEAD COVER S DESCRIPTION 373 REMOVAL 373 CLEANING 374 INSPECTION 374 INSTALLATION 374 INTAKE EXHAUST VALVES SEATS DESCRIPTION 375 STANDARD PROCEDURE VALVE SERVICE 375 REMOVAL REMOVAL...

Page 1601: ...93 OPERATION 393 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE OIL LEAKS 394 DIAGNOSIS AND TESTING ENGINE OIL PRESSURE 396 OIL STANDARD PROCEDURE ENGINE OIL 396 OIL FILTER REMOVAL 397 INSTALLATIO...

Page 1602: ...her mechanical e g a strange noise or performance e g engine idles rough and stalls Refer to 9 ENGINE DIAGNOSIS AND TEST ING Preformance or Refer to 9 ENGINE DIAG NOSIS AND TESTING Mechanical Refer to...

Page 1603: ...test and if necessary inspect fuel injector s and driver circuits Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL PUMP DIAGNOSIS AND TESTING 3 Low or no engine compression 3 Perform cylinder compression p...

Page 1604: ...er or replace spark plug cables Refer to 8 ELECTRICAL IGNITION CONTROL SPARK PLUG CABLE DIAGNOSIS AND TESTING 6 Faulty coil 6 Test and replace if necessary Refer to 8 ELECTRICAL IGNITION CONTROL IGNIT...

Page 1605: ...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 en...

Page 1606: ...nspect oil pickup tube and pump 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 fast...

Page 1607: ...orrect oil level 2 Faulty oil pressure sending unit 2 Replace sending unit 3 Low oil pressure 3 Check pump and bearing clearance 4 Clogged oil filter 4 Replace oil filter 5 Worn oil pump 5 Replace as...

Page 1608: ...iller cap Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and...

Page 1609: ...t the bore is clean Oil the bores after cleaning to prevent rusting STANDARD PROCEDURE FORM IN PLACE GASKETS AND SEALERS There are numerous places where form in place gaskets are used on the engine Ca...

Page 1610: ...with assembly Material in a can w applicator can be brushed on evenly over the sealing surfaces Material in an aerosol can should be used on engines with multi layer steel gaskets STANDARD PROCEDURE...

Page 1611: ...icle on a hoist 27 Remove the drain plug and drain the engine oil 28 Loosen front engine mount thru bolt nuts 29 Remove the transmission cooler line brackets from oil pan 30 Disconnect exhaust pipe at...

Page 1612: ...NSTAL LATION 35 Evacuate Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PRO CEDURE and charge the air conditioning system if equipped Refer to 24 HEATING AIR CONDI TIONING PLUMBING STANDARD PR...

Page 1613: ...Bolts Transmission Support Cushion 47 35 Bolts Transmission Support Cushion 47 35 Stud Nuts Water Pump to Chain Case Cover 41 30 Bolts 8 OL ENGINE DESCRIPTION SPECIFICATION CAMSHAFT Bearing Diameter N...

Page 1614: ...0 0762 mm 0 003 in Taper Max 0 127 mm 0 005 in Lifter Bore Diameter 22 982 23 010 mm 0 9048 0 9059 in DESCRIPTION SPECIFICATION CYLINDER HEAD AND VALVES Valve Seat Angle 44 5 Runout Max 0 0762 mm 0 00...

Page 1615: ...op of Skirt 0 013 0 038 mm 0 0005 0 0015 in Piston Length 82 5 mm 3 25 in Piston Ring Groove Depth 1 2 91 30 91 55 mm 3 594 3 604 in 3 92 90 93 15 mm DESCRIPTION SPECIFICATION 3 657 3 667 in Weight 46...

Page 1616: ...llowing engine serial number 0 2032 mm 0 008 in O S Hydraulic Tappets L Diamond shaped stamp top pad front of engine and flat ground on outside surface of each O S tappet bore 0 127 mm 0 005 in Valve...

Page 1617: ...nkshaft Sprocket Puller Tool 6444 Crankshaft Sprocket Puller Jaws Tool 6820 Crankshaft Sprocket Installer Tool 3718 Crankshaft Sprocket Installer Tool MD990799 Front Oil Seal Installer Tool 6806 Front...

Page 1618: ...Ring Compressor Tool C385 Seal Installer Tool 6687 Crankshaft Main Bearing Remover Installer Tool C3059 Puller 1026 Crankshaft Damper Removal Insert 8513 Pressure Tester Kit 7700 Bloc Chek Kit C 3685...

Page 1619: ...to air cleaner cover and tighten hose clamp to 3 N m 30 in lbs torque 5 If any other hose clamps were removed from air intake system tighten them to 3 4 N m 30 in lbs torque 6 If any bolts were remov...

Page 1620: ...NEVER PERMIT PRES SURE TO EXCEED 138 kPa 20 psi Install Cooling System Tester 7700 or equivalent to pressure cap neck Start the engine and observe the tester s pressure gauge If gauge pulsates with e...

Page 1621: ...gs CLEANING Clean all surfaces of cylinder block and cylinder heads Be sure material does not fall into the lifters and surrounding valley Clean cylinder block front and rear gasket surfaces using a s...

Page 1622: ...d drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 18 Install the intake manifold to generator bracket support rod Tighten the bolts to 41 N m 30 ft lbs torque 19 The cylinder he...

Page 1623: ...umber up CAUTION The cylinder head cover fasteners have a special plating DO NOT use alternative fasteners 3 Position the cylinder head cover onto the gas ket Install the stud bolts and hex head bolts...

Page 1624: ...lve to and from the indicator The total dial indicator reading should not exceed 0 432 mm 0 017 inch Ream the guides for valves with over size stems if dial indicator reading is excessive or if the st...

Page 1625: ...the blue is trans ferred to the top edge of valve face lower valve 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...

Page 1626: ...he spark plug hole apply 620 689 kPa 90 100 psi air pressure 7 Using Valve Spring Compressor Tool MD 998772A with adapter 6716A Fig 19 compress valve spring and remove retainer valve locks and valve s...

Page 1627: ...or checking with a dial indicator 2 Attach dial indicator Tool C 3339 to cylinder head and set it at right angles to valve stem being measured Fig 23 3 Move valve to and from the indicator The total d...

Page 1628: ...essor Tool MD 998772A and adapter 6716A install locks and release tool Tap the retainer with a brass or heavy plastic hammer to ensure locks have been seated 8 If valves and or seats were ground measu...

Page 1629: ...the engine is removed from the vehicle 1 With engine completely disassembled drive out rear cam bearing core hole plug NOTE It is not advisable to attempt to replace cam shaft bearings unless special...

Page 1630: ...0 051 0 152 mm 0 002 0 006 inch with a new thrust plate and up to 0 254 mm 0 010 inch with a used thrust plate If not within these limits install a new thrust plate 4 Line up key with keyway in sproc...

Page 1631: ...in the opposite bank The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps Limits of taper or out of round on any crankshaft journals should be held t...

Page 1632: ...KSHAFT MAIN BEARINGS STANDARD PROCEDURE FITTING CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly Upper and lower bearing halves...

Page 1633: ...l seal to pry the oil seal outward Be careful not to damage the crankshaft seal surface of the cover Fig 31 REMOVAL FRONT OIL SEAL FRONT COVER REMOVED 1 Remove engine front cover Refer to 9 ENGINE VAL...

Page 1634: ...age or wear 2 Position Special Tool 6687 Seal Guide onto the crankshaft 3 Position the oil seal onto the Seal guide then using Special Tool 8359 Seal Installer and C 4171 Driver Handle Install the oil...

Page 1635: ...pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily LOW Low oil level may allow oil pump to take in air When air is fed to the tappet...

Page 1636: ...the SET mark on the scale of the tester and tighten the hex nut 7 Slowly swing the weighted arm onto the push rod 8 Rotate the cup by turning the handle at the base of the tester clockwise one revolut...

Page 1637: ...tall cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 9 Install the air cleaner CAUTION To prevent damage to valve mechanism engine must not be run above fast idl...

Page 1638: ...reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation 5 Be sure the connecting rod and connecting rod cap are identified wit...

Page 1639: ...and tighten nuts to 61 N m 45 ft lbs torque 11 Install the oil pump pick up tube and oil pan Refer to 9 ENGINE LUBRICATION OIL PAN INSTALLATION 12 Install the cylinder head Refer to 9 ENGINE CYLINDER...

Page 1640: ...ing with the chamfer facing up Fig 43 An identification mark on the ring is a drill point a stamped letter O an oval depression or the word TOP facing up Fig 42 d Measure side clearance between piston...

Page 1641: ...following Radiator Refer to 7 COOLING ENGINE RA DIATOR INSTALLATION Accessory drive belt Refer to 7 COOLING AC CESSORY DRIVE DRIVE BELTS INSTALLATION Radiator fan Refer to 7 COOLING ENGINE RADIATOR FA...

Page 1642: ...ion support cushion to transmission sup port bracket Install stud nuts and tighten to 47 N m 35 ft lbs torque 3 Using the transmission jack lower the trans mission and support cushion onto the crossme...

Page 1643: ...d by manufacturer Start the engine and let idle for approximately 15 minutes Check the oil dipstick to be sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light s...

Page 1644: ...Fig 49 Engine Lubrication System DR ENGINE 8 0L 9 395 LUBRICATION Continued...

Page 1645: ...ating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Hoist vehicle 3 Remove oil fill cap 4 Place a suitable drain pan under crankcase drain 5 Remove drain plug from crank...

Page 1646: ...oil Refer to 9 ENGINE LUBRICATION OIL STANDARD PROCEDURE OIL PAN REMOVAL 1 Disconnect the negative cable from the battery 2 Raise vehicle 3 Drain engine oil 4 Remove left engine to transmission strut...

Page 1647: ...5 16 inch oil pan bolts Torque these bolts as shown in Oil Pan Bolts Torque Chart 8 Install the drain plug Tighten drain plug to 34 N m 25 ft lbs torque 9 Install the engine to transmission strut 10 L...

Page 1648: ...cifications replace timing chain cover Install inner rotor into timing chain cover pump body Fig 62 Inner rotor should be positioned with chamfer up or toward engine when cover is installed This allow...

Page 1649: ...riplate and install in the timing chain cover Use new parts as required Fig 64 2 Position the oil pump cover onto the timing chain cover Tighten cover screws to 14 N m 125 in lbs torque 3 Make sure th...

Page 1650: ...Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 3 Remove the accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove the generator brace and generator Fig...

Page 1651: ...g a suit able solvent 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...

Page 1652: ...ll the coil assemblies and the ignition wires 14 Connect the accelerator linkage and if so equipped the speed control and transmission kick down cables 15 Install the fuel lines Refer to 14 FUEL SYS T...

Page 1653: ...1 Disconnect the negative cable from the battery 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Remove the serpentine belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS REMOV AL 4 R...

Page 1654: ...oid damaging oil pan gasket Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 2 Aline camshaft and crankshaft centerline Remove camshaft sprocket attaching bolt and remove timing chain...

Page 1655: ...he camshaft bolt Tighten the bolt to 61 N m 45 ft lbs torque 6 Check camshaft end play The end play should be 0 051 0 152 mm 0 002 0 006 inch with a new thrust plate and up to 0 254 mm 0 010 inch with...

Page 1656: ...ION 14 INSTALLATION 14 CHARGE AIR COOLER AND PLUMBING DESCRIPTION 15 OPERATION 15 DIAGNOSIS AND TESTING CHARGE AIR COOLER SYSTEM LEAKS 15 REMOVAL 15 CLEANING 16 INSPECTION 16 INSTALLATION 16 EXHAUST S...

Page 1657: ...DIAGNOSIS AND TESTING GAS ENGINE EXHAUST SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE EXHAUST NOISE OR LEAKING EXHAUST GASES 1 Leaks at pipe joints 1 Tighten clamps bolts at le...

Page 1658: ...pe leaking at manifold flange 4 Tighten replace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak between exhaust manifold and cylinder head 6 Tighten...

Page 1659: ...IAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CON VERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME CAUTION DO NOT remove spark plu...

Page 1660: ...clamp when reinstalling the catalytic converter 1 Position the catalytic converter onto the exhaust pipe flange connection Tighten the nuts to 28 N m 250 in lbs torque 2 Install the muffler onto the c...

Page 1661: ...1 0 in is required 2 Position the exhaust pipe to manifold Install the bolts retainers and nuts Tighten the nuts to 31 N m 23 ft lbs torque 3 Tighten the clamp nuts to 48 N m 35 ft lbs torque 4 Lower...

Page 1662: ...ATION 1 Install the exhaust pipe into the transmission support and onto the turbocharger flange 2 Install the exhaust pipe to turbocharger elbow clamp and tighten to 31 N m 23 ft lbs torque 3 Install...

Page 1663: ...INSTALLATION 1 Assemble muffler and clamps loosely to permit proper alignment of all parts 2 Connect the muffler hangers 3 Tighten the clamp nuts to 48 N m 35 ft lbs torque 4 Lower the vehicle 5 Start...

Page 1664: ...rame parts Adjust the alignment if needed TAILPIPE 5 9L DIESEL REMOVAL 1 Disconnect the battery negative cables 2 Raise and support the vehicle 3 Saturate the clamp nuts with heat valve lubri cant All...

Page 1665: ...pport hangers 3 Position the exhaust tailpipe for proper clear ance with the underbody parts 4 Tighten all clamp nuts to 48 N m 35 ft lbs torque 5 Lower the vehicle 6 Start the engine and inspect for...

Page 1666: ...TURBOCHARGER DESCRIPTION The turbocharger is an exhaust driven supercharger which increases the pressure and density of the air entering the engine With the increase of air entering the engine more fu...

Page 1667: ...housing routes the engine oil back to the crankcase The most common turbocharger failure is bearing failure related to repeated hot shutdowns with inade quate cool down periods A sudden engine shut d...

Page 1668: ...harger air inlet hose Fig 18 6 Disconnect the turbocharger oil supply line and the oil drain tube from the turbocharger Fig 19 7 Disconnect the charge air cooler inlet pipe from the turbocharger compr...

Page 1669: ...using for an impeller rubbing condition Fig 20 Replace the turbocharger if the condition exists 4 Measure the turbocharger axial end play a Install a dial indicator as shown in Fig 21 Zero the indicat...

Page 1670: ...o the turbocharger compressor housing Pressur ized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator From the charge air cooler the air flows...

Page 1671: ...5 Continue flushing until all debris or oil are removed 6 Rinse the cooler with hot soapy water to remove any remaining solvent 7 Rinse thoroughly with clean water and blow dry with compressed air INS...

Page 1672: ...17 SPECIFICATIONS TORQUE 23 FRONT CROSSMEMBER REMOVAL 23 INSTALLATION 23 FRONT SKID PLATE REMOVAL 24 INSTALLATION 24 TRANSMISSION CROSSMEMBER REMOVAL 24 INSTALLATION 25 TRAILER HITCH REMOVAL 25 INSTAL...

Page 1673: ...onnect the fog lamp electrical connector at the left frame rail 3 Support the bumper with a suitable lifting device 4 Remove the center bracket nuts and bolts and remove bumper Fig 2 INSTALLATION 1 In...

Page 1674: ...ard bumper to bracket attachments must be secured before installing the fascia and step pad ST SLT SLT FASCIA INSTALLATION 1 Install the fascia 2 Position the close out panel and seat the 6 lower clip...

Page 1675: ...L SERIOUS EYE INJURY CAN RESULT BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA PERSONAL INJURY CAN RESU...

Page 1676: ...ig 6 7 Make a vertical mark on the inside and outside face of the frame rail 112 mm 4 5 in from the for ward edge of the PLP hole in the sides of the rail Fig 8 8 Using a straightedge connect the two...

Page 1677: ...Fig 9 c Remove any burrs at the holes and beveled edges 14 Dry fit the new rail to ensure alignment and fit and make any adjustments as necessary 15 Remove all internal and external OEM e coat within...

Page 1678: ...ack the ring fillet welds to hold them in place Fig 10 Fig 11 Fig 12 Fig 13 18 On 4X4 models install the sway bar tapping plate and secure with tack welds Fig 12 Fig 13 Fig 10 4X2 SLEEVE INSTALLATION...

Page 1679: ...ower FESM insulator and cab mounting bolt Fig 12 4X4 TAPPING PLATE SLEEVE INSTALLATION 1 REPLACEMENT FRAME TIP 2 FRAME RAIL 3 SERVICE SLEEVE 4 PLP 5 SWAY BAR MOUNTING BRACKET 6 TAPPING PLATE 7 ROOT WE...

Page 1680: ...The pre ferred method is GMAW MIG a Apply root pass welds to the root joint one quadrant at a time switching to the opposite side of the frame for each quadrant Fig 9 b Clean the welds of any flux and...

Page 1681: ...ular 0 035 Solid 3 329 Electrode Stick Out 3 89 1 29 1 29 5 89 N A Polarity Electrode 9 9 Work Piece 9 9 Electrode 9 9 Work Piece 9 9 Electrode 9 9 Work Piece 9 9 Shielding Gas Self Shielded 75 Ar 25...

Page 1682: ...Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy 4 Remove any burrs at the beveled edges 5 Using the Weld Process Specifi...

Page 1683: ...acing the entire hydro form 1 Disconnect and isolate the battery negative cable 2 Remove the front wheelhouse splash shield Refer to 23 BODY EXTERIOR FRONT WHEEL HOUSE SPLASH SHIELD REMOVAL 3 Remove t...

Page 1684: ...etal bracket s location in all three X Y and Z planes of space Fig 20 22 Complete all 360 plug welds NOTE Before the final welding use three dimen sional measuring equipment to ensure the part is in t...

Page 1685: ...TION 32 Install the air cleaner bracket and air cleaner if previously removed Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER ELEMENT INSTALLATION 33 Install the radiator assembly Refer to 7 COOLING E...

Page 1686: ...ailure can result When using heat to straighten frame components do not exceed 566 C 1050 F metal fatigue can result CAUTION This procedure is designed to replace the H section spare tire support loca...

Page 1687: ...ng Society welding pro cedures and utilizing the process specifications at the end of this section Refer to the Weld Process Speci fications welding schedule below 17 Dress the welded area and apply c...

Page 1688: ...Metal Arc Welding Process Butt joints apply two layers passes of weld metal First pass should only fill approximately 1 2 the thick ness Vertical position welds maintain electrode wire at leading edg...

Page 1689: ...Fig 24 FRAME DIMENSIONS 13 18 FRAMES BUMPERS DR FRAME Continued...

Page 1690: ...Fig 25 140 5 IN WHEELBASE HEAVY DUTY 2 WHEEL DRIVE DR FRAMES BUMPERS 13 19 FRAME Continued...

Page 1691: ...Fig 26 140 5 IN WHEELBASE HEAVY DUTY 4 WHEEL DRIVE 13 20 FRAMES BUMPERS DR FRAME Continued...

Page 1692: ...Fig 27 160 5 IN WHEELBASE HEAVY DUTY 2 WHEEL DRIVE DR FRAMES BUMPERS 13 21 FRAME Continued...

Page 1693: ...Fig 28 160 5 IN WHEELBASE HEAVY DUTY 4 WHEEL DRIVE 13 22 FRAMES BUMPERS DR FRAME Continued...

Page 1694: ...olt 170 125 Transfercase skid plate bolts 34 25 Transercase skid plate crossmember bolts 34 25 Transmission mount to crossmember nuts 61 45 FRONT CROSSMEMBER REMOVAL 1 Raise and support the vehicle Re...

Page 1695: ...1 Raise and support the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove the transfercase skid plate if equipped Refer to 13 FRAME BUMPERS FRAME TRANSFER CASE SKID PLATE...

Page 1696: ...evice lift and support the rear of the cargo box and remove the hitch INSTALLATION 1 Install the hitch onto the frame rails and make sure the locators on the inside of the hitch brackets are engaged w...

Page 1697: ...e bolts 4 Tighten the bolts to 34 N m 25 ft lbs FRONT TOW HOOK ASSEMBLY REMOVAL 1 Remove front bumper Refer to 13 FRAME BUMPERS BUMPERS FRONT BUMPER REMOVAL 2 Remove the bolts and remove the tow hook...

Page 1698: ...12 FUEL PUMP MODULE DESCRIPTION 12 OPERATION 12 REMOVAL 12 INSTALLATION 13 FUEL RAIL DESCRIPTION 13 OPERATION 13 REMOVAL 13 INSTALLATION 18 FUEL TANK DESCRIPTION 20 OPERATION 20 REMOVAL EXCEPT DIESEL...

Page 1699: ...n of the Evapora tive Control System is found in Emission Control Systems Both fuel filters at bottom of fuel pump module and within fuel pressure regulator are designed for extended service They do n...

Page 1700: ...ouch other end of jumper wire to negative terminal of battery for no more than a few seconds 11 Place a rag or towel below fuel line quick con nect fitting at fuel rail 12 Disconnect quick connect fit...

Page 1701: ...uel Filler Housing to Body Screws 2 17 Fuel Pump Module Lock Ring 54 40 Fuel Rail Mounting Bolts 3 7L 11 100 Fuel Rail Mounting Bolts 4 7L 11 100 Fuel Rail Mounting Bolts 5 7L 11 100 Fuel Rail Mountin...

Page 1702: ...Mounting Screws 3 7L 7 60 TPS Mounting Screws 4 7L 7 60 TPS Mounting Screws 5 9L 7 60 TPS Mounting Screws 8 0L 7 60 Throttle Body Mounting Bolts 3 7L 11 100 Throttle Body Mounting Bolts 4 7L 12 105 T...

Page 1703: ...approximately 339 kPa 34 kPa 49 2 psi 5 psi at the fuel injectors It contains a diaphragm calibrated springs and a fuel return valve The internal fuel filter Fig 2 is also part of the assembly Fuel i...

Page 1704: ...The varied voltage signal is returned back to the PCM through the sensor return circuit Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard wired not multi plexed...

Page 1705: ...r ring type Some are equipped with safety latch clips Some may require the use of a spe cial tool for disconnection and removal Refer to Quick Connect Fittings Removal Installation for more informatio...

Page 1706: ...While pressing release tab on side of fitting use screwdriver to pry up pull tab Fig 8 c Raise pull tab until it separates from quick connect fitting Fig 9 7 Two Tab Type Fitting This type of fitting...

Page 1707: ...ng to aid in dis connection b After disconnection plastic retainer ring will remain with quick connect fitting connector body c Inspect fitting connector body plastic retainer ring and fuel system com...

Page 1708: ...ent for damage Replace as necessary 2 Prior to connecting quick connect fitting to component being serviced check condition of fitting and component Clean parts with a lint free cloth Lubricate with c...

Page 1709: ...top of the fuel tank Fig 1 The complete assembly contains the following components A combination fuel filter fuel pressure regulator A separate fuel pick up or inlet filter An electric fuel pump A lo...

Page 1710: ...separate rail halves at connector tubes Fig 18 Due to design of tubes it does not use any clamps Never attempt to install a clamping device of any kind to tubes When removing fuel rail assembly for an...

Page 1711: ...from injector The factory fuel injection wiring har ness is numerically tagged INJ 1 INJ 2 etc for injector position identification If harness is not tagged note wiring location before removal 10 Disc...

Page 1712: ...tion before removal 11 Disconnect electrical connectors at all throttle body sensors 12 Remove 4 fuel rail mounting bolts and hold own clamps Fig 20 13 Gently rock and pull left side of fuel rail unti...

Page 1713: ...se procedure Refer to Fuel Delivery System section of this group 4 Disconnect throttle body linkage and remove throttle body from intake manifold Refer to Throttle Body removal in this group 5 Remove...

Page 1714: ...7 COIL TO 4 SPARK PLUG MARKED 4 7 9 2 COIL TO 3 SPARK PLUG MARKED 2 3 4 3 COIL TO 2 SPARK PLUG MARKED 2 3 10 6 COIL TO 1 SPARK PLUG MARKED 1 6 5 1 COIL TO 6 SPARK PLUG MARKED 1 6 11 4 COIL TO 7 SPARK...

Page 1715: ...ulder 7 Install 4 fuel rail mounting bolts and tighten Refer to torque specifications 8 Install 6 ignition coils Refer to Ignition Coil Removal Installation 9 Connect electrical connectors to throttle...

Page 1716: ...d Be careful not to tear injector o rings 6 Push right side of fuel rail down until fuel injectors have bottomed on shoulders Push left fuel rail down until injectors have bottomed on shoulders 7 Inst...

Page 1717: ...er to Fuel Tank Check Valve for additional information An evaporation control system is connected to the fuel tank to reduce emissions of fuel vapors into the atmosphere When fuel evaporates from the...

Page 1718: ...colored tab to unlock Push on black colored tab while removing connector 5 Disconnect fuel line at fuel filter fuel pressure regulator Fig 30 by pressing on tabs at side of quick connect fitting 6 Di...

Page 1719: ...AP line at tank Fig 1 6 Connect fuel pump module electrical connector Fig 30 at top of tank 7 Connect fuel line quick connect fitting to fuel filter fuel pressure regulator Fig 1 or Fig 30 8 Continue...

Page 1720: ...er is located on the bottom of the fuel pump module Fig 32 The fuel pump module is located inside of fuel tank 1 Snap new filter to bottom of module Be sure o ring is in correct position 2 Install fue...

Page 1721: ...RATION 52 REMOVAL 53 INSTALLATION 54 ACCELERATOR PEDAL REMOVAL The following procedure applies only to vehicles without the Adjustable Pedal Package code XAP The accelerator pedal is serviced as a com...

Page 1722: ...APPS assembly is located under the vehicle battery tray Fig 2 Access to APPS is gained from over top of left front tire 1 Disconnect negative battery cable at battery 2 Disconnect APPS cable at accele...

Page 1723: ...ined hole 5 7L V 8 The Crankshaft Position CKP sensor is mounted into the right rear side of the cylinder block It is positioned and bolted into a machined hole 5 9L V 8 Gas The Crankshaft Position CK...

Page 1724: ...PCM 5 7L V 8 Engine speed and crankshaft position are provided through the crankshaft position sensor The sensor generates pulses that are the input sent to the pow ertrain control module PCM The PCM...

Page 1725: ...n each set of notches Once the Powertrain Control Module PCM senses the last notch it will determine crankshaft position which piston will next be at Top Dead Center An input from the camshaft positio...

Page 1726: ...or at sensor 3 Remove CKP mounting bolt Fig 11 4 Carefully twist sensor from cylinder block 5 Remove sensor from vehicle 6 Check condition of sensor o ring 5 7L V 8 The Crankshaft Position CKP sensor...

Page 1727: ...l harness to side of engine block 5 Carefully pry sensor from cylinder block in a rocking action with two small screwdrivers 6 Remove sensor from vehicle 7 Check condition of sensor o ring Fig 16 INST...

Page 1728: ...r mounting tang may result 4 Install mounting bolt and tighten to 28 N m 21 ft lbs torque 5 Connect electrical connector to sensor 6 Lower vehicle 5 9L V 8 Gas 1 Position crankshaft position sensor to...

Page 1729: ...ives Battery voltage is supplied to the injectors through the ASD relay The PCM determines injector pulse width based on various inputs OPERATION PCM OUTPUT The nozzle ends of the injectors are positi...

Page 1730: ...eight pin height should be the same for all terminals within the PDC connector Repair if necessary before installing relay INSTALLATION The fuel pump relay is located in the Power Distri bution Center...

Page 1731: ...ded number of steps for that may have been 125 That 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 req...

Page 1732: ...r from throttle body INSTALLATION 3 7L V 6 The Idle Air Control IAC motor is located on the side of the throttle body Fig 20 1 Install IAC motor to throttle body 2 Install and tighten two mounting bol...

Page 1733: ...he IAT sensor provides an input voltage to the Powertrain Control Module PCM indicating the density of the air entering the intake manifold based upon intake manifold temperature At key on a 5 volt po...

Page 1734: ...old Fig 29 1 Clean dirt from intake manifold at sensor base 2 Disconnect electrical connector at sensor Fig 29 3 Remove sensor from intake manifold 8 0L V 10 The intake manifold air temperature sensor...

Page 1735: ...f the intake manifold air box plenum Fig 27 1 Check condition of sensor o ring 2 Clean sensor mounting hole in intake manifold 3 Position sensor into intake manifold and rotate clockwise until past re...

Page 1736: ...it sees it knows the current barometric pressure relative to altitude Once the engine starts the PCM looks at the voltage again continuously every 12 milliseconds and com pares the current voltage to...

Page 1737: ...nd MAP sensor 3 Remove 2 sensor mounting screws 4 Remove MAP sensor from intake manifold 5 Check condition of sensor o ring Fig 32 4 7L V 8 The MAP sensor is located on the front of the intake manifol...

Page 1738: ...While removing MAP sensor slide the vacuum rubber L shaped fitting Fig 37 from the throttle body 4 Remove rubber L shaped fitting from MAP sen sor 8 0L V 10 The MAP sensor is mounted into the right u...

Page 1739: ...or into manifold 4 Rotate sensor 1 4 turn clockwise for installa tion 5 Connect electrical connector 5 9L V 8 The MAP sensor is located on the front of the throttle body Fig 36 An L shaped rubber fitt...

Page 1740: ...rectly from the Powertrain Control Mod ule PCM through a Pulse Width Module PWM method Pulse Width Module PWM 5 9L 8 0L Voltage to the O2 sensor heating elements is supplied directly from the Powertra...

Page 1741: ...es at the downstream sensor the PCM calcu lates how much air fuel ratio change is required The PCM then looks at the upstream oxygen sensor volt age and changes fuel delivery until the upstream sensor...

Page 1742: ...ani cally limit the position of the throttle body throttle plate Never attempt to adjust the engine idle speed using this screw All idle speed functions are controlled by the PCM REMOVAL 3 7L V 6 A fa...

Page 1743: ...cally limit the position of the throttle body throttle plate Never attempt to adjust the engine idle speed using this screw All idle speed functions are controlled by the powertrain control module PCM...

Page 1744: ...up for additional informa tion 4 Remove four throttle body mounting nuts Fig 48 5 Remove throttle body from intake manifold 6 Discard old throttle body to intake manifold gasket INSTALLATION 3 7L V 6...

Page 1745: ...Leave ignition switch ON for a minimum of 10 seconds This will allow PCM to learn throttle body electrical parameters 5 9L V 8 A factory adjusted set screw is used to mechani cally limit the position...

Page 1746: ...re within cable sheathing while servicing accelerator pedal or throttle cable 1 From inside vehicle hold up accelerator pedal Remove plastic cable retainer clip and throttle cable core wire from upper...

Page 1747: ...thing while servicing accelerator pedal or cables 1 From inside vehicle hold up accelerator pedal Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm Fig 1 The plas...

Page 1748: ...h a small screwdriver Fig 55 To prevent cable housing breakage press on tab only enough to release cable from bracket Lift cable housing straight up from bracket while pressing on release tab Remove t...

Page 1749: ...ned to hole in mounting bracket 2 Hold throttle in wide open position While held in this position slide throttle cable pin into throttle body bellcrank 3 Push cable housing into rubber grommet and thr...

Page 1750: ...omatic transmis sions only REMOVAL 3 7L V6 The Throttle Position Sensor TPS is mounted to the throttle body Fig 56 or Fig 57 1 Remove air resonator tube at throttle body 2 Disconnect TPS electrical co...

Page 1751: ...eaner tube to throttle body 4 7L V 8 The throttle shaft end of throttle body slides into a socket in TPS Fig 62 The TPS must be installed so that it can be rotated a few degrees If sensor will not rot...

Page 1752: ...t in the TPS Fig 63 The TPS must be installed so that it can be rotated a few degrees If sensor will not rotate install sensor with throttle shaft on other side of socket tangs The TPS will be under s...

Page 1753: ...OPERATION 64 DIAGNOSIS AND TESTING FUEL INJECTION PUMP TIMING 65 REMOVAL 65 INSTALLATION 67 FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION 68 OPERATION 68 REMOVAL REMOVAL INSTALLATION 68 FUEL LINES DESCRI...

Page 1754: ...ele ment and then enters the Fuel Pump Gear Pump which is attached to the rear of the fuel injection pump The Fuel Pump Gear Pump is a low pressure pump and produce pressures ranging from 551 5 kpa 80...

Page 1755: ...g new parts lubricate them with clean engine oil or clean diesel fuel only Fig 1 DIESEL FUEL SYSTEM COMPONENTS 1 ENGINE COOLANT TEMPERATURE ECT SENSOR 14 FUEL SUPPLY LINE LOW PRESSURE TO ENGINE 2 THRO...

Page 1756: ...fter 25 seconds turn key OFF Repeat previous step until engine starts 3 Fuel system priming is now completed 4 Attempt to start engine If engine will not start proceed to following steps When engine d...

Page 1757: ...Minimum 9 5 psi FUEL INJECTOR FIRING ORDER DIESEL 1 5 3 6 2 4 SPECIAL TOOLS DIESEL FUEL SYSTEM FUEL PRESSURE TEST ADAPTER 9012 FUEL PRESSURE TEST ADAPTER 9014 FUEL INJECTOR REMOVER 9010 PRESSURE CAP 9...

Page 1758: ...illumi nated Note that lamp will be illuminated for approximately two seconds when ignition key is ini tially placed in ON position for a bulb check 1 A drain hose Fig 3 or Fig 4 is located at bottom...

Page 1759: ...ted components 2 Fuel Filter a The engine has a self priming low pres sure fuel system Refer to Standard Proce dures Fuel System Priming b Install new o ring to canister lid and lubri cate o ring with...

Page 1760: ...atts at 0 degrees F DIAGNOSIS AND TESTING FUEL HEATER The fuel heater is used to prevent diesel fuel from waxing during cold weather operation NOTE The fuel heater element fuel heater relay and fuel h...

Page 1761: ...Repair if necessary before installing relay INSTALLATION The fuel heater relay is located in the Power Dis tribution Center PDC Fig 7 Refer to label under PDC cover for relay location 1 Install relay...

Page 1762: ...e Always wash clean any fuel system component thoroughly before disassembly and then air dry Cap or cover any open part after disassembly Before assembly examine each part for dirt grease or other con...

Page 1763: ...2 PUMP MOUNTING NUTS 3 3 FUEL INJECTION PUMP 4 CASCADE OVERFLOW VALVE Fig 11 FUEL CONTROL ACTUATOR 1 ACTUATOR MOUNTING BOLTS 2 FCA FUEL CONTROL ACTUATOR 3 ACTUATOR ELECTRICAL CONNECTOR Fig 12 PUMP DRI...

Page 1764: ...r other contaminants and clean if necessary When installing new parts lubricate them with clean engine oil or clean diesel fuel only 1 Inspect pump mounting surfaces at pump and mounting flange for ni...

Page 1765: ...battery cables to both batteries 20 Check system for fuel or engine oil leaks FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION The fuel gauge sending unit fuel level sensor is attached to the side of the fu...

Page 1766: ...SURE FUEL LEAKS WITH A SHEET OF CARDBOARD HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN DIAGNOSIS AND TESTING HIGH PRESSURE FUEL LINE LEAKS High pressure fuel...

Page 1767: ...l line support clamps Fig 17 and bracket bolts at intake manifold 6 Place shop towels around fuel lines at fuel rail and injectors If possible do not allow fuel to drip down side of engine CAUTION WHE...

Page 1768: ...bolt to 77 N m 56 lb ft 7 If fuel line at either 1 or 2 cylinder has been replaced install intake manifold air heater elements to top of intake manifold Refer to Intake Air Heater Removal Installation...

Page 1769: ...excessive the pressure limiting valve opens and vents excess pressure into the fuel drain circuit REMOVAL The fuel pressure limiting valve is located on the top of the fuel rail Fig 20 CAUTION Cleanli...

Page 1770: ...n top of tank module Fig 21 5 Drain fuel tank by attaching drain hose from an approved draining station to auxiliary fitting on top of tank module Fig 21 Tank Removal 1 Loosen clamp and disconnect rub...

Page 1771: ...supply and return lines to tank module 6 Continue raising tank until positioned snug to body 7 Install and position both tank support straps Install 2 fuel tank strap nuts and tighten Tighten rear st...

Page 1772: ...asket must be replaced 1 Thoroughly clean locknut and locknut threads at top of tank 2 Using new gasket carefully position fuel tank module into opening in fuel tank 3 Position locknut over top of fue...

Page 1773: ...o the fuel tank REMOVAL The fuel transfer pump fuel lift pump is attached to the rear of the fuel filter water separator housing Fig 25 1 Drain fuel from fuel filter housing Refer to Fuel Filter Water...

Page 1774: ...n pump is directed to the cascade overflow valve The cascade valve regulates how much excess fuel is used for lubrication of the injection pump and is also used to route excess fuel through the drain...

Page 1775: ...is pressurized and sent into a passage in the fuel pump At this point the fuel is channeled into two passages One passage sends fuel to the FCA Fuel Control Actua tor The other passage sends fuel to t...

Page 1776: ...ON 93 REMOVAL 93 INSTALLATION 94 MAP SENSOR DESCRIPTION 94 THROTTLE CONTROL CABLE REMOVAL 94 INSTALLATION 96 ACCELERATOR PEDAL POSITION SENSOR DESCRIPTION DESCRIPTION EARLY The APPS assembly is locate...

Page 1777: ...g 2 and pull cable rearward to remove from cable mount ing bracket 8 If equipped with an automatic transmission refer to 21 Transmission for transmission control cable removal procedures 9 Disconnect...

Page 1778: ...CLIP 4 CALIBRATION SCREWS NO ADJUSTMENT 5 APPS ASSEMBLY Fig 4 APPS CONNECTOR 1 APPS 2 TAB 3 PUSH FOR REMOVAL 4 APPS CONNECTOR Fig 5 APPS LOCATION LATE 1 BATTERY TRAY 2 APPS LOCATION 3 APPS MOUNTING B...

Page 1779: ...l connector to APPS 3 If necessary connect cable to APPS lever ball socket snaps on 4 Snap APPS cable cover closed 5 Position APPS assembly to bottom of battery tray and install 3 bolts Refer to Torqu...

Page 1780: ...bolt be sure sensor is completely flush to back of timing chain cover If sensor is not flush damage to sen sor mounting tang may result 4 Install mounting bolt and tighten Refer to Torque Specificatio...

Page 1781: ...he engine is running the ECM uses the CMP as a backup sensor for engine speed REMOVAL 1 Raise and support vehicle 2 Disconnect electrical connector at CKP sensor Fig 12 3 Remove 1 sensor mounting bolt...

Page 1782: ...corrosion or damage Shake the FCA and listen for a rattle If FCA does not rattle replace it INSTALLATION 1 Install new o rings to the Fuel Control Actua tor FCA 2 Lubricate o rings with clean light gr...

Page 1783: ...The result will be a possible fuel injector miss fire and low power The fuel injectors use hole type nozzles High pres sure flows into the side of the injector the ECM acti vates the solenoid causing...

Page 1784: ...occur b The rocker housing Fig 18 is bolted to the top of cylinder head The mounting stud from tool 9010 was meant to temporarily replace a rocker housing mounting bolt Remove the necessary rocker ho...

Page 1785: ...intake manifold Position injector into cylinder head bore being extremely careful not to allow injector tip to touch sides of bore Press fuel injector into cylinder head with finger pressure only 7 I...

Page 1786: ...hen air dry Cap or cover any open part after disassembly Before assembly examine each part for dirt grease or other contaminants and clean if necessary When installing new parts lubricate them with cl...

Page 1787: ...fil ter cover OPERATION The Inlet Air Temperature Pressure Sensor is a combination dual function sensor The sensor element extends into the intake air stream at the top of the air filter housing Ambi...

Page 1788: ...solate ends of both cables 2 Remove both the intake manifold air intake tube above injection pump and its rubber connector hose Fig 27 3 Lift 2 rubber covers Fig 28 to gain access to 2 positive cable...

Page 1789: ...RATION The Engine Control Module ECM operates the 2 heating elements through the 2 intake manifold air heater relays Fig 27 INTAKE TUBE AND CONNECTING HOSE 1 MANIFOLD ABOVE HEATERS 2 RUBBER CONNECTING...

Page 1790: ...R TEMPERATURE SENSOR MAP SENSOR DESCRIPTION The combination dual function Intake Manifold Air Temperature Sensor MAP Sensor is installed into the top of the intake manifold OPERATION The combination d...

Page 1791: ...s tic cable retainer snaps into pedal arm 3 From inside vehicle remove cable clip Fig 33 4 Remove cable core wire at pedal arm 5 Remove cable housing from dash panel and pull cable into engine compart...

Page 1792: ...edal Position Sensor APPS Removal Installation 5 From inside vehicle remove cable clip Fig 36 6 Remove cable housing from dash panel and pull cable into engine compartment 7 Remove cable housing at AP...

Page 1793: ...ct negative battery cables to both batter ies 6 Before starting engine operate accelerator pedal to check for any binding 7 Install cable lever cover Late Diesel Engine 1 Attach cable to Accelerator P...

Page 1794: ...he power steering pump and system if any other fluid is used and do not overfill Power steering systems consist of Steering column Rack and pinion steering gear Belt driven hydraulic steering pump Pum...

Page 1795: ...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 component...

Page 1796: ...d repair as necessary 5 Internal gear leak 5 Replace gear STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Tire pressure 1 Adjust tire pressure 2 Wheel alignment 2 Align front end 3 Lack of...

Page 1797: ...and repair as necessary The initial pressure reading should be in the range of 345 552 kPa 50 80 psi 11 Increase the engine speed to 1500 RPM and read the flow meter If the flow rate GPM is below spe...

Page 1798: ...AL TOOLS STEERING PULLER 8677 ADAPTERS POWER STEERING FLOW PRESSURE TESTER 6893 ANALYZER SET POWER STEERING FLOW PRESSURE 6815 ADAPTER POWER STEERING FLOW PRESSURE 6825A DR STEERING 19 5 STEERING Cont...

Page 1799: ...ed without remov ing the steering column from the vehicle To service the steering wheel switches or airbag refer to Restraints and follow all WARNINGS and CAUTIONS WARNING THE AIRBAG SYSTEM IS A SENSI...

Page 1800: ...nd cable from the battery 3 Remove the two switches from the steering wheel 4 Remove the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL 5 Remove the steering wheel with special tool CJ9...

Page 1801: ...efer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH REMOVAL 16 Remove the four steering column mounting nuts Fig 6 17 Remove the steering column assembly from the vehicle Fig 7 Fig 3 SHIFT...

Page 1802: ...on the wheel hub to shaft 14 Then install the steering wheel and install a new bolt Tighten the bolt to 61 N m 45 ft lbs 15 Install the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG INSTALLAT...

Page 1803: ...LLY DESIGNED FOR THE AIRBAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES ANYTIME A NEW FASTENER IS NEEDED REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LIS...

Page 1804: ...IN IGNITION SWITCH DESCRIPTION The key in ignition switch is integral to the igni tion switch which is mounted on the left side of the steering column It closes a path to ground for the Central Timer...

Page 1805: ...HIFT LEVER REMOVAL 1 Remove the kneeblocker Refer to 23 BODY INSTRUMENT PANEL KNEE BLOCKER REMOV AL 2 Remove the upper and lower column shroud 3 Remove and discard the brake light switch 4 Loosen the...

Page 1806: ...ve battery cable NOTE The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key...

Page 1807: ...ods of locking the steering wheel for service will have to be used 3 Lock the steering wheel with the tire in the straight position 4 Remove the left front tire and wheel assembly 5 Mark both coupler...

Page 1808: ...ssembly Refer to 22 TIRES WHEELS WHEELS STAN DARD PROCEDURE 6 Lower the vehicle 7 Reconnect the negative battery cable 8 Unlock the steering wheel STEERING WHEEL REMOVAL 1 Disable and remove the drive...

Page 1809: ...ed with the key Alternative meth ods of locking the steering wheel for service will have to be used 1 Lock the steering wheel 2 Drain and siphon the power steering fluid from the reservoir 3 Raise the...

Page 1810: ...ATION 5 Install the pressure power steering hose to the steering gear and tighten to 32 N m 23 ft lbs Refer to 19 STEERING PUMP HOSES INSTAL LATION 6 Install the return power steering hose to the stee...

Page 1811: ...sing care not to strike the gear 3 Remove the front mounting bushings 4 Remove the rear mounting bushings 5 Remove the steering gear from the vise and place it on the bench INSTALLATION NOTE Coat all...

Page 1812: ...ck piston The worm shaft is sup ported by a thrust bearing at the lower end and a bearing assembly at the upper end When the worm shaft is turned from input from the steering column the rack piston mo...

Page 1813: ...INSTALLA TION 4 Install the washer and retaining nut on the pit man shaft Tighten the nut to 305 N m 225 ft lbs 5 Connect fluid hoses to steering gear Refer to 19 STEERING PUMP HOSES INSTALLATION tigh...

Page 1814: ...nd record the peak torque measure on or near cen ter This total on center torque reading must be 5 9 in lbs higher than the previously measured preload torque without exceeding a total of 17 in lbs Th...

Page 1815: ...e Line To Pump 37 27 Steering Gear Adjustment Screw Locknut 31 23 Steering Gear Pitman Shaft Nut 305 225 Steering Gear Pitman Shaft Cover Bolts 68 50 Steering Gear Valve Housing to Gear Bolts 54 40 St...

Page 1816: ...osition 5 Remove the pitman shaft cover bolts NOTE The pitman shaft will not clear the housing if it is not centered 6 Remove the pitman shaft from the gear 7 Remove dust seal from the housing with a...

Page 1817: ...ig 5 CAUTION Use care not to score the housing bore when prying out seals 10 Remove retaining ring with snap ring pliers 11 Remove washer from the housing NOTE Tighten the slide hammer adapter 8990 in...

Page 1818: ...g 7 7 Install protective seal protector 8993 over the shaft Fig 8 8 Install the pitman shaft into the steering gear until it fully seats into the bearing 9 Install the new cover bolts and tighten to 6...

Page 1819: ...g and wormshaft assembly from the steering gear housing and place the valve housing in a soft jawed vise Fig 11 11 Remove the retainer ring set screw from the valve housing Fig 12 Fig 9 CENTERING STEE...

Page 1820: ...a pick Fig 15 CAUTION Use care not to score the housing bore when removing seals 15 Remove the snap ring with snap ring pliers Fig 16 Fig 13 REATINER RING REMOVAL 1 SPECIAL TOOL 8988 2 RATCHET Fig 14...

Page 1821: ...ering gear Fig 19 Tighten the new bolts to 54 N m 40 ft lbs 7 Install the input shaft seal protector 8986 Fig 20 8 Coat the new seal in high temp grease and Install the new oil seal using special tool...

Page 1822: ...19 STEERING LINKAGE PITMAN ARM REMOVAL 2 Clean exposed end of pitman shaft and housing with a wire brush 3 Rotate the steering wheel from stop to stop and count the number of turns 4 Center the steeri...

Page 1823: ...it fully seats into the bearing 3 Install the new cover bolts and tighten to 68 N m 50 ft lbs 4 Perform over center meshload adjustment Refer to 19 STEERING GEAR ADJUSTMENTS 5 Install the pitman arm R...

Page 1824: ...then zero the dial indicator 4 Position indicator plunger on the topside of the outer tie rod end NOTE The dial indicator plunger must be perpen dicular to the machined surface of the outer tie rod en...

Page 1825: ...e outer tie rod end into the steering knuckle Fig 2 3 Tighten the ball stud nut on the ball stud to 61 N m 45 ft lbs then an additional 90 4 Set wheel toe pattern Refer to 2 SUSPEN SION WHEEL ALIGNMEN...

Page 1826: ...7 LINKAGE LINK COIL DESCRIPTION The steering linkage is comprised of a tie rod end tie rod drag link steering damper and pitman arm Fig 1 CAUTION If any steering components are replaced or serviced an...

Page 1827: ...HART TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Pitman Arm Gear Shaft Nut 300 225 Drag Link Pitman Arm 88 65 Drag Link Tie Rod 108 80 Drag Link Adjuster Clamp 61 45 Tie Rod End Knuckle 108 80...

Page 1828: ...n to 108 N m 80 ft lbs 3 Install tie rod to the left steering knuckle and drag link Install the nuts and tighten to 108 N m 80 ft lbs 4 Remove the supports and lower the vehicle to the surface Center...

Page 1829: ...fter adjustment tighten tie rod adjustment sleeve clamp bolts to 61 N m 45 ft lbs NOTE Position the clamp on the sleeve so retain ing bolt is located on the bottom side of the sleeve TIE ROD END REMOV...

Page 1830: ...mp bolts to 61 N m 45 ft lbs NOTE Position the clamp on the sleeve so retain ing bolt is located on the bottom side of the sleeve TRACK BAR REMOVAL 1 Raise and support the axle 2 Remove the track bar...

Page 1831: ...ON RETURN HOSE GEAR TO COOLER 44 INSTALLATION PRESSURE HOSE 44 INSTALLATION RETURN HOSE RESERVOIR TO COOLER 44 POWER STEERING PRESSURE SWITCH DESCRIPTION 45 OPERATION 45 REMOVAL 3 7L 4 7L 5 7L 45 INST...

Page 1832: ...oth direction and verify power assist and quiet operation of the pump If the fluid is extremely foamy or milky looking allow the vehicle to stand a few minutes and repeat the procedure CAUTION Do not...

Page 1833: ...1 Drain and siphon the power steering fluid from the reservoir 2 Remove the serpentine belt CAUTION Do not remove the fitting on the pump that the high pressure hose screws into The fitting may come l...

Page 1834: ...intake plenum bolts Fig 3 5 Tighten the inner cooler tube clamp at the intake plenum 6 Install 3 pump mounting bolts through the pul ley access holes Tighten the bolts to 28 N m 21 ft lbs 7 Tighten th...

Page 1835: ...d on the dipstick COLD and HOT Before opening power steering system wipe the reservoir filler cap free of dirt and debris Remove the cap and check the fluid level on its dipstick When the fluid is at...

Page 1836: ...n shroud 5 Remove the support and lower the vehicle 6 Refill the power steering system Refer to 19 STEERING PUMP STANDARD PROCEDURE INSTALLATION PRESSURE HOSE NOTE Be sure to align the pressure hose s...

Page 1837: ...Refer to 19 STEERING PUMP STANDARD PROCEDURE INSTALLATION PRESSURE HOSE NOTE Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail 1 Install the pressure hose to...

Page 1838: ...er steering pressure switch is installed in the power steering high pressure hose Fig 9 1 Disconnect electrical connector from power steering pressure switch 2 Place a small container or shop towel be...

Page 1839: ...ower steering fluid from the reservoir 2 Remove the serpentine belt 3 Remove the power steering pump Refer to 19 STEERING PUMP REMOVAL 4 Remove the reservoir mounting bolts 5 Remove the reservoir 6 Re...

Page 1840: ...ts consist of the forks shaft shift lever socket and detent components OPERATION The manual transmission receives power through the clutch assembly from the engine The clutch disc is splined to the tr...

Page 1841: ...Fig 1 NV3500 TRANSMISSION 21 2 MANUAL TRANSMISSION NV3500 DR MANUAL TRANSMISSION NV3500 Continued...

Page 1842: ...hard shift ing and noise Shift component damage or damaged clutch pres sure plate or disc are additional probable causes of increased shift effort Worn damaged pressure plate or disc can cause incorre...

Page 1843: ...ssure plate Then lower jack and remove transmission from under vehicle DISASSEMBLY FRONT HOUSING 1 Shift transmission into Neutral 2 If lubricant was not drained out of transmis sion during removal re...

Page 1844: ...the retainer to break sealer bead loose Fig 8 8 Remove bearing retainer from input shaft Fig 9 9 Remove input shaft snap ring Fig 10 Fig 7 SHAFT LOCK BOLT 1 SHIFT SHAFT LOCK BOLT 2 SHAFT SOCKET Fig 8...

Page 1845: ...g retainer Leave one bolt in place until geartrain is ready to be removed from case 13 Separate the housings Fig 12 by tapping the front housing off alignment dowels with a plastic hammer 14 Remove in...

Page 1846: ...gear teeth 5 Tighten remover to press the roll pin down ward and out of the shift socket Fig 16 NOTE Roll pin must only clear the shift shaft Do not push the pin into the geartrain 6 Drive out shift b...

Page 1847: ...11 Remove reverse idler shaft support bolt and loosen rear reverse idler shaft bolt Fig 22 Fig 18 SHIFT SHAFT 1 SHIFT SHAFT 2 3 4 FORK 3 SHAFT DETENT NOTCHES Fig 19 SHIFT SOCKET ROLL PIN 1 SHAFT BORE...

Page 1848: ...place while housing and geartrain is being rotated into upright position 14 Remove rear bolt holding reverse idler shaft in housing REAR HOUSING 2WD 1 On 2 wheel drive transmission remove three bolts...

Page 1849: ...aft rear bearing from coun tershaft Fig 28 Fig 26 SEPARATE REAR HOUSING OUTPUT SHAFT BEARING 1 REAR HOUSING 2 MALLET 3 FIXTURE Fig 27 REAR HOUSING 2WD 1 REAR HOUSING 2 SHIFT FORKS AND GEARTRAIN Fig 28...

Page 1850: ...ft rear adapter housing upward and off geartrain Fig 32 Fig 29 REAR SEAL 1 SLIDE HAMMER 2 REMOVER TOOL 3 REAR SEAL Fig 30 REAR SEAL FACE 1 DIMPLES 2 SEAL FACE Fig 31 REAR BEARING SNAP RING 1 HEAVY DUT...

Page 1851: ...Synchronizer hubs and sleeves are different and must not be mixed Remove each synchronizer unit as an assembly to avoid mixing parts Mark each synchro hub and sleeve with a scriber or paint for correc...

Page 1852: ...d first gear from output shaft with shop press Fig 39 10 Remove first gear needle bearing Fig 40 Fig 36 TWO PIECE THRUST WASHER 1 SECOND GEAR 2 THRUST WASHER 2 PIECE 3 WASHER LOCATING LUG Fig 37 SECON...

Page 1853: ...with shop press Fig 45 Fig 41 OUTPUT SHAFT BEARING SNAP RING 1 OUTPUT SHAFT BEARING 2 BEARING SNAP RING 3 SNAP RING PLIERS Fig 42 FIFTH GEAR 1 FIFTH GEAR AND SYNCHRO RING Fig 43 FIFTH GEAR NEEDLE BEAR...

Page 1854: ...ndition of the shift shaft detent plunger and spring The plunger should be smooth and free of nicks or scores The plunger spring should be straight and not collapsed or distorted Minor scratches or ni...

Page 1855: ...the threads are damaged or if the retainer is bent or cracked COUNTERSHAFT BEARINGS AND RACES The countershaft bearings and races are machine lapped during manufacture to form matched sets The bearin...

Page 1856: ...se Mopar Gasket Maker or equivalent for all case joints and Mopar silicone sealer or equivalent for the input shaft bearing retainer SYNCHRONIZER 1 Slide sleeve onto the hub leaving enough room to ins...

Page 1857: ...ered the tapered side faces the front of the shaft 5 Install new fifth reverse hub snap ring Fig 54 Verify snap ring is seated in the groove Fig 51 REVERSE GEAR 1 REVERSE GEAR Fig 52 REVERSE GEAR SYNC...

Page 1858: ...so fifth gear is seated on the tool Fig 58 10 Install first gear bearing on output shaft Fig 58 Verify bearing is seated on shaft shoulder and is properly joined Fig 55 FIFTH GEAR SYNCHRO RING 1 FIFTH...

Page 1859: ...shop press Fig 62 CAUTION Keep synchro ring and sleeve aligned as the hub is being pressed onto the shaft The syn chro ring can be cracked if it becomes misaligned Fig 59 FIRST GEAR 1 FIRST GEAR 2 CO...

Page 1860: ...cond gear needle bearing on shaft Fig 65 20 Install second gear onto shaft and bearing Fig 66 Verify second gear is seated on synchro components Fig 63 1 2 SYNCHRO HUB SNAP RING 1 1 2 SYNCHRO 2 COLLAR...

Page 1861: ...cating dimple is between thrust washer halves 23 Seat thrust washer retaining ring with plastic mallet Fig 69 Fig 67 TWO PIECE THRUST WASHER 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS 4...

Page 1862: ...eve can be installed backwards if care is not exercised One side of the sleeve has grooves in it this side must faces the front of the shaft Fig 70 THIRD GEAR BEARING 1 THIRD GEAR BEARING Fig 71 THIRD...

Page 1863: ...side of fifth reverse sleeve must face forward REVERSE IDLER ASSEMBLY 1 Lubricate idler components with gear lube 2 Slide idler gear bearing on shaft Fig 78 Bearing fits either way on shaft 3 Slide ge...

Page 1864: ...FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 78 IDLER GEAR BEARING 1 IDLER GEAR 2 BEARING 3 LOCK BALL 4 REAR OF SHAFT Fig 79 IDLER GEAR REAR THRUST W...

Page 1865: ...e the short end of Installer 8119 to install the new bearing e Bearing is correctly installed if flush with the transmission case 4 Inspect detent plunger bushings for damage NOTE The detent plunger b...

Page 1866: ...r goes toward the input shaft 4 Install fourth gear synchro ring on input shaft Fig 83 5 Adjust height of idler gear pedestal on fixture Fig 84 Start with a basic height of 18 4 cm 7 1 4 in Final adju...

Page 1867: ...ist This will not interfere with assembly If difference is greater than this the coun tershaft adapter tool is probably upside down 10 Position reverse idler in support cup of fixture Fig 87 Verify id...

Page 1868: ...s must be in Neutral position to prevent damaging the synchro and shift components when installing the housings 1 Drive adapter housing alignment dowels back into housing until dowels are flush with m...

Page 1869: ...lation 7 Install rear housing onto geartrain Fig 94 and verify bearing retainer pilot stud is in correct bolt hole in housing Verify countershaft and output shaft bearings are aligned in housing and o...

Page 1870: ...s bolt shanks and under hex heads of bearing retainer bolts Fig 95 4 Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race 5 Install countershaft rear bearing in bear...

Page 1871: ...ll be in Neutral position to prevent damaging the housings shift forks and gears while installing the housings 2 Install 3 4 shift fork in synchro sleeve Fig 100 Verify groove in fork arm is aligned w...

Page 1872: ...roll pins can be installed when the shaft is 180 off If this occurs the trans mission will have to be disassembled again to cor rect shaft alignment 9 Select correct new roll pin for shift shaft lever...

Page 1873: ...pin holes in shift socket and shift shaft Then start roll pin into shift shaft by hand Fig 109 14 Seat roll pin in shift socket with pin punch Roll pin must be flush with socket after installation Fig...

Page 1874: ...haft front bearing Then insert bearing in front housing race Fig 113 Large diameter side of bearing cage goes toward countershaft Fig 114 Small diameter side goes toward bearing race in housing 3 Reac...

Page 1875: ...nd threads Fig 116 11 Install and start housing attaching bolts by hand Fig 116 Then tighten bolts to 34 N m 25 ft lbs 12 Install shift shaft bushing lock bolt Fig 117 Apply Mopar Gasket Maker or equi...

Page 1876: ...y bolt holes are aligned before seating retainer CAUTION Be sure sealer does not get into the oil feed hole in the transmission case or bearing retainer Fig 118 BACKUP LIGHT SWITCH 1 BACKUP LIGHT SWIT...

Page 1877: ...temperature bearing grease or equivalent to contact surfaces Fig 126 of following components release fork ball stud release bearing slide surface input shaft splines release bearing bore propeller sha...

Page 1878: ...NS DESCRIPTION N m Ft Lbs In Lbs Crossmember Nuts 102 75 Transmission Mount Bolts 4WD 68 50 Transmission Mount Bolts 2WD 68 50 Structural Dust Cover Bolts 73 54 Drain Fill Plug 9 27 14 20 Front To Rea...

Page 1879: ...MOVER C 3985 B INSTALLER C 3972 A REMOVER 6957 INSTALLER 6951 HANDLE C 4171 REMOVER INSTALLER 6858 FIXTURE 6747 ADAPTER 6747 1A ADAPTER 6747 2A 21 40 MANUAL TRANSMISSION NV3500 DR MANUAL TRANSMISSION...

Page 1880: ...LITTER 1130 TUBE 6310 1 INSTALLER 8118 REMOVER INSTALLER 8119 ALIGNMENT STUD 8120 INSTALLER C 3860 A INSTALLER 8123 INSTALLER 64428 REMOVER 8117A DR MANUAL TRANSMISSION NV3500 21 41 MANUAL TRANSMISSIO...

Page 1881: ...pported on caged type roller bearings Drive gear thrust reac tion is controlled by a needle type thrust bearing The bearing is located at the forward end of the mainshaft The transmission is a top loa...

Page 1882: ...adequate sealer gaps in the sealer incorrect bolt tightening or use of a non recommended sealer A leak at the front of the transmission will be from either the front bearing retainer or retainer seal...

Page 1883: ...ge at trans fer case range lever Then remove transfer case shift mechanism from transmission Fig 4 2 Support and secure transfer case to transmis sion jack with safety chains 3 Remove transfer case mo...

Page 1884: ...mission EXTENSION ADAPTER HOUSING 1 Remove bolts attaching extension adapter hous ing to gear case Fig 8 Fig 5 SHIFT MECHANISM COVER BOLTS 1 SHIFT MECHANISM COVER 2 BOLTS Fig 6 LOOSEN SHIFT MECHANISM...

Page 1885: ...Install Socket 6993 4X2 or Socket 6984 4X4 with breaker bar to hold mainshaft and remove fifth gear nut NOTE Wedge breaker bar handle against workbench Purpose of socket wrench and breaker bar is to p...

Page 1886: ...asher from countershaft Fig 15 NOTE Note washer bore locating notch for assem bly reference 9 Remove thrust washer locating pin from coun tershaft 10 Remove mainshaft fifth gear with Puller Set 6444 a...

Page 1887: ...th retaining nuts Fig 19 Tighten puller bolt to remove gear from shaft splines 14 Remove mainshaft rear bearing plate bolts and remove fifth gear plate end play shims and bear ing cup Fig 20 Fig 17 PU...

Page 1888: ...ig 23 Insert Jaws 6453 1 in puller flange Narrow lip of puller jaws will go under bearing cup 5 Install Disc C 4487 1 into bearing retainer for Insert 6453 2 to rest upon 6 Install assembled tools in...

Page 1889: ...HAFT AND GEARTRAIN 1 Move 1 2 and 3 4 synchro sleeves into neutral 2 Remove drive gear thrust bearing from forward end of mainshaft Fig 29 3 Remove fourth gear clutch gear and synchro stop ring from m...

Page 1890: ...2 DRIVE GEAR THRUST BEARING Fig 30 FOURTH GEAR CLUTCH GEAR STOP RING 1 FOURTH GEAR SYNCHRO STOP RING 2 FOURTH SPEED CLUTCH GEAR Fig 31 MAINSHAFT AND GEARTRAIN 1 MAINSHAFT AND CASE Fig 32 COUNTERSHAFT...

Page 1891: ...them in place 7 Remove idler gear thrust washers from gear case Install washers on idler shaft to keep them together for cleaning and inspection Fig 33 END PLAY SHIM AND REAR BEARING CUP 1 COUNTERSHA...

Page 1892: ...oun tershaft out of gear case Fig 39 13 Remove countershaft front bearing with Puller Flange 6444 1 and Puller Bolts 6444 4 Fig 40 14 Position first Jaw 6451 on bearing and seat puller flange in notch...

Page 1893: ...al 1 Remove drive gear thrust bearing from end of mainshaft if not previously removed 2 Place 3 4 gear in a press with support under 3rd gear and Remove 3 4 synchro hub third gear stop ring and third...

Page 1894: ...NG 1 THIRD GEAR NEEDLE BEARING Fig 46 SNAP RING AND THIRD GEAR BEARING SPACER 1 SECOND GEAR THRUST WASHER 2 THRUST WASHER SNAP RING 3 THIRD GEAR BEARING SPACER Fig 47 SECOND GEAR THRUST WASHER 1 SECON...

Page 1895: ...nap ring from mainshaft synchro hub groove Fig 51 Fig 48 THRUST WASHER LOCATING PIN 1 THRUST WASHER LOCATING PIN Fig 49 SECOND GEAR 1 SECOND GEAR Fig 50 SECOND GEAR BEARING 1 SECOND GEAR NEEDLE BEARIN...

Page 1896: ...ve first gear clutch cone front snap ring from mainshaft hub Fig 56 Fig 52 SECOND GEAR CLUTCH CONE AND RING 1 1 2 SLEEVE AND HUB 2 SYNCHRO STOP RING 3 CLUTCH RING 4 SECOND GEAR CLUTCH CONE Fig 53 1 2...

Page 1897: ...4 19 Position the first Jaw 6445 on the bearing cone and seat Puller Flange 6444 1 in notch of jaw Fig 58 20 Install second Jaw 6445 on the bearing cone and puller flange Slide Collar 6444 8 over jaws...

Page 1898: ...problems 25 Remove reverse gear bearing assembly from mainshaft Fig 61 26 Remove reverse gear bearing spacer from mainshaft Fig 62 27 Remove reverse clutch gear snap ring Fig 62 Heavy duty snap ring p...

Page 1899: ...aring surfaces splines snap ring grooves and threads Replace the shaft if any surfaces exhibit considerable wear or damage Inspect the countershaft and bearings Replace the shaft if any surfaces exhib...

Page 1900: ...one with petroleum jelly 4 Position gear case on end with rear of case fac ing up Fig 67 5 Install countershaft in gear case Fig 67 NOTE Do not install rear countershaft bearing on countershaft at thi...

Page 1901: ...ing cup 15 Lubricate countershaft rear bearing cup and cone with petroleum jelly 16 Install countershaft rear bearing cup in gear case and over rear bearing Fig 73 Tap cup into place with plastic mal...

Page 1902: ...be 0 051 0 15 mm 0 002 0 006 in 4 Remove countershaft rear bearing plate 5 Install a end play shim that will provide mini mum countershaft end play Position shim on rear bearing cup Fig 77 Fig 73 COUN...

Page 1903: ...or component identi fication and location Lubricate mainshaft bearing surfaces and all bear ing assemblies with Castrolt Syntorq or with petro leum jelly 1 Install first snap ring in rear most groove...

Page 1904: ...in above surface of work bench Then allow sleeve to drop down on hub Fig 83 c Install springs and struts in hub Fig 83 Use lots of petroleum jelly to hold them in place Then compress struts with your...

Page 1905: ...Verify snap ring is seated in groove in mainshaft hub 9 Assemble second gear clutch cone clutch ring and stop ring Fig 87 Fig 84 FIRST GEAR STOP RING IN SYNCHRO HUB Fig 85 1 2 SYNCHRO 1 MAINSHAFT HUB...

Page 1906: ...ll second gear bearing on mainshaft Fig 90 13 Install second gear on mainshaft and bearing Rotate gear until tabs of second gear clutch ring are seated in tab slots in gear Fig 91 Fig 88 SECOND GEAR C...

Page 1907: ...ush with mainshaft hub NOTE If bearing is not flush with hub the bearing spacer or snap ring was not installed 19 Install third gear over bearing and onto main shaft Fig 96 Fig 92 THRUST WASHER PIN 1...

Page 1908: ...ller C 4040 Fig 99 23 Verify 3 4 synchro hub is seated on shaft with approximately 3 mm 0 125 in of shaft spline visi ble NOTE If hub is not seated stop ring lugs are mis aligned Rotate ring until lug...

Page 1909: ...ide of the sleeve faces rearward a Position sleeve on hub so tapered side of sleeve faces rearward Fig 103 b Rotate sleeve to align teeth on sleeve and hub Sleeve will slide easily into place on hub w...

Page 1910: ...38 Install fourth gear clutch gear in stop ring Fig 108 39 Roll gear case onto its left side 40 Grip mainshaft at pilot bearing hub and just behind reverse gear Then lift assembly and guide rear of s...

Page 1911: ...install it in drive gear bore 3 Install drive gear on mainshaft Work gear rearward until mainshaft hub is seated in pilot bear ing 4 Install bearing cup in front retainer with Han dle C 4171 and Inst...

Page 1912: ...y 4 Place gear case in upright position on bench Either cut hole in bench to accept drive gear and front retainer or use C clamps to secure transmission on bench NOTE Do not leave transmission unsuppo...

Page 1913: ...cone side faces the front 3 Lubricate and install fifth gear bearing on countershaft Fig 120 Fig 116 REAR BEARING PLATE 1 BEARING PLATE OIL HOLE AT TOP 2 MAINSHAFT REAR BEARING PLATE Fig 117 MAINSHAF...

Page 1914: ...and fork into place with plastic or rawhide mallet 7 Install fifth gear synchro struts and springs Fig 124 Fig 121 SYNCHRO SLEEVE ON COUNTERSHAFT FIFTH 1 GEAR HUB 2 SYNCHRO SLEEVE 3 COUNTERSHAFT FIFTH...

Page 1915: ...5 Place 10 15 drops of Loctite 272 onto the main shaft threads where the fifth gear nut will be engaged 6 Install fifth gear nut on mainshaft Fig 127 7 Hold mainshaft Socket 6993 4X2 or Socket 6984 4...

Page 1916: ...lt Syn torq gear lubricant or equivalent Then apply light coat of petroleum jelly to shift fork contact surfaces 4 Verify shift fork pads Fig 130 are secure 5 Verify 1 2 and 3 4 synchro sleeves and fo...

Page 1917: ...bolts to 10 2 11 25 N m 7 5 8 3 ft lbs 10 Install the shift lever extension onto the shift tower and lever assembly 11 Install shift boot and bezel 12 Connect battery negative cable FOUR WHEEL DRIVE 1...

Page 1918: ...35 Front Bearing Retainer Bolts 27 34 20 25 235 305 Mainshaft Bearing Plate Bolts 19 26 14 19 170 230 PTO Cover Bolts 27 54 20 40 Extension Adapter Housing Bolts 41 68 30 50 Shift Mechanism Cover Bolt...

Page 1919: ...AL C 3972 A INSTALLER SEAL 8154 INSTALLER SEAL C 3860 A WRENCH 6443 WRENCH 6743 SOCKET 6441 SOCKET 6442 SOCKET 6993 SOCKET 6984 PULLER 6444 21 80 MANUAL TRANSMISSION NV4500 DR MANUAL TRANSMISSION NV45...

Page 1920: ...JAWS 6459 JAWS 6820 JAWS INSERT 6453 JAWS 6447 JAWS 6449 JAWS 6451 REMOVER 6454 INSTALLER 6061 INSTALLER C 4340 DR MANUAL TRANSMISSION NV4500 21 81 MANUAL TRANSMISSION NV4500 Continued...

Page 1921: ...INSTALLER 6446 JAWS 6445 INSTALLER C 4040 INSTALLER 6448 INSTALLER C 4308 INSTALLER 6052 ROD EXTENSION 8161 21 82 MANUAL TRANSMISSION NV4500 DR MANUAL TRANSMISSION NV4500 Continued...

Page 1922: ...1 Mark the propeller shaft and yoke for installa tion reference 2 Remove the propeller shaft 3 Remove extension housing seal Fig 132 using Remover C 3985 B 4 On heavy duty 4X2 vehicles remove extensi...

Page 1923: ...hanism cover at slots provided in cover Fig 136 4 Raise cover enough to disengage it from align ment dowels in gear case Fig 137 5 Raise front of shift mechanism cover and lift cover up and off gear c...

Page 1924: ...p pads into place and verify locating tabs are locked in SHIFT COVER 1 Clean mating surfaces of shift mechanism cover and gear case with wax and grease remover 2 Apply a small amount of Mopar silicone...

Page 1925: ...ission shift cover 5 Remove the shift tower and isolator plate from the transmission shift cover INSTALLATION 1 Clean the mating surfaces of shift tower isola tor plate and shift cover with suitable w...

Page 1926: ...sh manual transmission Fig 1 All gear ranges including reverse are synchronized First and second gears uti lize dual cone synchronizers in order to aid shifting Sixth gear is an overdrive range The tr...

Page 1927: ...Fig 1 NV5600 MANUAL TRANSMISSION 21 88 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSION NV5600 Continued...

Page 1928: ...lt of an overfill condition Leaks at the rear of the extension or adapter housing will be from the hous ing oil seals Leaks at component mating surfaces will probably be the result of inadequate seale...

Page 1929: ...ts at the engine block 5 Slide transmission and jack rearward until input shaft clears clutch disc and pressure plate 6 Lower transmission jack and remove transmis sion from under vehicle FOUR WHEEL D...

Page 1930: ...plug Fig 7 5 Remove primary shift rail detent spring Fig 8 Fig 5 REMOVE SHIFT TOWER 1 SHIFT TOWER 2 TRANSMISSION Fig 6 SHIFT TOWER ISOLATOR PLATE 1 ISOLATOR PLATE 2 TRANSMISSION Fig 7 PRIMARY SHIFT R...

Page 1931: ...extension adapter housing from the transmission gear case with Puller 8244 Fig 12 NOTE It may be necessary to straighten the hous ing during removal due to the tendency for the reverse idler shaft to...

Page 1932: ...m between the bearing race and the housing Fig 16 8 Remove crossover cam bushing from the exten sion adapter housing with Remover 8240 9 On 4X2 vehicles remove extension housing seal with a pry tool o...

Page 1933: ...perate countershaft reverse gear and sleeve 7 Remove output shaft nut with Wrench 8226 on the shaft nut and Socket 6993 or 6984 to hold the shaft Fig 20 Discard output shaft nut from the output shaft...

Page 1934: ...with a heat gun Do not use a torch to heat the sleeve or damage to the output shaft may occur 11 Remove roll pin securing the reverse shift fork to the reverse shift rail with a 6 mm 7 32 in punch an...

Page 1935: ...ase 5 Attach an engine crane or equivalent to Fixture 8232 and remove the transmission gear case from the clutch housing Fig 25 6 Remove rear output shaft and countershaft bearing races from the trans...

Page 1936: ...5 6 syn chro together during the removal operation NOTE Note the order of the shift fork arms at the primary shift rail while in the Neutral position 7 Raise geartrain and shift rails until all the s...

Page 1937: ...from the synchro hub COUNTERSHAFT BEARINGS 1 Remove snap ring holding the front counter shaft bearing onto the countershaft 2 Remove front countershaft bearing with Collar 6444 8 Jaws 6451 Puller Rods...

Page 1938: ...r Rods 6444 4 for 4X4 vehicles with the remainder of Puller 6444 to remove the rear output shaft bearing from the output shaft 5 Remove rear output shaft thrust washer from the output shaft INPUT SHAF...

Page 1939: ...haft Fig 38 3 Remove first gear blocker rings 2 and cones from the 1 2 synchro assembly Fig 39 4 Install the remainder of the output shaft into Fixture 8227 with press blocks under second gear 5 Insta...

Page 1940: ...NGS 3 FIRST GEAR FRICTION CONE Fig 40 SECOND GEAR 1 2 SYNCHRO FIRST GEAR BEARING SLEEVE 1 OUTPUT SHAFT 2 FIRST GEAR BEARING SLEEVE 3 SECOND GEAR 4 FIXTURE 5 1 2 SYNCHRO Fig 41 SIXTH GEAR COMPONENTS 1...

Page 1941: ...haft Fig 43 6 Remove countershaft from the press and Fix ture 8227 7 Remove fourth countershaft gear friction cone blocker ring and bearing from the countershaft Fig 44 8 Install countershaft into Fix...

Page 1942: ...ved from the countershaft If neces sary slide 2 3 thrust washer off countershaft CLUTCH HOUSING 1 Remove input shaft retainer bolts from the clutch housing and remove retainer Fig 47 Fig 45 THIRD COUN...

Page 1943: ...hed out with crocus cloth Inspect the reverse idler gear bearings shaft and thrust washers Replace the bearings if the rollers are worn chipped cracked flat spotted or brinnelled Replace the gear if t...

Page 1944: ...e locating pin notches are distorted Inspect the case and housing adapter sealing and mating surfaces are free of burrs and nicks Inspcet the alignment dowels in the case top surface and in the housin...

Page 1945: ...ch ring up 12 Install first gear synchro inner blocker ring onto first gear Fig 51 13 Install first gear synchro friction cone over the blocker ring and onto first gear Fig 52 14 Install first gear sy...

Page 1946: ...ar bearing over the output shaft and into first gear 20 Install output shaft thrust washer onto the output shaft Fig 59 Fig 57 FIRST GEAR BEARING SLEEVE 1 INSTALLER 2 FIRST GEAR BEARING SLEEVE Fig 58...

Page 1947: ...24 Install sixth gear bearing onto the output shaft 25 Install sixth gear onto the output shaft and over the sixth gear bearing Fig 61 26 Install the sixth gear friction cone onto sixth gear 27 Insta...

Page 1948: ...g onto the output shaft 32 Press pocket bearing the remainder of the way onto the output shaft using Guide 8235 and a shop press Fig 65 33 Install a new snap ring to hold the output shaft pocket beari...

Page 1949: ...rshaft gear 7 Install 2 3 thrust washer onto the countershaft 8 Place third gear 3 4 synchro assembly in a shop press 9 Install countershaft through the third gear 3 4 synchro assembly 10 Press counte...

Page 1950: ...Place sixth countershaft gear in the shop press 18 Position fourth countershaft gear assembly onto the sixth countershaft gear Fig 70 19 Install countershaft into the fourth sixth coun tershaft gear a...

Page 1951: ...ler 8236 and Handle C 4171 25 Install a new snap ring to hold the front countershaft bearing onto the countershaft 26 Place rear countershaft bearing onto the coun tershaft INPUT SHAFT 1 Place the inp...

Page 1952: ...using so that the bearing race protrudes 0 4 in above the front surface of the clutch housing Install bearing race with Remover 6061 1 and Han dle C 4171 3 Install countershaft oil guide and spacer in...

Page 1953: ...fth gear friction cone onto the input shaft 3 Install fifth gear blocker ring onto the fifth gear friction cone 4 Install output shaft into the input shaft Fig 77 5 Install countershaft into the Suppo...

Page 1954: ...0 Install geartrain and shift rails into the clutch housing Lower the geartrain and rails into the hous ing slowly while guiding input shaft through input shaft seal Avoid any binds on the shift rails...

Page 1955: ...install the transmission gear case 4 Apply sealant to the clutch housing 5 Attach an engine crane or equivalent to Fixture 8232 and install the transmission gear case onto the clutch housing Fig 83 6...

Page 1956: ...he input shaft retainer and install retainer onto the clutch housing Install bolts and tighten to 28 N m 20 ft lbs REVERSE GEAR 1 Install reverse shift fork and synchronizer as an assembly onto the re...

Page 1957: ...punch 9 Press countershaft reverse gear into the sleeve with a shop press 10 Install reverse countershaft rear bearing onto the countershaft reverse gear assembly with Installer C 4652 and Handle C 41...

Page 1958: ...sure the distance from the back of the bearing race to Gauge Bar 6311 Fig 92 8 Measure thickness of the gauge bar and record the total of the two measurements 9 Clean all the sealer from the extension...

Page 1959: ...l shift tower 1 Apply a light coat of Mopar high temperature bearing grease or equivalent to contact surfaces of following components input shaft splines release bearing slide surface of front retaine...

Page 1960: ...ts to 41 47 N m 30 35 ft lbs if case has 3 8 studs If case has 5 16 studs tighten to 30 41 N m 22 30 ft lbs 5 Connect transfer case shift lever to range lever on transfer case 6 Install propeller shaf...

Page 1961: ...using 48 35 Bolt Extension Adapter Housing 48 35 Bolt Shift Tower 9 7 80 Switch Back up Lamp 28 20 Bolt Shift Blocker 55 41 Bolt PTO Cover 40 30 Pivot Clutch Release Lever 22 16 Plug Fill 30 22 Nut Ou...

Page 1962: ...CH 8226 SOCKET 6984 SOCKET 6984 PULLER 6444 JAWS 6447 JAWS 6451 INSTALLER 6061 INSTALLER 6448 INSTALLER C 4308 ROD EXTENSION 8161 DR MANUAL TRANSMISSION NV5600 21 123 MANUAL TRANSMISSION NV5600 Contin...

Page 1963: ...FIXTURE 8227 INSTALLER 8228 FIXTURE 8230 FIXTURE 8232 REMOVER 8233 REMOVER 8234 GUIDE 8235 INSTALLER 8236 21 124 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSION NV5600 Continued...

Page 1964: ...INSTALLER REMOVER 8237 INSTALLER REMOVE 8238 INSTALLER 8239 REMOVER 8240 FIXTURE 8241 HOLDING 8242 REMOVER 8243 PULLER 8244 DR MANUAL TRANSMISSION NV5600 21 125 MANUAL TRANSMISSION NV5600 Continued...

Page 1965: ...T STAND 8246 REMOVER 8262 REMOVER 8271 DIAL INDICATOR C 3339 INSTALLER C 4965 REMOVER L 4418 PULLER C 293 PA ADAPTERS C 293 52 INSTALLER MD998805 21 126 MANUAL TRANSMISSION NV5600 DR MANUAL TRANSMISSI...

Page 1966: ...er shaft and pinion yoke for installation reference and remove the propeller shaft 2 Remove extension housing seal with a pry tool or a slide hammer and screw 3 Remove extension housing bushing with R...

Page 1967: ...gear case with suitable wax and grease remover 3 Apply Mopar Gasket Maker or equivalent to the sealing surface of the transmission Do not over apply sealant 4 Install isolator plate onto the transmiss...

Page 1968: ...NTERLOCK SYSTEM DESCRIPTION 194 OPERATION 194 DIAGNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK 195 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 195 ELECTRONIC GOVERNOR DESCRIPTION 196 OPERAT...

Page 1969: ...ERATION 249 DISASSEMBLY 249 CLEANING 250 INSPECTION 250 ASSEMBLY 250 REAR SERVO DESCRIPTION 252 OPERATION 252 DISASSEMBLY 252 CLEANING 252 ASSEMBLY 253 SHIFT MECHANISM DESCRIPTION 253 OPERATION 253 SO...

Page 1970: ...so contains the kickdown front and the low reverse rear bands which along with the over running clutch and overdrive clutch serve as the holding components The driving and holding compo nents combine...

Page 1971: ...Fig 1 46RE Transmission 21 132 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 1972: ...arious conditions such as when the O D switch is OFF when the vehicle is cruising on a level surface after the vehicle has warmed up The torque converter clutch can also be engaged in the manual secon...

Page 1973: ...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 1974: ...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 1975: ...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 1976: ...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 1977: ...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 1978: ...DIAGNOSIS 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 VEH...

Page 1979: ...ch is slipping If the transmission does not slip in Reverse the rear clutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive clutch is slipping Simi larly if th...

Page 1980: ...2 Range This test checks pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this test 1 Leave vehicle in place on hoist and leave Test Gauge C 3292 connected to accum...

Page 1981: ...prevent wheels from rotating 7 Compare results of pressure test with analysis chart Test Six Transmission In Overdrive Fourth Gear This test checks line pressure at the overdrive clutch in fourth gea...

Page 1982: ...HOUSING FLUID LEAK When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source of the leak Som...

Page 1983: ...may occur if the band is still tightened to the front clutch retainer 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatext No 2 to plug threads and tighten plug to 17 N m...

Page 1984: ...OM 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 linkage if worn or da...

Page 1985: ...nspect adjust and 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 procedu...

Page 1986: ...et 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 overdrive annulus g...

Page 1987: ...ction 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 DRBT scan tool 7 PC...

Page 1988: ...ear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid...

Page 1989: ...een passages 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 Planetar...

Page 1990: ...RS IMMEDIATELY AFTER 2 3 SHIFT 1 Overdrive Solenoid Connector or Wiring Shorted 1 Test connector and wiring for loose connections shorts or ground and repair as needed 2 TPS Malfunction 2 Test TPS and...

Page 1991: ...ine no start 7 PCM Malfunction 7 Check with DRBT scan tool and replace if necessary 8 Overdrive Solenoid Shorted Open 8 Replace solenoid if shorted or open and repair loose or damaged wires DRBT scan...

Page 1992: ...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 1993: ...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 1994: ...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 1995: ...attery negative cable 2 Raise vehicle 3 Remove the transfer case skid plate Fig 12 if equipped 4 Disconnect and lower or remove necessary exhaust components 5 Remove engine to transmission struts Fig...

Page 1996: ...shift rod from transfer case shift lever 16 Support rear of engine with safety stand or jack 17 Raise transmission slightly with service jack to relieve load on crossmember and supports 18 Remove bol...

Page 1997: ...input shaft end play as follows Fig 20 a Attach Adapter 8266 5 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission an...

Page 1998: ...d and valve body out of case Fig 23 10 Remove accumulator outer spring piston and inner spring Fig 24 Note position of piston and springs for assembly reference Remove and discard piston seals if worn...

Page 1999: ...e oil pump bolts c Thread Slide Hammer Tools C 3752 into threaded holes in flange of oil pump housing Fig 27 d Remove oil pump and reaction shaft support by bumping slide hammers outward alternately t...

Page 2000: ...slide band over front clutch retainer and out of case Fig 31 18 Remove front and rear clutch assemblies as a unit Fig 32 Fig 32 Removing Front Rear Clutch Assemblies 1 FRONT AND REAR CLUTCH ASSEMBLIES...

Page 2001: ...ed install Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 24 Loosen rear band locknut and loosen adjus...

Page 2002: ...ch assembly Fig 40 Assembly can be removed without displacing rollers and springs if care is exercised Note position of rollers and springs for assembly reference Fig 38 Low Reverse Drum And Thrust Wa...

Page 2003: ...ress servo spring retainer only enough to permit snap ring removal 36 Remove servo piston snap ring Fig 44 Start one end of ring out of bore Then carefully work removal tool around back of snap ring u...

Page 2004: ...skets seal rings or O rings during overhaul Replace these parts as a matter of course Also do not reuse snap rings or E clips that are bent or distorted Replace these parts as well ASSEMBLY Do not all...

Page 2005: ...bore in case with transmission fluid 6 Install front servo piston in bore Carefully run small suitable tool around piston ring to press it back into groove and ease installation Fig 48 Rotate piston i...

Page 2006: ...VERSE DRUM 1 Install overrunning clutch components 2 Position rear band and link in case Fig 50 3 Install low reverse drum Fig 51 Slide drum through rear band onto piston retainer hub and into engagem...

Page 2007: ...gnment Shaft 6227 2 if installed previously 2 Install assembled intermediate shaft and plan etary geartrain Fig 55 Support shaft carefully dur ing installation Do not allow shaft bearing bushing surfa...

Page 2008: ...b 7 Place transmission case in upright position or place blocks under front end of transmission repair stand to tilt case rearward This makes it easier to install front rear clutch assembly 8 Align di...

Page 2009: ...ace Then install washer over reaction shaft hub and seat it on pump Fig 63 CAUTION The thrust washer bore I D is cham fered on one side Make sure the chamfered side is installed so it faces the pump 4...

Page 2010: ...d check for bind If bind exists components are either mis assembled or not seated Disassemble and correct as necessary before proceed ing Fig 62 Oil Pump Gasket And Pilot Studs 1 OIL PUMP GASKET 2 PIL...

Page 2011: ...at seal with 15 16 inch deep well socket 3 Install valve body as follows a Start park rod into park pawl If rod will not slide past park pawl pawl is engaged in park gear Rotate overdrive output shaft...

Page 2012: ...seal lip with transmission fluid 3 Lubricate converter pilot hub of the crankshaft with a light coating of Mopart High Temp Grease 4 Align and install converter in oil pump 5 Carefully insert converte...

Page 2013: ...R INSTALLATION 25 Connect cooler lines Fig 71 to transmission 26 Install transmission fill tube Install new seal on tube before installation 27 Install any exhaust components previously removed 28 Ali...

Page 2014: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK DR AUTOMATIC TRANSMISSION 46RE 21 175 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2015: ...HYDRAULIC FLOW IN NEUTRAL 21 176 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 2016: ...HYDRAULIC FLOW IN REVERSE DR AUTOMATIC TRANSMISSION 46RE 21 177 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2017: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 178 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 2018: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR DR AUTOMATIC TRANSMISSION 46RE 21 179 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2019: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED 21 180 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 2020: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 46RE 21 181 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2021: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 182 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 2022: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED DR AUTOMATIC TRANSMISSION 46RE 21 183 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2023: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 184 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 2024: ...HYDRAULIC FLOW IN MANUAL SECOND 2 DR AUTOMATIC TRANSMISSION 46RE 21 185 AUTOMATIC TRANSMISSION 46RE Continued...

Page 2025: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING 21 186 AUTOMATIC TRANSMISSION 46RE DR AUTOMATIC TRANSMISSION 46RE Continued...

Page 2026: ...IMENSIONS Component Metric Inch Front clutch thrust washer reaction shaft support hub 1 55 mm 0 061 in 2 15 mm 0 084 in 2 59 mm 0 102 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Inte...

Page 2027: ...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 2028: ...essure C 3293SP Set Dial Indicator C 3339 Compressor Spring C 3422 B Adapter Band Adjuster C 3705 Stand Transmission Repair C 3750 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer...

Page 2029: ...nstaller Seal C 3995 A Handle Universal C 4171 Remover Installer Bushing C 4470 Dial Caliper C 4962 Spring Compressor and Alignment Shaft 6227 Bar Gauge 6311 Gauge Block 6312 21 190 AUTOMATIC TRANSMIS...

Page 2030: ...is located in a housing attached to the side of the valve body Fig 73 Retainer Detent Ball and Spring 6583 Installer Overdrive Piston Seal 8114 Socket TRS Mounting Bracket 8581 Installer Seal 9037 Fi...

Page 2031: ...band application After the kickdown servo has become immovable line pressure will fin ish pushing the accumulator up into its bore When the large end of the accumulator piston is seated in its bore th...

Page 2032: ...the rear planet carrier sta tionary by being mounted around and applied to the low reverse drum ADJUSTMENTS ADJUSTMENT BANDS FRONT BAND The front kickdown band adjusting screw is located on the left...

Page 2033: ...Y posi tion An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed approximately one half an inch A magnetic holding device in...

Page 2034: ...ey cylinder is in the LOCK posi tion Cable will not adjust correctly in any other position 7 Ensure that the cable is free to self adjust by pushing cable rearward and releasing 8 Push the gearshift c...

Page 2035: ...pressure to the governor pressure solenoid valve and to return governor pressure The governor pressure solenoid valve is mounted in the governor body The body is bolted to the lower side of the transf...

Page 2036: ...speeds and harsh shifts The elec tronically controlled low temperature governor pres sure curve is higher than normal to make the transmission shift at normal speeds and sooner The PCM uses a tempera...

Page 2037: ...pressure sensor from governor body 8 Remove bolts holding governor body to valve body 9 Separate governor body from valve body Fig 87 10 Remove governor body gasket Fig 84 Governor Solenoid And Pressu...

Page 2038: ...ure solenoid to bore in governor body Fig 89 9 Push solenoid into governor body 10 Place solenoid retainer in position on governor Fig 90 11 Install screws to hold pressure solenoid retainer to govern...

Page 2039: ...eal Remover C 3985 B Fig 94 from overdrive housing INSTALLATION 1 Place seal in position on overdrive housing 2 Drive seal into overdrive housing with Seal Installer C 3995 A Fig 95 3 Carefully guide...

Page 2040: ...sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped clean before checking fluid level Dirt grease and other foreign material on the ca...

Page 2041: ...ll PROCEDURE TWO 1 Start engine and apply parking brake 2 Shift the transmission into DRIVE for approxi mately 2 seconds 3 Shift the transmission into REVERSE for approximately 2 seconds 4 Shift the t...

Page 2042: ...le Inspect the sealing surfaces of the gasket If the sealing ribs on both surfaces appear to be in good condition clean the gasket of any foreign material and reinstall 4 Position the oil pan gasket o...

Page 2043: ...number of discs and plates may vary with each engine and vehicle combination OPERATION To apply the clutch pressure is applied between the clutch retainer and piston The fluid pressure is provided by...

Page 2044: ...m pressor tool 4 Remove clutch piston springs Fig 102 Note position of piston springs for assembly reference 5 Remove clutch piston from retainer with a twisting motion 6 Remove and discard clutch pis...

Page 2045: ...piston check ball The ball should be securely in place Replace the piston if the ball is missing or seized in place ASSEMBLY NOTE The 46RE transmission uses three plates and discs for the front clutch...

Page 2046: ...waved snap ring 16 Check clutch pack clearance with feeler gauge Fig 106 Clearance between waved spring and pres sure plate should 1 78 3 28 mm 0 070 0 129 in If clearance is incorrect clutch plates c...

Page 2047: ...applied giving a small amount of overlap between them DISASSEMBLY 1 Remove seal ring from rod guide Fig 108 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from...

Page 2048: ...e pressure Engine starts must be possible b PARK position Apply downward force on the shift arm and remove pressure Engine starts must be possible c NEUTRAL position Normal position Engine starts must...

Page 2049: ...the opening in the dash panel Fig 116 2 Seat the cable grommet into the dash panel opening 3 Snap the cable into the steering column bracket so the retaining ears Fig 117 are engaged and snap the cabl...

Page 2050: ...s in any position other than PARK or NEUTRAL or if the engine will not start at all the transmission range sensor may be faulty Gearshift Adjustment Procedure 1 Shift transmission into PARK 2 Release...

Page 2051: ...e oil pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body DISASSEMBLY 1 Mark position of support in oil pu...

Page 2052: ...ool C 3981 Discard seal after removal Fig 121 Pump Gears 1 GEAR BORE 2 PUMP BODY 3 INNER GEAR 4 OUTER GEAR Fig 122 Oil Pump Assembly 1 OIL SEAL 7 BOLTS 6 2 VENT BAFFLE 8 1 THRUST WASHER SELECTIVE 3 OI...

Page 2053: ...chipped or damaged Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn scored or damaged It is not necessary to replace the bushings unl...

Page 2054: ...haft 3 Tap bushing into place until Installer Tool SP 5118 bottoms in pump cavity Keep tool and bush ing square with bore Do not allow bushing to become cocked during installation 4 Stake pump bushing...

Page 2055: ...N The reaction shaft support seal rings will break if overspread or twisted If new rings are being installed spread them only enough for instal lation Also be very sure the ring ends are securely hook...

Page 2056: ...er to 21 TRANSMISSION AUTOMATIC OVERDRIVE REMOVAL 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear bearing into overdrive housing Fig 131 4 Using a suitable drive...

Page 2057: ...plate are lugged to the overdrive housing This allows the intermediate shaft to transfer the engine torque to the planetary gear and overrunning clutch This drives the planetary gear inside the annul...

Page 2058: ...r from the lever 1 Pull the connector out of the lever just enough to grasp it CAUTION Be careful not to bend the pins on the overdrive off switch Use care when installing the switch as it is not inde...

Page 2059: ...rmediate shaft Do not tilt unit during removal Keep it as level as possible 11 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and over...

Page 2060: ...ainer Fig 142 Fig 139 Overdrive Piston Thrust Bearing Removal Installation 1 THRUST BEARING 2 OVERDRIVE PISTON 3 THRUST PLATE Fig 140 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PIS...

Page 2061: ...ring is located in same groove as wave spring Fig 143 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig 144 Overdrive Clutch Pack Removal 1 OVERDRIVE CLUTCH PAC...

Page 2062: ...snap ring that retains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 152 Fig 148 Access Cover Screw Removal 1 TORX SCREWDRIVER T25 2 ACCESS COVER SCREWS Fig 149 Access Cove...

Page 2063: ...t flange with steel press plates as shown and center assembly under press ram 3 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pr...

Page 2064: ...and pliers to grip hub splines and remove clutch with counterclockwise twisting motion Fig 159 Overrunning Clutch Assembly Removal Installation 1 OVERRUNNING CLUTCH 2 NEEDLE BEARING Fig 156 Direct Clu...

Page 2065: ...lus gear and output shaft for assem bly alignment reference Fig 163 Use punch or scriber to mark gear and shaft Fig 160 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment 1 DIRECT CLUT...

Page 2066: ...seal if loose distorted or damaged Examine the overdrive and direct clutch discs and plates Replace the discs if the facing is worn severely scored or burned and flaking off Replace the clutch plates...

Page 2067: ...part ATF 4 Automatic Transmission fluid Allow discs to soak for 10 20 minutes 2 Install new pilot bushing and clutch hub bush ing in output shaft if necessary Fig 166 Lubricate bushings with petroleum...

Page 2068: ...all bearing if it does not seat squarely 10 Install overrunning clutch in output shaft Fig 172 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockw...

Page 2069: ...are fully seated before proceeding 15 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assem bly mounted in p...

Page 2070: ...s rearward Splines at rear of hub are raised slightly Counter bore in plate fits over raised splines Plate should be flush with this end of hub Fig 179 Fig 178 46RE Direct Clutch Pack Components 1 CLU...

Page 2071: ...on hub and hold it in place 22 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 23 Realign clut...

Page 2072: ...t seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 186 Fig 186 Correct Rear Bearing Locating Ring Position 1 CASE ACCESS HOLE 2 TAB ENDS OF LO...

Page 2073: ...ends Fig 190 2 Install wave spring on top of reaction ring Fig 191 Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ensure that the e...

Page 2074: ...ial Tool 6312 through sun gear planetary gear and into pilot bushing in output shaft Be sure tool bottoms against planetary shoulder b Position Gauge Tool 6311 across face of over drive case Fig 194 T...

Page 2075: ...piston to the two mating holes in retainer b Lubricate overdrive piston seals with Mopart Door Ease or equivalent c Install piston over Seal Guide 8114 3 and inside Guide Ring 8114 1 d Push overdrive...

Page 2076: ...s attaching overdrive unit to trans mission unit Tighten bolts in diagonal pattern to 34 N m 25 ft lbs 13 Connect the transmission speed sensor and overdrive wiring connectors 14 Install the transfer...

Page 2077: ...unning clutch assembly clutch cam low reverse drum and overdrive piston retainer in solvent Dry them with compressed air after clean ing INSPECTION Inspect condition of each clutch part after cleaning...

Page 2078: ...Bolt SP 3701 and Press Plate SP 3583 A Fig 205 6 Install assembled puller plate and bolt Fig 206 Insert bolt through cam case and adapter tool Be sure plate is seated squarely on cam Fig 206 Position...

Page 2079: ...retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 14 Position overdrive piston retainer on trans mission case and align bolt holes in retainer gasket and c...

Page 2080: ...100 lbs 100 in or 1 pound per square inch or PSI as it is commonly referred to PRESSURE ON A CONFINED FLUID Pressure is exerted on a confined fluid Fig 211 by applying a force to some given area in co...

Page 2081: ...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 2082: ...n the front planetary gearset must be driven NOTE Gear ratios are dependent on the number of teeth on the annulus and sun gears DISASSEMBLY 1 Remove planetary snap ring from intermediate shaft Fig 215...

Page 2083: ...rear annulus gear Fig 222 Fig 218 Driving Shell Thrust Washer Removal 1 DRIVING SHELL 2 TABBED THRUST WASHER 3 SUN GEAR Fig 219 Sun Gear And Driving Shell Removal 1 INTERMEDIATE SHAFT 2 DRIVING SHELL...

Page 2084: ...t 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 ASSEMBLY...

Page 2085: ...er on planetary gear was not displaced during installation 9 Install tabbed thrust washer in driving shell Fig 229 be sure washer tabs are seated in tab slots of driving shell Use extra petroleum jell...

Page 2086: ...arrier is seated on intermediate shaft 13 Place geartrain in upright position Rotate gears to be sure all components are seated and prop erly assembled Snap ring groove at forward end of intermediate...

Page 2087: ...lutch assembly Fig 235 is composed of the rear clutch retainer pressure plate clutch plates driving discs piston Belleville spring and snap rings The Belleville spring acts as a lever to multi ply the...

Page 2088: ...n The check valve is needed to eliminate the pos sibility of plate drag caused by centrifugal force acting on the residual fluid trapped in the clutch pis ton retainer DISASSEMBLY 1 Remove fiber thrus...

Page 2089: ...for nicks or 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...

Page 2090: ...etainer groove 11 Install pressure plate Fig 236 Ridged side of plate faces downward toward piston and flat side toward clutch pack 12 Install first clutch disc in retainer on top of pressure plate Th...

Page 2091: ...lder of the plug and fully applies the band The period of time from the initial application until the piston is against the shoulder of the plug represents a reduced shocking of the band that cushions...

Page 2092: ...line motion The solenoids used in transmission applications are attached to valves which can be classified as nor mally open or normally closed The normally open solenoid valve is defined as a valve w...

Page 2093: ...over the park gear and monitors transmission output shaft rotating speed OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face Input signals fr...

Page 2094: ...throttle body lever 5 Compare position of cable end to attachment stud on throttle body lever Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in eith...

Page 2095: ...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 transmission to move out of its i...

Page 2096: ...uel economy when engaged Clutch engagement also provides reduced transmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded...

Page 2097: ...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 250 Impeller 1 ENGINE FLEXPLATE 4 EN...

Page 2098: ...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 251 Turbi...

Page 2099: ...s lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impeller and turbine were mecha...

Page 2100: ...otating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to s...

Page 2101: ...otate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 257 Surface of converter lugs should be 1 2 in to rear of straightedge...

Page 2102: ...the instrument cluster The sensor is mounted in the transmission housing near the valve body just above the pan rail It s in the same position as the Park Neutral switch on other transmissions The TR...

Page 2103: ...Information 1 Raise vehicle on 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...

Page 2104: ...pins of the TRS The resistance should be 59 9 ohms If the resistance is not correct replace the TRS 11 With the manual lever in the SECOND posi tion the SECOND position is with the manual lever moved...

Page 2105: ...operation Fig 265 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 2106: ...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 2107: ...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 2108: ...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 2109: ...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 2110: ...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 2111: ...lator valve Fig 271 has a spring on one end that pushes the valve to the left This closes a dump vent that is used to lower pressure The closing of the dump will cause the oil pressure to increase Oil...

Page 2112: ...Fig 271 Regulator Valve in PARK Position Fig 272 Regulator Valve in NEUTRAL Position DR AUTOMATIC TRANSMISSION 46RE 21 273 VALVE BODY Continued...

Page 2113: ...r gear posi tions 145 280 psi The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there...

Page 2114: ...Fig 274 Regulator Valve in REVERSE Position DR AUTOMATIC TRANSMISSION 46RE 21 275 VALVE BODY Continued...

Page 2115: ...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 2116: ...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 2117: ...the right the middle land of the valve will close off the circuit supplying the throttle pres sure to the right side of the valve When the throttle pressure is closed off the valve will move even far...

Page 2118: ...the vehicle is in motion and under acceleration there is throttle pressure being applied to the spring side of the valve and between lands 3 and 4 As vehicle speed increases governor pressure increase...

Page 2119: ...Fig 281 2 3 Shift Valve Before Shift Fig 282 2 3 Shift Valve After Shift 21 280 AUTOMATIC TRANSMISSION 46RE DR VALVE BODY Continued...

Page 2120: ...shift valve in an upshift position The purpose is to prevent the 2 3 valve from downshifting before the 3 4 valve Fig 283 3 4 QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of t...

Page 2121: ...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 2122: ...nsmission input shaft into the con verter through the converter back out between the input shaft and the reaction shaft and back up to the switch valve From the switch valve the fluid pressure is dire...

Page 2123: ...side of the torque converter piston This pressure differential causes the piston to apply against the fric tion material cutting off any further flow of line pres sure oil After the switch valve is s...

Page 2124: ...3 downshift until the TCC is completely unlocked and the clutch is disen gaged SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves When the manual valve is posi...

Page 2125: ...on temperature thermistor Converter clutch overdrive solenoid assembly and harness Governor housing gasket Solenoid case connector O rings 1 Shift transmission into NEUTRAL 2 Raise vehicle 3 Remove ge...

Page 2126: ...governor body and gas ket from transfer plate 4 Remove governor pressure sensor from gover nor body 5 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and d...

Page 2127: ...6583 POSITIONED ON DETENT HOUSING Fig 295 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 296 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLE...

Page 2128: ...l magnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 303 Fig 300 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD F...

Page 2129: ...remove switch valve regulator valve and spring and manual valve Fig 306 20 Remove kickdown detent kickdown valve and throttle valve and spring Fig 306 21 Loosen left side 3 4 accumulator housing atta...

Page 2130: ...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 307 Accumulator Housing Screw Locatio...

Page 2131: ...fall out when lower housing and separator plate are removed 27 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 312 Note position of boost valve tube brace for...

Page 2132: ...r plate for assembly reference 33 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 316 Fig 313 Number 10 Check Ball 1 NUMBER 10 CHE...

Page 2133: ...hift control valve and spring Fig 320 10 Remove 1 2 shift valve and spring Fig 320 11 Remove 2 3 shift valve and spring from valve body Fig 320 12 Remove pressure plug cover Fig 320 13 Remove line pre...

Page 2134: ...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 2135: ...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 2136: ...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 2137: ...essure Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth Position the crocus cloth on a surface plate sheet of plate glass or equal...

Page 2138: ...do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve sticking cross leakage and unsatisfactory operation Tighten v...

Page 2139: ...diameter The remaining 6 check balls are approxi mately 6 3 mm 1 4 in in diameter 2 Position assembled transfer plate and upper housing separator plate on upper housing Fig 327 Be sure filter screen i...

Page 2140: ...lve and 2 3 throttle plug from limit valve housing 6 Install limit valve housing and cover plate Tighten screws to 4 N m 35 in lbs 7 Install shuttle valve as follows a Insert plastic guides in shuttle...

Page 2141: ...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 2142: ...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 2143: ...p and against tube to hold it in position Fig 336 8 Tighten all valve body housing screws to 4 N m 35 in lbs torque after tube and brace are installed Tighten screws in diagonal pattern starting at ce...

Page 2144: ...ccumulator 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 Fi...

Page 2145: ...rottle valve and spring 13 Install kickdown valve and detent 14 Install pressure regulator valve 15 Install switch valve 16 Position adjusting screw bracket on valve body Align valve springs and press...

Page 2146: ...h 15 16 deep well socket Fig 344 3 Check condition of seals on accumulator piston Install new piston seals if necessary 4 Verify that transmission range sensor is NOT installed Valve body cannot be in...

Page 2147: ...sure last LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 345 Distance should be 33 4 mm 1 5 16 in If adjustment...

Page 2148: ...ng Turn throttle lever stop 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 kickdow...

Page 2149: ...SHIFT INTERLOCK SYSTEM DESCRIPTION 375 OPERATION 375 DIAGNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK 375 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 376 ELECTRONIC GOVERNOR DESCRIPTION 376...

Page 2150: ...LY 427 CLEANING 428 INSPECTION 428 ASSEMBLY 428 REAR SERVO DESCRIPTION 429 OPERATION 429 DISASSEMBLY 430 CLEANING 430 ASSEMBLY 430 SHIFT MECHANISM DESCRIPTION 430 OPERATION 430 SOLENOID DESCRIPTION 43...

Page 2151: ...o contains the kickdown front and the low reverse rear bands which along with the over running clutch and overdrive clutch serve as the holding components The driving and holding compo nents combine t...

Page 2152: ...Fig 1 48RE Transmission DR AUTOMATIC TRANSMISSION 48RE 21 313 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2153: ...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 The torque converter clutch can also be engaged in the...

Page 2154: ...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 2155: ...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 2156: ...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 2157: ...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 2158: ...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 2159: ...DIAGNOSIS 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 VEH...

Page 2160: ...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 tr...

Page 2161: ...one detent rear ward from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge 5 Line pressure should be 54...

Page 2162: ...pressure at the overdrive clutch in fourth gear range Use 300 psi Test Gauge C 3293 SP for this test The test should be performed on the road or on a chassis dyno 1 Remove tachometer it is not needed...

Page 2163: ...he servo when air pressure is removed DIAGNOSIS AND TESTING CONVERTER HOUSING FLUID LEAK When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak...

Page 2164: ...6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatext No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and conve...

Page 2165: ...OM 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 linkage if worn or da...

Page 2166: ...nspect adjust and 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 procedu...

Page 2167: ...et 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 overdrive annulus g...

Page 2168: ...ction 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 DRBT scan tool 7 PC...

Page 2169: ...ear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid...

Page 2170: ...een passages 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 Planetar...

Page 2171: ...RS IMMEDIATELY AFTER 2 3 SHIFT 1 Overdrive Solenoid Connector or Wiring Shorted 1 Test connector and wiring for loose connections shorts or ground and repair as needed 2 TPS Malfunction 2 Test TPS and...

Page 2172: ...ine no start 7 PCM Malfunction 7 Check with DRBT scan tool and replace if necessary 8 Overdrive Solenoid Shorted Open 8 Replace solenoid if shorted or open and repair loose or damaged wires DRBT scan...

Page 2173: ...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 2174: ...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 2175: ...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 2176: ...attery negative cable 2 Raise vehicle 3 Remove the transfer case skid plate Fig 12 if equipped 4 Disconnect and lower or remove necessary exhaust components 5 Remove engine to transmission struts Fig...

Page 2177: ...shift rod from transfer case shift lever 16 Support rear of engine with safety stand or jack 17 Raise transmission slightly with service jack to relieve load on crossmember and supports 18 Remove bol...

Page 2178: ...input shaft end play as follows Fig 20 a Attach Adapter 8266 5 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission an...

Page 2179: ...d and valve body out of case Fig 23 10 Remove accumulator outer spring piston and inner spring Fig 24 Note position of piston and springs for assembly reference Remove and discard piston seals if worn...

Page 2180: ...e oil pump bolts c Thread Slide Hammer Tools C 3752 into threaded holes in flange of oil pump housing Fig 27 d Remove oil pump and reaction shaft support by bumping slide hammers outward alternately t...

Page 2181: ...slide band over front clutch retainer and out of case Fig 31 18 Remove front and rear clutch assemblies as a unit Fig 32 Fig 32 Removing Front Rear Clutch Assemblies 1 FRONT AND REAR CLUTCH ASSEMBLIES...

Page 2182: ...erdrive unit is not to be serviced install Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components Fig 33 Front...

Page 2183: ...ch assembly Fig 40 Assembly can be removed without displacing rollers and springs if care is exercised Note position of rollers and springs for assembly reference 29 Remove rear band adjusting lever a...

Page 2184: ...antity of lint can block fluid pas sages and interfere with valve body operation Lubricate transmission parts with Mopart ATF 4 Automatic Transmission fluid during overhaul and assembly Use petroleum...

Page 2185: ...thrust washers and plates in position during assem bly Do not use chassis grease bearing grease white grease or similar lubricants on any part These types of lubricants can eventually block or restric...

Page 2186: ...compress rod guide while simulta neously easing seal ring into bore with suitable tool 9 Install rod guide snap ring Fig 47 OVERRUNNING CLUTCH REAR BAND AND LOW REVERSE DRUM 1 Install overrunning clut...

Page 2187: ...27 2 if installed previously 2 Install assembled intermediate shaft and plan etary geartrain Fig 49 Support shaft carefully during installation Do not allow shaft bearing bushing surfaces to become ni...

Page 2188: ...iner Fig 53 Use petroleum jelly to hold washer in place Position washer so grooves are facing outward Washer only fits one way in clutch retainer hub 7 Place transmission case in upright position or p...

Page 2189: ...led Verify that front rear clutch assembly is still properly seated before tightening band OIL PUMP 1 Install oil pump Pilot Studs C 3288 B in case Fig 56 2 Install new oil pump gasket on pilot studs...

Page 2190: ...to seat pump 8 Remove pilot studs and install oil pump bolts Tighten pump bolts alternately and evenly to fully seat pump in case Then final tighten pump bolts to 20 N m 15 ft lbs torque 9 Verify cor...

Page 2191: ...past park pawl pawl is engaged in park gear Rotate overdrive output shaft with suitable size 12 point socket this will free pawl and allow rod to engage b Align and seat valve body on case Be sure ma...

Page 2192: ...pocket in the rear oil pump seal lip with transmission fluid 3 Lubricate converter pilot hub of the crankshaft with a light coating of Mopart High Temp Grease 4 Align and install converter in oil pump...

Page 2193: ...ll damage the clutch surface inside the converter 22 Install torque converter to driveplate bolts 23 Install converter housing access cover 24 Install starter motor and cooler line bracket Refer to 8...

Page 2194: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK DR AUTOMATIC TRANSMISSION 48RE 21 355 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2195: ...HYDRAULIC FLOW IN NEUTRAL 21 356 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued...

Page 2196: ...HYDRAULIC FLOW IN REVERSE DR AUTOMATIC TRANSMISSION 48RE 21 357 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2197: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 21 358 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued...

Page 2198: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR CONVERTER CLUTCH NOT APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 359 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2199: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR CONVERTER CLUTCH APPLIED 21 360 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued...

Page 2200: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 361 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2201: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR CONVERTER CLUTCH APPLIED 21 362 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued...

Page 2202: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED DR AUTOMATIC TRANSMISSION 48RE 21 363 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2203: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED 21 364 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued...

Page 2204: ...HYDRAULIC FLOW IN MANUAL LOW 1 DR AUTOMATIC TRANSMISSION 48RE 21 365 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2205: ...HYDRAULIC FLOW IN MANUAL SECOND 2 21 366 AUTOMATIC TRANSMISSION 48RE DR AUTOMATIC TRANSMISSION 48RE Continued...

Page 2206: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING GEAR DR AUTOMATIC TRANSMISSION 48RE 21 367 AUTOMATIC TRANSMISSION 48RE Continued...

Page 2207: ...R SNAP RING 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...

Page 2208: ...d filter 4 35 Bolt oil pump 20 15 Bolt overrunning clutch cam 17 13 Bolt O D to trans 34 25 Bolt O D piston retainer 17 13 Plug pressure test port 14 10 Bolt reaction shaft support 20 15 Locknut rear...

Page 2209: ...essure C 3293SP Set Dial Indicator C 3339 Compressor Spring C 3422 B Adapter Band Adjuster C 3705 Stand Transmission Repair C 3750 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Installer...

Page 2210: ...nstaller Seal C 3995 A Handle Universal C 4171 Remover Installer Bushing C 4470 Dial Caliper C 4962 Spring Compressor and Alignment Shaft 6227 Bar Gauge 6311 Gauge Block 6312 DR AUTOMATIC TRANSMISSION...

Page 2211: ...is located in a housing attached to the side of the valve body Fig 69 Retainer Detent Ball and Spring 6583 Installer Overdrive Piston Seal 8114 Socket TRS Mounting Bracket 8581 Installer Seal 9037 Fi...

Page 2212: ...ied NOTE The accumulator is shown in the inverted position for illustrative purposes INSPECTION Inspect the accumulator piston and seal rings Replace the seal rings if worn or cut Replace the pis ton...

Page 2213: ...o the low reverse drum ADJUSTMENTS ADJUSTMENT BANDS FRONT BAND The front kickdown band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve le...

Page 2214: ...he brake pedal is depressed the shifter is unlocked and will move into any position The inter lock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless t...

Page 2215: ...e ignition key should not rotate from off to lock 3 Shifting out of PARK should be possible when the ignition key cylinder is in the off position 4 Shifting out of PARK should not be possible while ap...

Page 2216: ...50 degrees F or in the absence of sump temperature data after the first 10 minutes of vehicle operation Calibration of the pressure transducer offset occurs each time the output shaft speed falls belo...

Page 2217: ...a heavily loaded vehicle or on steep grades When hunting occurs it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration WIDE OPEN THROTTLE OPERA...

Page 2218: ...solenoid in the governor body replace o ring seals clean the gasket surfaces and replace gasket 1 Place gasket in position on back of governor body Fig 84 2 Place governor body in position on valve b...

Page 2219: ...Mark propeller shaft and axle yoke for align ment reference 3 Disconnect and remove propeller shaft 4 Remove old seal with a screw mounted in a slide hammer INSTALLATION 1 Place seal in position on o...

Page 2220: ...sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped clean before checking fluid level Dirt grease and other foreign material on the ca...

Page 2221: ...DURE TWO 1 Start engine and apply parking brake 2 Shift the transmission into DRIVE for approxi mately 2 seconds 3 Shift the transmission into REVERSE for approximately 2 seconds 4 Shift the transmiss...

Page 2222: ...urfaces appear to be in good condition clean the gasket of any foreign material and reinstall 4 Position the oil pan gasket onto the oil pan 5 Position the oil pan and gasket onto the trans mission an...

Page 2223: ...s the clutch through the hub of the reaction shaft support With pressure applied between the clutch retainer and piston the pis ton moves away from the clutch retainer and com presses the clutch pack...

Page 2224: ...be bent cracked or damaged in any way Replace the piston springs and spring retainer if either are distorted warped or broken Check the lug grooves in the clutch piston retainer The steel plates shoul...

Page 2225: ...0 015 0 020 in thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition neve...

Page 2226: ...its guide against the apply lever Release of the servo at the 2 3 upshift is accom plished by a combination of spring and line pressure acting on the bottom of the larger land of the piston The small...

Page 2227: ...ed or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse suspect parts ASSEMBLY Clean and inspect front servo components 1 Lubric...

Page 2228: ...on Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply upward force on the shift arm Transmission shall not be able to shift from neutral to reverse REMOVAL 1 Shi...

Page 2229: ...the opening in the dash panel Fig 108 2 Seat the cable grommet into the dash panel opening 3 Snap the cable into the steering column bracket so the retaining ears Fig 109 are engaged and snap the cabl...

Page 2230: ...s in any position other than PARK or NEUTRAL or if the engine will not start at all the transmission range sensor may be faulty Gearshift Adjustment Procedure 1 Shift transmission into PARK 2 Release...

Page 2231: ...teeth increases in the crescent area and creates a suction at the inlet side of the pump This suction draws fluid through the pump inlet from the oil pan As the clearance between the gear teeth in th...

Page 2232: ...tion shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both clearances can be mea sured at the same time by installing the gears in the pump body and measure pump component clearances as f...

Page 2233: ...ation 4 Align and install reaction shaft support on pump body 5 Install bolts attaching reaction shaft support to pump Tighten bolts to 20 N m 175 in lbs torque Fig 114 Oil Pump Assembly 1 OIL SEAL 7...

Page 2234: ...snap ring groove is visible 3 Install snap ring to hold bearing onto output shaft 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle OUTPUT SHAFT REAR BEARING REMOVAL 1 Rem...

Page 2235: ...hrough the control valves and passageways and enters the clutch through passages at the lower rear portion of the valve body area With pressure applied between the piston retainer and piston the pisto...

Page 2236: ...ERDRIVE ELECTRICAL CONTROLS The overdrive off switch valve body solenoid case connectors and related wiring can all be tested with a 12 volt test lamp or a volt ohmmeter Check conti nuity of each comp...

Page 2237: ...rmediate shaft Do not allow the shaft to support the entire weight of the over drive unit 10 Carefully work overdrive unit off intermediate shaft Do not tilt unit during removal Keep it as level as po...

Page 2238: ...acer It is a select fit part and may possibly be reused Fig 125 Transmission Speed Sensor 1 SOCKET AND WRENCH 2 SPEED SENSOR 3 O RING Fig 126 Overdrive Piston Thrust Bearing Removal Installation 1 THR...

Page 2239: ...33 5 disc clutch only Fig 129 Overdrive Piston Removal 1 PISTON RETAINER 2 OVERDRIVE PISTON Fig 130 Removing Overdrive Clutch Pack Retaining Ring 1 OVERDRIVE CLUTCH PACK RETAINING RING Fig 131 Overdri...

Page 2240: ...se shaft bearing from locating ring Fig 137 6 Lift gear case up and off geartrain assembly Fig 138 Fig 134 Overdrive Clutch Reaction Snap Ring Removal 1 REACTION RING 2 CLUTCH HUB Fig 135 Access Cover...

Page 2241: ...RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 1 Mount geartrain assembly in shop press Fig 140 2 Position Compressor Tool 6227 1 on clutch hub Fig 140 Support output sha...

Page 2242: ...moved GEARTRAIN 1 Remove direct clutch hub and spring Fig 144 Fig 141 Direct Clutch Pack Snap Ring Removal 1 CLUTCH HUB 2 SPECIAL TOOL 6227 1 3 DIRECT CLUTCH PACK SNAP RING 4 PRESS PLATES 5 CLUTCH DRU...

Page 2243: ...eference Fig 147 Use small center punch or scriber to make alignment marks 7 Remove direct clutch drum rear retaining ring Fig 148 Fig 146 Overrunning Clutch Assembly Removal Installation 1 OVERRUNNIN...

Page 2244: ...ft seal CLEANING Clean the geartrain and case components with sol vent Dry all parts except the bearings with com pressed air Allow bearings to air dry Do not use shop towels for wiping parts dry unle...

Page 2245: ...an assembly The gear and bushings are not serviced separately The planetary carrier and pinions must be in good condition Also be sure the pinion pins are secure and in good condition Replace the car...

Page 2246: ...all bearing if it does not seat squarely 9 Install overrunning clutch in output shaft Fig 158 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with coun terclockw...

Page 2247: ...are fully seated before proceeding 14 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assem bly mounted in p...

Page 2248: ...external lugs fol lowed by a disc with internal spline teeth Con tinue alternating internal and external discs until all discs have been installed c Install pressure plate This is last clutch pack it...

Page 2249: ...hold it in place 21 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 22 Realign clutch pack on...

Page 2250: ...t 5 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 171 6 Support geartrain on Tool 6227 1 Fig 172 Be sure tool is securely seated in clutch hub 7 Install o...

Page 2251: ...d plates in same order 6 Install clutch pack pressure plate 7 Install clutch pack wire type retaining ring Fig 177 INTERMEDIATE SHAFT SPACER SELECTION 1 Place overdrive unit in vertical position Mount...

Page 2252: ...of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 180 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and...

Page 2253: ...t over drive unit will have to be disassembled in order to realign splines 2 If overdrive piston retainer was not removed during service and original case gasket is no longer reusable prepare new gask...

Page 2254: ...g 184 consists of an inner race an outer race or cam rollers and springs and the spring retainer The number of roll ers and springs depends on what transmission and which overrunning clutch is being d...

Page 2255: ...an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace...

Page 2256: ...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 shavings generated during...

Page 2257: ...r equivalent c Install piston over Seal Guide 8114 3 and inside Guide Ring 8114 1 d Push overdrive piston into position in retainer e Verify that the locating lugs entered the lug bores in the retaine...

Page 2258: ...area If the force is 100 lbs and the piston area is 10 sq in then the pressure created equals 10 PSI Another interpretation of Pascal s Law is that regardless of container shape or size the pressure w...

Page 2259: ...e planetary gear assem blies and located in such order A simple planetary gearset consists of three main members The sun gear which is at the center of the sys tem The planet carrier with planet pinio...

Page 2260: ...driving shell Fig 202 Note washer position for assembly reference Fig 199 Removing Planetary Snap Ring 1 PLANETARY SNAP RING Fig 200 Removing Front Planetary And Annulus Gears 1 DRIVING SHELL 2 FRONT...

Page 2261: ...ct the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then replace the nece...

Page 2262: ...gear on intermediate shaft Fig 208 4 Install thrust washer to rear planetary gear Fig 209 using petroleum jelly Be sure washer is seated against corner witht teh tabs completely in the locating holes...

Page 2263: ...e sure washer tabs are seated in tab slots of driving shell Use extra petroleum jelly to hold washer in place if desired 10 Install tabbed thrust washer on front plane tary gear Fig 214 Seat washer ta...

Page 2264: ...groove at forward end of intermediate shaft will be completely exposed when components are assembled correctly 15 Install new planetary snap ring in groove at end of intermediate shaft Fig 217 16 Turn...

Page 2265: ...e front clutch pack is needed to hold against the greater torque load imposed onto the rear pack The rear clutch is directly behind the front clutch and is considered a driving component NOTE The numb...

Page 2266: ...n The check valve is needed to eliminate the pos sibility of plate drag caused by centrifugal force acting on the residual fluid trapped in the clutch pis ton retainer DISASSEMBLY 1 Remove fiber thrus...

Page 2267: ...ed or damaged in any way ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install new seal rings on clutch retainer hub and input shaft if necessary a Be sure c...

Page 2268: ...etroleum jelly to hold washer in place 17 Set rear clutch aside for installation during final assembly REAR SERVO DESCRIPTION The rear low reverse servo consists of a single stage or diameter piston a...

Page 2269: ...ND 2 range provides first and second gear only DRIVE range provides first second third and over drive fourth gear ranges The shift into overdrive fourth gear range occurs only after the transmission h...

Page 2270: ...ire 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 so...

Page 2271: ...ow simultaneous movement without causing the transmission throttle lever to either move ahead of or lag behind the lever on the throttle body ADJUSTMENT VERIFICATION 1 Turn ignition key to OFF positio...

Page 2272: ...to the UP position Fig 232 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 le...

Page 2273: ...VERTER DESCRIPTION The torque converter Fig 233 is a hydraulic device that couples the engine crankshaft to the transmission The torque converter consists of an outer shell with an internal turbine a...

Page 2274: ...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 234 Impeller 1 ENGINE FLEXPLATE 4 EN...

Page 2275: ...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 235 Turbi...

Page 2276: ...s lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impeller and turbine were mecha...

Page 2277: ...e is transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a clockwise direction following the impeller As the fluid is leav ing the trailing e...

Page 2278: ...smission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work sur...

Page 2279: ...iced as an assembly it is not repairable Do not clean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates significant...

Page 2280: ...e TRS signal The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL providing...

Page 2281: ...Information 1 Raise vehicle on 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...

Page 2282: ...pins of the TRS The resistance should be 59 9 ohms If the resistance is not correct replace the TRS 11 With the manual lever in the SECOND posi tion the SECOND position is with the manual lever moved...

Page 2283: ...operation Fig 249 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 2284: ...t allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and transfer...

Page 2285: ...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 2286: ...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 2287: ...2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE...

Page 2288: ...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 2289: ...ft This closes a dump vent that is used to lower pressure The clos ing of the dump will cause the oil pressure to increase Oil pressure on the opposite end of the valve pushes the valve to the right o...

Page 2290: ...Fig 255 Regulator Valve in Park Position Fig 256 Regulator Valve in Neutral Position DR AUTOMATIC TRANSMISSION 48RE 21 451 VALVE BODY Continued...

Page 2291: ...gear positions 145 280 psi The higher pressure for REVERSE is achieved by the man ual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there is...

Page 2292: ...Fig 258 Regulator Valve in Reverse Position DR AUTOMATIC TRANSMISSION 48RE 21 453 VALVE BODY Continued...

Page 2293: ...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 2294: ...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 2295: ...the right the middle land of the valve will close off the circuit supplying the throttle pres sure to the right side of the valve When the throttle pressure is closed off the valve will move even far...

Page 2296: ...or piston by the 1 2 shift control valve During the 1 2 upshift this pressure is used to control the kick down servo apply pressure that is needed to apply the kickdown and accumulator pistons Thus th...

Page 2297: ...ressure to the front clutch After the shift Fig 266 line pressure is directed to the release side of the kickdown servo This releases the front band and applies the front clutch shifting into third ge...

Page 2298: ...ming valve holds the 2 3 shift valve in an upshift position The purpose is to prevent the 2 3 valve from down shifting while either the overdrive clutch or converter clutch is applied Fig 267 Fig 266...

Page 2299: ...d reduce line pressure too much Throttle pressure which increases with engine speed throttle opening is used to oppose the move ment of the pressure valve to help control the meter ing passage at the...

Page 2300: ...nsmission input shaft into the converter through the converter back out between the input shaft and the reaction shaft and back up to the switch valve From the switch valve the fluid pressure is direc...

Page 2301: ...ply side of the torque converter piston This pressure differential causes the piston to apply against the friction material cutting off any further flow of line pressure oil After the switch valve is...

Page 2302: ...3 downshift until the TCC is completely unlocked and the clutch is disen gaged SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves When the manual valve is posi...

Page 2303: ...on temperature thermistor Converter clutch overdrive solenoid assembly and harness Governor housing gasket Solenoid case connector O rings 1 Shift transmission into NEUTRAL 2 Raise vehicle 3 Remove ge...

Page 2304: ...governor body and gas ket from transfer plate 4 Remove governor pressure sensor from gover nor body 5 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and d...

Page 2305: ...6583 POSITIONED ON DETENT HOUSING Fig 279 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS Fig 280 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLE...

Page 2306: ...l magnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 287 Fig 284 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD F...

Page 2307: ...290 20 Remove kickdown detent kickdown valve and throttle valve and spring Fig 290 21 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right side hou...

Page 2308: ...VERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING Fig 291 Accumulator Housing Screw Locations 1 LOOSEN THIS SCREW 2 REMOVE THESE SCREWS 3 3 4 ACCUMULATOR HOUSIN...

Page 2309: ...fall out when lower housing and separator plate are removed 27 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 296 Note position of boost valve tube brace for...

Page 2310: ...r plate for assembly reference 33 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 300 Fig 297 Number 10 Check Ball 1 NUMBER 10 CHE...

Page 2311: ...urn upper housing around and remove limit valve and shift valve covers Fig 304 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 3...

Page 2312: ...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 2313: ...2 1 2 SHIFT VALVE AND SPRING 8 RETAINER 3 2 3 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE...

Page 2314: ...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 2315: ...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 2316: ...ulder bolt switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E clip fluid filter and screws detent b...

Page 2317: ...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 2318: ...4 Install brace plate Fig 311 Tighten brace attaching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in lbs torque Fig 308 3 4 Accumu...

Page 2319: ...tion lower housing separator plate on transfer plate Fig 315 5 Install lower housing on assembled transfer plate and upper housing Fig 316 6 Install and start all valve body screws by hand except for...

Page 2320: ...g and cover plate Tighten screws to 4 N m 35 in lbs 7 Install shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Install shuttle v...

Page 2321: ...g ports with transmission fluid or petroleum jelly 3 Start tube in lower housing port first Then swing tube downward and work opposite end of tube into upper housing port Fig 320 4 Insert and seat eac...

Page 2322: ...VALVE AND SPRING 4 2 3 THROTTLE PLUG 10 PRESSURE PLUG COVER 5 LIMIT VALVE HOUSING 11 PLUG SLEEVE 6 LIMIT VALVE COVER 12 THROTTLE PRESSURE SPRING AND PLUG Fig 320 Boost Valve Tube 1 BOOST VALVE TUBE 2...

Page 2323: ...g valve and spring 5 Position plug on end of converter clutch valve spring Then compress and hold springs and plug in place with fingers of one hand 6 Swing accumulator housing upward over valve sprin...

Page 2324: ...rottle valve and spring 13 Install kickdown valve and detent 14 Install pressure regulator valve 15 Install switch valve 16 Position adjusting screw bracket on valve body Align valve springs and press...

Page 2325: ...eals on accumulator piston Install new piston seals if necessary 4 Verify that transmission range sensor is NOT installed Valve body cannot be installed with sensor in place 5 Place valve body manual...

Page 2326: ...he 33 4 mm 1 5 16 in setting is an approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw ch...

Page 2327: ...TRANSMISSION SHIFT INTERLOCK 540 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 540 FLUID AND FILTER DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL 541 DIAGNOSIS AND TEST...

Page 2328: ...io capability with precise ratio steps for optimum driveability The three planetary gear sets also make available a unique alternate second gear ratio The primary 2nd gear ratio fits between 1st and 3...

Page 2329: ...ncreasing pressure in proportion to demand A high travel torque converter damper assembly allows earlier torque converter clutch engagement to reduce slippage Needle type thrust bearings reduce intern...

Page 2330: ...for broken or disconnected gearshift cable 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmissio...

Page 2331: ...only with the output shaft speed below 150 rpm 545RFE CLUTCH APPLICATION CHART SLP UD OD R 2C 4C L R OVERRUNNING P PARK ON R REVERSE ON ON N NEUTRAL ON D OVERDRIVE FIRST ON ON ON SECOND ON ON SECOND...

Page 2332: ...s the transmission oil pan must be removed the pres sure port plugs removed and Valve Body Pressure Tap Adapter 8258 A Fig 5 installed The extensions supplied with Adapter 8258 A will allow the instal...

Page 2333: ...SURES ENGINE 1 2 2 3 2prime 3 3 4 2prime 4 2 5 3 5 4 5 5 7L 150 125 125 135 135 135 135 135 3 7L 4 7L 120 120 120 120 120 120 120 130 DOWNSHIFT PRESSURES ENG INE 5 4 5 3 5 2 4 3 4 2 prime 3 2 3 2 prim...

Page 2334: ...used to locate a leak TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are 1 Leaks at the weld joint around the outside diameter weld Fig 7 2 Leaks at the converter hub weld Fig 7 STAN...

Page 2335: ...10 14 Disengage the transmission solenoid TRS assembly connector from the transmission solenoid TRS assembly Fig 11 15 Disengage the line pressure sensor connector from the line pressure sensor Fig 12...

Page 2336: ...e during trans mission removal 26 Lower transmission and remove Fig 14 assembly from under the vehicle 27 To remove torque converter carefully slide torque converter out of the transmission DISASSEMBL...

Page 2337: ...dicator C 3339 measure and record the output shaft end play Fig 18 12 Remove the bolts holding the transmission oil pan to the transmission case 13 Remove the transmission oil pan from the transmissio...

Page 2338: ...e the input clutch assembly may become dislodged Fig 19 Remove Primary Oil and Cooler Filters 1 PRIMARY OIL FILTER 2 COOLER RETURN FILTER 3 COOLER RETURN FILTER BYPASS VALVE 4 VALVE BODY Fig 20 Remove...

Page 2339: ...n annulus from the reac tion planetary carrier Fig 26 32 Remove the number 7 bearing Fig 26 33 Remove the reaction sun gear Fig 26 34 Remove the number 8 bearing from the reac tion planetary carrier F...

Page 2340: ...9 6 THRUST PLATE SELECT 3 REACTION PLANETARY CARRIER 7 BEARING NUMBER 6 4 REACTION SUN GEAR 8 REACTION ANNULUS Fig 27 Remove Park Sprag Snap Ring 1 SNAP RING Fig 28 Remove Park Sprag Gear 1 PARK SPRAG...

Page 2341: ...re to avoid rounding off sharp edges Sharp edges are vital as they pre vent foreign matter from getting between the valve and valve bore Do not reuse oil seals gaskets seal rings or O rings during ove...

Page 2342: ...case will have to be replaced if it exhibits any type of damage or wear ASSEMBLY 1 Clean and inspect all components Replace any components which show evidence of excessive wear or scoring 2 Install t...

Page 2343: ...erage of these measurements is the 2C clutch pack clearance The correct clutch clearance is 0 455 1 335 mm 0 018 0 053 in The reaction plate is not selective If the clutch pack clearance is not within...

Page 2344: ...s mission case Fig 40 The reaction plate is direc tional The plate must be installed with the flat side toward the front of the transmission 25 Install the 2C clutch pack into the transmis sion case F...

Page 2345: ...ion annulus with the oil grooves facing the annulus gear and the tabs and notches aligned as shown in Fig 42 32 Install the number 6 bearing against the output shaft selective thrust plate with the fl...

Page 2346: ...sing onto the transmission case 39 Install and torque the bolts to hold the exten sion adapter housing onto the transmission case The correct torque is 54 N m 40 ft lbs 40 Install the number 5 bearing...

Page 2347: ...when the input shaft is pulled out ward is the movement of the input shaft in the input clutch housing hub This value should not be included in the end play measured value and there fore must be recor...

Page 2348: ...and the oil cooler return filter Fig 51 Tighten the screw to hold the pri mary oil filter to the valve body to 4 5 N m 40 in lbs Using Oil Filter Wrench 8321 tighten the cooler return oil filter to t...

Page 2349: ...enough to hold transmission in alignment 10 Apply a light coating of Mopart High Temp Grease to the torque converter hub pocket in the rear pocket of the engine s crankshaft 11 Raise transmission Fig...

Page 2350: ...riveplate bolts Tighten bolts to 31 N m 270 in lbs 23 Install starter motor and cooler line bracket 24 Connect cooler lines to transmission 25 Install transmission fill tube 26 Install exhaust compone...

Page 2351: ...ssary 30 Install any skid plates removed previously Refer to 13 FRAMES BUMPERS FRAME TRANSFER CASE SKID PLATE INSTALLATION 31 Lower vehicle 32 Fill transmission with Mopart ATF 4 Auto matic Transmissi...

Page 2352: ...SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS HYDRAULIC FLOW IN PARK NEUTRAL DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 513 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2353: ...HYDRAULIC FLOW IN NEUTRAL OVER 8MPH 21 514 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2354: ...HYDRAULIC FLOW IN REVERSE DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 515 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2355: ...HYDRAULIC FLOW IN REVERSE BLOCK 21 516 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2356: ...HYDRAULIC FLOW IN FIRST GEAR FROM N OR OD DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 517 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2357: ...HYDRAULIC FLOW IN FIRST GEAR AFTER LAUNCH FROM REST 21 518 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2358: ...HYDRAULIC FLOW IN FIRST GEAR FROM K D DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 519 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2359: ...HYDRAULIC FLOW IN SECOND GEAR 21 520 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2360: ...HYDRAULIC FLOW IN SECOND GEAR EMCC DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 521 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2361: ...HYDRAULIC FLOW IN SECOND PRIME GEAR 21 522 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2362: ...HYDRAULIC FLOW IN SECOND PRIME GEAR EMCC DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 523 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2363: ...HYDRAULIC FLOW IN DIRECT GEAR 21 524 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2364: ...HYDRAULIC FLOW IN DIRECT GEAR FAILSAFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 525 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2365: ...HYDRAULIC FLOW IN DIRECT GEAR EMCC 21 526 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2366: ...HYDRAULIC FLOW IN FOURTH DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 527 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2367: ...HYDRAULIC FLOW IN FOURTH EMCC 21 528 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2368: ...HYDRAULIC FLOW IN FIFTH DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 529 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2369: ...HYDRAULIC FLOW IN FIFTH EMCC 21 530 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2370: ...HYDRAULIC FLOW IN MANUAL LOW OR AUTOSTICK 1ST DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 531 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2371: ...HYDRAULIC FLOW IN MANUAL SECOND 21 532 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2372: ...HYDRAULIC FLOW IN MANUAL SECOND FAILSAFE DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 533 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2373: ...m Ft Lbs In Lbs Fitting cooler line at trans 17 5 155 Bolt torque convertor 31 23 Bolt nut crossmember 68 50 Bolt driveplate to crankshaft 75 55 Bolt oil pan 11 8 105 Screw primary fluid filter 4 5 40...

Page 2374: ...Gauge Oil Pressure C 3293SP Dial Indicator C 3339 Installer Seal C 3860 A Compressor Spring 8249 Compressor Spring 8250 Compressor Spring 8251 Installer Piston 8252 DR AUTOMATIC TRANSMISSION 45RFE 545...

Page 2375: ...taller Snap ring 8255 Stand Support 8257 Adapter Pressure Tap 8258 A Adapter Line Pressure 8259 Fixture Input Clutch Pressure 8260 Plate Alignment 8261 21 536 AUTOMATIC TRANSMISSION 45RFE 545RFE DR AU...

Page 2376: ...Wrench Filter 8321 Installer Piston 8504 End Play Set 8266 Compressor Spring 8285 Installer Bearing 8320 DR AUTOMATIC TRANSMISSION 45RFE 545RFE 21 537 AUTOMATIC TRANSMISSION 45RFE 545RFE Continued...

Page 2377: ...60 7 Remove the 4C piston return spring and piston from the retainer bulkhead Fig 60 Use 20 psi of air pressure to remove the piston if necessary ASSEMBLY 1 Clean and inspect all components Replace an...

Page 2378: ...spring Fig 60 13 Using Spring Compressor 8249 and a suitable shop press Fig 62 compress the belleville spring until the snap ring is engaged with the snap ring groove in the retainer bulkhead ADAPTER...

Page 2379: ...h 12mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressi...

Page 2380: ...and develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case ai...

Page 2381: ...It is located on the right side of the engine Be sure to wipe all dirt from dipstick handle before removing The torque converter fills in both the P PARK and N NEUTRAL positions Place the selector lev...

Page 2382: ...ion of this group CLEANING 1 Using a suitable solvent clean pan and magnet 2 Using a suitable gasket scraper clean original sealing material from surface of transmission case and the transmission pan...

Page 2383: ...to transmis sion 3 Check the transmission fluid Refer to 21 TRANSMISSION AUTOMATIC RFE FLUID STANDARD PROCEDURE and adjust as required GEARSHIFT CABLE DIAGNOSIS AND TESTING GEARSHIFT CABLE 1 Engine st...

Page 2384: ...e opening in the dash panel Fig 72 2 Seat the cable grommet into the dash panel opening 3 Snap the cable into the steering column bracket so the retaining ears Fig 73 are engaged and snap the cable ey...

Page 2385: ...sion manual shift lever 5 Verify transmission shift lever is in PARK detent by moving lever fully rearward Last rearward detent is PARK position 6 Verify positive engagement of transmission park lock...

Page 2386: ...park reverse neutral and first gear only at low speeds by pressurized fluid against the Low Reverse clutch piston When the Low Reverse clutch is applied the input annulus assembly is held or grounded...

Page 2387: ...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 21 548 AUTOMATIC TRANSMISSION 45RFE...

Page 2388: ...ifferent 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 und...

Page 2389: ...rom the input clutch retainer Fig 79 2 Remove the reverse reaction plate from the input clutch retainer 3 Remove the reverse hub and reverse clutch pack from the input clutch retainer 4 Remove the num...

Page 2390: ...reaction plate tapered snap ring from the input clutch retainer 12 Remove the UD OD reaction plate from the input clutch retainer 13 Remove the UD OD reaction plate flat snap ring from the input clut...

Page 2391: ...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 Th...

Page 2392: ...TCH RETAINER 4 SNAP RING 14 SEAL 5 SNAP RING 15 OD REV PISTON 6 UD BALANCE PISTON 16 BELLEVILLE SPRING 7 SNAP RING 17 SNAP RING 8 UD PISTON 18 SEAL RINGS 9 SPRING 19 INPUT SHAFT 10 DISC 20 LUBRICATION...

Page 2393: ...TCH RETAINER 4 SNAP RING 14 SEAL 5 SNAP RING 15 OD REV PISTON 6 UD BALANCE PISTON 16 BELLEVILLE SPRING 7 SNAP RING 17 SNAP RING 8 UD PISTON 18 SEAL RINGS 9 SPRING 19 INPUT SHAFT 10 DISC 20 LUBRICATION...

Page 2394: ...nstall Piston Guide 8252 into the input clutch retainer Fig 84 to guide the UD OD balance piston seal into position inside the underdrive piston 11 Install the UD OD balance piston into the input clut...

Page 2395: ...p down 16 Install the UD OD reaction plate upper tapered snap ring with tapered side up Fig 86 Input Clutch Assembly Part II 1 BEARING NUMBER 3 10 SNAP RING SELECT 2 OD HUB SHAFT 11 PLATE 3 SNAP RING...

Page 2396: ...20 Install the OD reverse reaction plate into the input clutch retainer The reaction plate is non direc tional Fig 86 21 Install the OD reverse reaction plate flat snap ring into the input clutch reta...

Page 2397: ...e hub with petroleum jelly 33 Install the reverse hub into the input clutch retainer 34 Install the complete reverse clutch pack 35 Install the reverse reaction plate and snap ring 36 Push up on react...

Page 2398: ...solenoid moni tors the transmission line pressure and completes the feedback loop to the TCM The TCM uses this infor mation to adjust its control of the pressure control solenoid to achieve the desire...

Page 2399: ...tch snap ring from the low reverse clutch retainer Fig 93 2 Remove the outer low reverse reaction plate flat snap ring Fig 93 3 Remove the low reverse clutch and the over running clutch from the low r...

Page 2400: ...l a new seal on the low reverse piston Lubricate the seal with Mopart ATF 4 Automatic Transmission Fluid prior to installation 3 Install the low reverse piston into the low re verse clutch retainer 4...

Page 2401: ...on draws fluid through the pump inlet from the oil pan As the gear teeth come back into mesh pressurized fluid is forced into the pump outlet and to the oil pump valves At low speeds both sides of the...

Page 2402: ...he proper level Refer to the Fluid Level Check procedure in this section If necessary fill the transmission to the proper level with Mopart ATF 4 Automatic Trans mission Fluid 1 Disconnect the To cool...

Page 2403: ...g the reaction shaft support to the oil pump Fig 100 2 Remove the reaction shaft support from the oil pump Fig 100 3 Remove all bolts holding the oil pump halves together Fig 100 4 Using suitable pryi...

Page 2404: ...The gears are select fit and if the oil pump is to be reused the gears must be returned to their original locations 8 Remove the oil pump gears from the oil pump case Fig 101 Fig 101 Oil Pump Housing...

Page 2405: ...rpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the oil pump cover Use a penl...

Page 2406: ...mary inputs to the Transmission Control Module TCM OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating As the teeth of the input clutch hub pass by the sensor...

Page 2407: ...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 is turned to the O...

Page 2408: ...a Given a 100 lb block and an area of 100 sq in on the floor the pressure exerted by the block is 100 lbs 100 in or 1 pound per square inch or PSI as it is commonly referred to PRESSURE ON A CONFINED...

Page 2409: ...sign and operation of all shift valves and limiting valves in the valve body as well as the pistons of the transmission which activate the clutches and bands It is nothing more than using a difference...

Page 2410: ...ear of the reaction planetary geartrain are a single component which is held by the 2C clutch when required The reaction annulus gear is a stand alone component that can be driven by the reverse clutc...

Page 2411: ...low reverse clutch The reverse planetary annulus input planetary carrier and output shaft are all one piece INPUT PLANETARY GEARTRAIN The input sun gear of the input planetary geartrain is driven by...

Page 2412: ...r sets if gears pinion pins or carrier are damaged in any way Replace the annulus gears and supports if either component is worn or damaged Replace the output shaft if the machined surfaces are scored...

Page 2413: ...ed position thus directing fluid to the L R clutch circuit In 2nd 3rd 4th and 5th if applicable gears the solenoid switch valve will be in the upshifted position and directs the fluid into the torque...

Page 2414: ...nst the spring pressure and the load applied by the fluid the valve is controlling The plunger is normally directly attached to the valve which it is to operate When the current is removed from the co...

Page 2415: ...converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving members of the system Fig 118 Impeller 1 ENGINE FLEXPLATE 4 ENGINE...

Page 2416: ...ugh the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 119 Turbine 1...

Page 2417: ...lippage condition could be obtained A hydraulic piston with friction material was added to the tur bine assembly to provide this mechanical lock up In order to reduce heat build up in the transmission...

Page 2418: ...from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbin...

Page 2419: ...vice or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when sep...

Page 2420: ...e sen sor thermistor that communicates transmission temperature to the TCM and PCM OPERATION The Transmission Range Sensor TRS communi cates shift lever position to the TCM as a combina tion of open a...

Page 2421: ...ement 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 tested Each soleno...

Page 2422: ...ransmission solenoid TRS assembly onto the valve body 4 Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first Tighten the screws to 5 7 N m 50 in lbs...

Page 2423: ...he torque converter clutch bands and frictional clutches The valve body con tains the following components Fig 129 and Fig 130 Solenoid switch valve Manual valve Low reverse switch valve 5 Accumulator...

Page 2424: ...nected mechanically by a cable to the gearshift mechanism The valve is held in each of its positions by a roller detent spring Fig 131 that engages the roostercomb of the TRS selector plate LOW REVERS...

Page 2425: ...id and pressure switch assembly from the valve body 3 Remove the screw holding the detent spring Fig 135 onto the valve body 4 Remove the detent spring from the valve body 5 Remove the TRS selector pl...

Page 2426: ...lls 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 locati...

Page 2427: ...d 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 croc...

Page 2428: ...o replace a valve body assembly unless it is damaged in han dling Inspect all the accumulator bores in the valve body Use a penlight to view the bore interiors Replace the valve body if any bores are...

Page 2429: ...ighten 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 and the solenoid and pressure switch as...

Page 2430: ...creased low speed torque capability The gear cases and extension are all of aluminum Fig 1 Drive sprockets and an interconnecting drive chain are used to transmit engine torque to the front rear prope...

Page 2431: ...g properly refer to the Diagnosis Chart for further information DIAGNOSIS CHART Condition Possible Cause Correction Transfer Case difficult to shift or will not shift into desired range 1 Vehicle spee...

Page 2432: ...d dry surfaces in the 4H position 1 Operate vehicle in the 2H position on hard dry surfaces REMOVAL 1 Raise and support vehicle 2 Remove skid plate if equipped Refer to 13 FRAMES BUMPERS FRAME TRANSFE...

Page 2433: ...lamp Fig 4 4 Remove the front propeller shaft seal boot Fig 5 5 Remove the front output shaft seal slinger by bending Fig 6 the slinger ears away from the transfer case Fig 4 Remove Boot Clamp 1 SEAL...

Page 2434: ...ic mallet to break sealer bead and loosen it 3 Remove output bearing retaining ring with heavy duty snap ring pliers Fig 10 Fig 7 Remove Slinger From Shaft 1 SLINGER 2 PRY TOOL Fig 8 Remove Rear Exten...

Page 2435: ...earing inner race and will become mis aligned if the bolts are loosened If the transfer case failure has gener ated any debris which may have become trapped in the oil pump the rear case and oil pump...

Page 2436: ...detent plug spring and plunger Fig 18 Note that the plug has an O ring seal Remove and discard this seal Fig 15 Removing Front Sprocket Retaining Ring 1 FRONT SPROCKET 2 RETAINING RING 3 FRONT OUTPUT...

Page 2437: ...mbly Fig 22 Note which way the sleeve fits in the fork long side of sleeve goes to front Fig 19 Remove Front Output Shaft Snap ring 1 FRONT OUTPUT SHAFT 2 SNAP RING Fig 20 Remove Front Output Shaft 1...

Page 2438: ...he drive sprocket thrust washer Fig 27 from the output shaft Fig 23 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 24 Remove Sector Support 1 SECTOR SUPPORT 2 FRONT CASE 3 SECTOR SHAFT Fig 25...

Page 2439: ...nput gear retaining ring Fig 33 with heavy duty snap ring pliers 3 Place front case in horizontal position Then remove input gear and low range gear as an assem Fig 28 Remove Drive Sprocket 1 OUTPUT S...

Page 2440: ...etainer Fig 36 Fig 35 Input Gear Snap Ring Removal 1 INPUT GEAR SNAP RING Fig 36 Input Gear Retainer Removal 1 INPUT GEAR 2 LOW RANGE GEAR 3 RETAINER Fig 33 Remove Input Gear Retaining Ring 1 INPUT GE...

Page 2441: ...The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage The carrier will have to be replaced as an asse...

Page 2442: ...hain and shaft bearings replace the chain if stretched distorted or if any of the links bind Replace the bearings if rough or noisy Fig 40 Input Gear And Carrier Components 1 PLANETARY CARRIER 4 CARRI...

Page 2443: ...steel inserts if required OIL PUMP OIL PICKUP Examine the oil pump pickup parts Replace the pump if any part appears to be worn or damaged Do not disassemble the pump as individual parts are not avail...

Page 2444: ...4454 and Cup 8148 Fig 47 9 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 48 The bearing bore is chamfered at the top Install the bearing so it is flush with the lower edge of this...

Page 2445: ...input gear is fully seated 4 Install remaining thrust washer in low range gear and on top of input gear Be sure washer tabs are properly aligned in gear notches 5 Install retainer on input gear and in...

Page 2446: ...D MAINSHAFT 1 Lubricate mainshaft splines with recommended transmission fluid 2 Install the mode hub Fig 55 onto the output shaft 3 Install the mode hub retaining ring Fig 56 onto the output shaft Fig...

Page 2447: ...ket thrust washer Fig 60 onto the output shaft Fig 60 Install Drive Sprocket Thrust Washer 1 OUTPUT SHAFT 2 THRUST WASHER 3 DRIVE SPROCKET Fig 57 Install Sprocket Hub 1 OUTPUT SHAFT 2 SPROCKET HUB Fig...

Page 2448: ...nd install range fork and hub Fig 64 Be sure hub is properly seated in low range gear and engaged to the input gear 12 Align and insert range fork pin in shift sector slot 13 Install the range fork re...

Page 2449: ...torque 18 Install range lever on sector shaft Fig 68 19 Install washer and nut on sector shaft to secure shift lever Apply 1 2 drops Mopart Lock N Seal or equivalent to nut threads before installation...

Page 2450: ...ring Fig 72 onto the output shaft 3 Install the new front output shaft seal with Installer MB991168A Fig 69 O Ring Installation On Detent Plug 1 O RING 2 DETENT PLUG Fig 70 Install Detent Plug Spring...

Page 2451: ...rear output shaft inner bear ing race and will become mis aligned if the bolts are loosened If the transfer case failure has gener ated any debris which may have become trapped in the oil pump the rea...

Page 2452: ...Tighten bolts to 20 27 N m 15 24 ft lbs 5 Install rear output bearing snap ring Fig 79 to output shaft SEAL BOOT 1 Install the front output shaft seal slinger with Installer 8840 Install the slinger o...

Page 2453: ...Tighten nuts to 30 41 N m 20 30 ft lbs 3 Remove jack stand from under transmission 4 Align and connect propeller shafts Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION 5...

Page 2454: ...al C 4171 Installer Seal 6888 Installer Bearing 6953 Installer Seal C 4210 Remover Bushing 6957 Installer Bushing 8157 Installer Seal D 163 Installer Seal 7884 Installer Bushing 5066 DR TRANSFER CASE...

Page 2455: ...g in extension housing with fluid port in bushing aligned with slot in housing 3 Using Installer 8157 drive bushing into hous ing until installer seats against case 4 Using Installer D 163 install sea...

Page 2456: ...atic Transmis sion fluid 7 Install and tighten fill plug to 41 54 N m 30 40 ft lbs 8 Lower vehicle FRONT OUTPUT SHAFT SEAL REMOVAL 1 Remove the front propeller shaft Refer to 3 DIFFERENTIAL DRIVELINE...

Page 2457: ...aft Refer to 3 DIF FERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION POSITION SENSOR DESCRIPTION The transfer case position sensor is an electronic device whose output can be interprete...

Page 2458: ...fer case position sensor connector from the position sensor 3 Remove the position sensor from the transfer case INSTALLATION 1 Inspect the o ring seal on the transfer case position sensor Replace the...

Page 2459: ...e 5 Remove transfer case shifter knob cap 6 Remove nut holding shifter knob to shift lever 7 Remove shifter knob 8 Remove the shift boot from the shifter console 9 Remove the bolts securing the shifte...

Page 2460: ...d position from full forward 6 Install trunnion to shift lever if necessary 7 Install shift rod to trunnion if necessary 8 Tighten the shift rod lock bolt to 10 N m 90 in lbs 9 Remove the shifter adju...

Page 2461: ...e lower shifter lever with the adjustment channel on the shifter bracket assembly Fig 90 7 Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold t...

Page 2462: ...es and extension are all of aluminum Fig 1 Drive sprockets and an interconnecting drive chain are used to transmit engine torque to the front rear propeller shafts The mainshaft input gear and front o...

Page 2463: ...osis Chart for further information DIAGNOSIS CHART Condition Possible Cause Correction Transfer Case difficult to shift or will not shift into desired range 1 Vehicle speed too great to permit shiftin...

Page 2464: ...support vehicle 2 Remove skid plate if equipped Refer to 13 FRAMES BUMPERS FRAME TRANSFER CASE SKID PLATE REMOVAL 3 Position drain oil container under transfer case 4 Remove transfer case drain plug a...

Page 2465: ...using seal 7 Remove rear extension bolts Fig 5 8 Remove rear extension housing Fig 6 Tap extension once or twice with a plastic mallet to break sealer bead and loosen it Fig 3 Remove Companion Flange...

Page 2466: ...o front case bolts Fig 9 4 Remove the rear output shaft bearing inner snap ring Fig 10 from the output shaft using suit able snap ring pliers Fig 10 Remove Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT...

Page 2467: ...TPUT SHAFT AND DRIVE CHAIN 1 Remove the oil pick up tube Fig 14 and screen from the front case half Fig 14 Remove Oil Pick Up Tube and Screen 1 FRONT CASE HALF 2 OIL SCREEN 3 PICK UP TUBE Fig 11 Remov...

Page 2468: ...sprocket splines 6 Remove chain and sprockets as an assembly Fig 15 Remove Shift Rail Spring 1 SHIFT RAIL 2 SPRING Fig 16 Remove Front Output Shaft Sprocket Retaining Ring 1 FRONT OUTPUT SHAFT 2 DRIV...

Page 2469: ...lug Fig 21 6 Remove detent plug spring and plunger Fig 22 Note that the plug has an O ring seal Remove and discard this seal Fig 19 Remove Manual Shift Lever 1 SHIFT SECTOR 2 SECTOR SUPPORT 3 MANUAL S...

Page 2470: ...26 Note which way the sleeve fits in the fork long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case Fig 23 Remove Front Output Shaft Bearing Inner Snap Ring 1 FRO...

Page 2471: ...ut put shaft 2 Remove the mode hub retaining ring Fig 30 from the mainshaft Fig 30 Remove Mode Hub Retaining Ring 1 MAINSHAFT 2 MODE HUB 3 RETAINING RING Fig 27 Range Fork And Hub Removal 1 RANGE HUB...

Page 2472: ...t case in horizontal position Then remove input gear and low range gear as an assem bly Fig 34 Tap gear out of bearing with plastic mallet if necessary Fig 31 Remove Mode Hub 1 MAINSHAFT 2 MODE HUB Fi...

Page 2473: ...put gear Fig 38 Fig 38 Remove Input Gear From Planetary 1 INPUT GEAR 2 LOW RANGE PLANETARY Fig 35 Remove Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 36 Remove Input Gear Retainer 1 INP...

Page 2474: ...k the contact surfaces in the sprocket bore and on the mainshaft Minor nicks and scratches can be smoothed with 320 400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe...

Page 2475: ...gear is only serviced as part of the front case If the gear is damaged it will be necessary to replace the gear and front case as an assembly Do not attempt to remove the gear Fig 43 FRONT CASE AND R...

Page 2476: ...front case half with Installer 8151 inverted on Handle C 4171 Fig 45 4 Install the input shaft bearing snap ring into the front case half with suitable snap ring pliers 5 Remove the front output shaft...

Page 2477: ...Remover L 4454 and Cup 8148 Fig 49 12 Install new bearing with Tool Handle C 4171 and Installer 8128 Fig 50 The bearing bore is chamfered at the top Install the bearing so it is flush with the lower...

Page 2478: ...nstaller 7888 Fig 54 Fig 53 Remove Rear Output Bearing Outer Snap Ring 1 REAR CASE HALF 2 REAR OUTPUT SHAFT BEARING 3 SNAP RING Fig 54 Remove Rear Output Shaft Bearing 1 REAR CASE HALF 2 INSTALLER 788...

Page 2479: ...re prop erly aligned in gear notches 3 Install input gear in low range gear Fig 57 Be sure input gear is fully seated 4 Install remaining thrust washer Fig 58 in low range gear and on top of input gea...

Page 2480: ...nto front bearing Fig 62 8 Install a new input gear seal using Installer 8841 and Handle C 4171 9 Install a new input gear oil seal with Installer 9036 and Handle C 4171 Fig 59 Install Input Gear Reta...

Page 2481: ...5 onto the mainshaft 5 Install the clutch gear Fig 66 onto the output shaft Verify that the pointed ends of the clutch gear teeth are pointing to the front of the mainshaft Fig 64 Install Mode Hub 1 M...

Page 2482: ...ge gear and engaged to the input gear 9 Align and insert range fork pin in shift sector slot 10 Install mode fork and shift rail onto the mode sleeve 11 Install the mode fork sleeve and shift rail int...

Page 2483: ...o 27 34 N m 20 25 ft lbs torque 16 Install new o ring on detent plug Fig 73 17 Install detent plunger spring and plug Fig 74 Tighten the plug to 16 25 N m 12 18 ft lbs Fig 71 Install Position Sensor 1...

Page 2484: ...ssembly until the front sprocket is positioned over the front output shaft 7 Align the splines in the sprockets to the splines on the output shafts and install the sprockets onto the output shafts 8 I...

Page 2485: ...hat the case alignment dowels correctly seat into their mating recesses 4 Install 4 5 rear case to front case bolts Fig 83 to hold rear case in position Tighten bolts snug but not to specified torque...

Page 2486: ...ube o ring is on the tube and is correctly installed to the oil pump Fig 83 Install Case Half Bolts 1 FRONT CASE HALF 2 REAR CASE HALF 3 BOLTS Fig 84 Install Rear Bearing Inner Snap Ring 1 OUTPUT SHAF...

Page 2487: ...case half 5 Install rear extension bolts Fig 88 Tighten the bolts to 27 34 N m 20 25 ft lbs 6 Install the extension housing boot and seal assembly with Installer 9037 and Handle C 4171 Fig 89 Fig 87 I...

Page 2488: ...nd connect propeller shafts Refer to 3 DIFFERENTIAL DRIVELINE PROPELLER SHAFT PROPELLER SHAFT INSTALLATION 5 Connect vent hose and transfer case position sensor connector 6 Connect shift rod to transf...

Page 2489: ...NV271 NV273 Handle Universal C 4171 Remover L 4454 Installer Bearing 6953 Installer Pump Housing Seal 7888 Installer Bearing 8128 Cup 8148 Installer 8151 Installer 8152 21 650 TRANSFER CASE NV271 DR T...

Page 2490: ...Installer 8891 Socket 9033 Installer Bearing 9035 Installer Seal 9036 Installer Seal 9037 DR TRANSFER CASE NV271 21 651 TRANSFER CASE NV271 Continued...

Page 2491: ...LER SHAFT INSTALLATION 4 Verify proper transfer case fluid level 5 Lower vehicle FLUID STANDARD PROCEDURE FLUID DRAIN AND REFILL The fill and drain plugs are both in the rear case Fig 93 1 Raise vehic...

Page 2492: ...de hammer remove the front output shaft seal INSTALLATION 1 Install the new front output shaft seal with Installer MB991168A 2 Install the front companion flange onto the front output shaft 3 Install...

Page 2493: ...ansfer case Refer to the Operat ing Mode Versus Resistance table for the correct resistance for each position Fig 96 OPERATING MODE VERSUS RESISTANCE SENSOR POSITION OPERATING MODE SENSOR RESISTANCE o...

Page 2494: ...icle 5 Remove transfer case shifter knob cap 6 Remove nut holding shifter knob to shift lever 7 Remove shifter knob 8 Remove the shift boot from the shifter console 9 Remove the bolts securing the shi...

Page 2495: ...cond position from full forward 6 Install trunnion to shift lever if necessary 7 Install shift rod to trunnion if necessary 8 Tighten the shift rod lock bolt to 10 N m 90 in lbs 9 Remove the shifter a...

Page 2496: ...the lower shifter lever with the adjustment channel on the shifter bracket assembly Fig 99 7 Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hol...

Page 2497: ...lts The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case halves OPERATING RANGES Transfer case operating ranges are 2WD 2 wheel drive 4HI 4 wheel drive 4L...

Page 2498: ...nsfer 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 surfac...

Page 2499: ...nded operation in 4HI mode on dry surfaces 1 Operate vehicle in 2WD mode on dry surfaces REMOVAL 1 Shift transfer case into 2WD 2 Raise vehicle 3 Drain transfer case lubricant 4 Mark front and rear pr...

Page 2500: ...ding Fig 6 the slinger ears away from the transfer case 6 Using a suitable pry tool Fig 7 remove the slinger from the output shaft using care not to dam age the shaft Fig 4 Remove Boot Clamp Typical 1...

Page 2501: ...th heavy duty snap ring pliers Fig 10 OIL PUMP AND REAR CASE 1 Remove rear case to front case bolts Fig 11 Fig 8 Remove Rear Extension Bolts 1 EXTENSION HOUSING 2 TRANSFER CASE Fig 9 Remove Rear Exten...

Page 2502: ...se failure has gener ated any debris which may have become trapped in the oil pump the rear case and oil pump assembly MUST be replaced 5 Remove the oil pump pickup tube FRONT OUTPUT SHAFT AND DRIVE C...

Page 2503: ...iscard this seal 3 Remove the front output shaft snap ring Fig 18 4 Remove front output shaft from bearing in case Fig 19 Fig 16 Remove Front Sprocket and Drive Chain 1 FRONT DRIVE SPROCKET 2 DRIVE CH...

Page 2504: ...ig 22 Note fork position for installation reference 9 Remove shift sector Fig 23 10 Remove the shift sector o ring Fig 24 Fig 20 Remove Mainshaft 1 FRONT CASE 2 MAINSHAFT Fig 21 Mode Fork And Sleeve R...

Page 2505: ...from the output shaft Fig 25 Remove The Drive Sprocket Retaining Ring 1 OUTPUT SHAFT 2 RETAINING RING 3 DRIVE SPROCKET Fig 26 Remove Drive Sprocket Thrust Washer 1 OUTPUT SHAFT 2 THRUST WASHER 3 DRIVE...

Page 2506: ...front case in horizontal position Then remove input gear and low range gear as an assem bly Fig 33 Tap gear out of bearing with plastic mallet if necessary Fig 30 Remove Retaining Ring 1 OUTPUT SHAFT...

Page 2507: ...tches can be smoothed with an oilstone However replace any part that is damaged Check the contact surfaces in the sprocket bore and on the mainshaft Minor nicks and scratches can be smoothed with 320...

Page 2508: ...BS SLEEVES Check condition of the shift forks and mode fork shift rail Fig 40 Minor nicks on the shift rail can be smoothed with 320 400 grit emery cloth Fig 39 Input Gear and Carrier Components 1 PLA...

Page 2509: ...k for gouges and severe scoring of case sealing sur faces Also make sure the front case mounting studs are in good condition Check the front case mounting studs and vent tube The tube can be secured w...

Page 2510: ...ar bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 46 Fig 46 Front Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 43 Re...

Page 2511: ...bearing Fig 50 into the rear case using Remover Installer 6953 and Handle C 4171 Fig 47 Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 Fig 48 Outp...

Page 2512: ...nap ring 6 Align and install low range input gear assem bly in front case Fig 52 Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing 7...

Page 2513: ...the out put shaft 5 Install the clutch gear Fig 57 onto the output shaft 6 Install the drive sprocket Fig 58 onto the out put shaft Fig 54 Install Mode Hub 1 OUTPUT SHAFT 2 MODE HUB Fig 55 Install Mo...

Page 2514: ...it will be aligned with shift fork pin when shift forks are installed 10 Install the shift sector o ring Fig 58 Install Drive Sprocket 1 OUTPUT SHAFT 2 DRIVE SPROCKET Fig 59 Install Drive Sprocket Th...

Page 2515: ...aft through the mode and range sleeves and into the input gear 17 Install new o ring on detent plug Fig 65 18 Install detent plunger spring and plug Fig 66 Tighten the plug to 16 25 N m 12 18 ft lbs F...

Page 2516: ...54 cm one inch and seat front sprocket on front output shaft 7 If mainshaft and mode sleeve were unseated during chain installation align and reseat mainshaft in input gear and hub 8 Install front sp...

Page 2517: ...ig 74 to hold rear case in position Tighten bolts snug but not to specified torque at this time CAUTION Verify that shift rail and case alignment dowels are seated before installing any bolts Case cou...

Page 2518: ...to the transmission 5 Install and tighten transfer case attaching nuts to 27 34 N m 20 25 ft lbs torque 6 Connect the vent hose 7 Connect the shift motor and mode sensor wir ing connectors Secure wire...

Page 2519: ...ng 16 24 12 18 Bolt Case Half 20 27 15 24 Screw Oil Pump 12 16 8 12 Nuts Mounting 30 41 20 30 Bolts Shift Motor and Mode Sensor Assembly 16 24 12 18 SPECIAL TOOLS TRANSFER CASE NV241 NV243 Handle Univ...

Page 2520: ...hing 8157 Installer Seal D 163 Installer Seal 7884 Installer Bushing 5066 Plug Extension C 293 3 Remover L 4454 Cup 8148 Installer Pump Housing Seal 7888 DR TRANSFER CASE NV243 21 681 TRANSFER CASE NV...

Page 2521: ...ig 77 5 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 6 Verify proper transfer case fluid level 7 Lower vehicle FLUID STANDARD PROCEDURE FLUI...

Page 2522: ...aft seal INSTALLATION 1 Install the new front output shaft seal with Installer MB991168A 2 Install the front output shaft seal slinger with Installer 8840 Install the slinger onto the shaft until the...

Page 2523: ...gnal between 3 8 Volts and 0 8 Volts is considered to be undefined Refer to SECTOR ANGLES vs TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted tra...

Page 2524: ...850 2300 4HI E 3050 5950 2WD Default F 9 5 12 5K In between positions G 15 5K Open For resistances between the ranges B E shown for each valid position T Case NEUTRAL 4LO 4HI 2WD the TCCM may interpre...

Page 2525: ...t motor Fig 85 consists of a permanent magnet D C motor with gear reduction to convert a high speed low torque device into a low speed high torque device The output of the device is coupled to a shaft...

Page 2526: ...attached with bolts The mainshaft front and rear bearings are mounted in aluminum case halves OPERATING RANGES Transfer case operating ranges are 2WD 2 wheel drive 4HI 4 wheel drive 4LO 4 wheel drive...

Page 2527: ...ange 1 Transfer case electronically controlled shift system malfunction 1 Verify proper operation per the appropriate diagnostic manual 2 If vehicle was operated for an extended period in 4HI mode on...

Page 2528: ...nded operation in 4HI mode on dry surfaces 1 Operate vehicle in 2WD mode on dry surfaces REMOVAL 1 Shift transfer case into 2WD 2 Raise vehicle 3 Drain transfer case lubricant 4 Mark front and rear pr...

Page 2529: ...se Flange puller 8992 to remove the companion flange 5 Use a suitable chisel or pry tool to remove the rear extension housing dust boot Fig 4 6 Use a suitable chisel or pry tool to remove the rear ext...

Page 2530: ...as removed with the tube and is in good condition Replace the o ring if necessary 2 Remove the oil pump Fig 8 3 Remove rear case to front case bolts Fig 9 Fig 6 Remove Extension Housing 1 REAR CASE HA...

Page 2531: ...f case Fig 12 7 Unseat rear case from alignment dowels 8 Remove the rear case from the front case Fig 13 Fig 10 Remove Rear Bearing Inner Snap Ring 1 OUTPUT SHAFT 2 REAR CASE HALF 3 SNAP RING Fig 11 R...

Page 2532: ...rear output shaft sprocket splines 5 Remove chain and sprockets as an assembly Fig 14 Remove Oil Pick Up Tube and Screen 1 FRONT CASE HALF 2 OIL SCREEN 3 PICK UP TUBE Fig 15 Remove Front Output Shaft...

Page 2533: ...unger Fig 21 Note that the plug has an O ring seal Remove and discard this seal Fig 18 Remove Shift Motor Assembly Bolts 1 TRANSFER CASE 2 SHIFT MOTOR ASSEMBLY 3 BOLTS Fig 19 Remove Shift Motor Assemb...

Page 2534: ...ssembly Fig 25 Note which way the sleeve fits in the fork long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case Fig 22 Remove Front Output Shaft Bearing Inner Snap...

Page 2535: ...he mode hub retaining ring Fig 29 from the mainshaft 3 Remove the mode hub Fig 30 from the main shaft Fig 26 Range Fork And Hub Removal 1 RANGE HUB 2 RANGE FORK Fig 27 Remove Shift Sector 1 SHIFT SECT...

Page 2536: ...tion Then remove input gear and low range gear as an assem bly Fig 33 Tap gear out of bearing with plastic mallet if necessary Fig 30 Remove Mode Hub 1 MAINSHAFT 2 MODE HUB Fig 31 Remove the Drive Spr...

Page 2537: ...of sealer from the cases and retainers with a scraper and 3M all purpose cleaner Use compressed air to remove solvent residue from oil feed passages in the case halves retainers gears and shafts Fig...

Page 2538: ...or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage Check the pinion gear thrust wash er...

Page 2539: ...bearings Replace the chain and both sprockets if the chain is stretched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condit...

Page 2540: ...haft bearing from the front case half with Installer 6953 and Handle C 4171 Fig 43 3 Install the input shaft bearing into the front case half with Installer 8151 inverted on Handle C 4171 Fig 44 4 Ins...

Page 2541: ...ut shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 48 12 Install new bearing with Tool Handle C 4171 and Installer 8128 Fig 49 The bearing bore is Fig 47 Remove Input G...

Page 2542: ...r output shaft bearing from the rear case using Installer 7888 Fig 53 Fig 53 Remove Rear Output Shaft Bearing 1 REAR CASE HALF 2 INSTALLER 7888 Fig 50 Output Shaft Rear Bearing Installation Depth 1 BE...

Page 2543: ...ttom thrust washer Fig 55 in low range gear planetary Be sure washer tabs are prop erly aligned in gear notches 3 Install input gear in low range gear Fig 56 Be sure input gear is fully seated Fig 54...

Page 2544: ...nge gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing Fig 59 Install Input Gear Retaining Ring 1 INPUT GEAR 2 RETAINING RING Fig 60 Install Input Plan...

Page 2545: ...sprocket hub with ATF 4 and install the drive sprocket drive hub Fig 62 onto the mainshaft 3 Install the mode hub Fig 63 onto the main shaft 4 Install the mode hub retaining ring Fig 64 onto the main...

Page 2546: ...he sector support with Socket 9033 to 27 34 N m 20 25 ft lbs 8 Assemble and install range fork and hub Fig 67 Be sure hub is properly seated in low range gear and engaged to the input gear 9 Align and...

Page 2547: ...sor assembly to the transfer case Tighten the bolts to 16 25 N m 12 18 ft lbs Fig 69 O Ring Installation On Detent Plug 1 O RING 2 DETENT PLUG Fig 70 Install Detent plug Spring and Plunger 1 FRONT CAS...

Page 2548: ...ive sprocket 6 Position rear drive sprocket Fig 76 over the output shaft and lower the sprocket and chain assembly until the front sprocket is positioned over the front output shaft 7 Align the spline...

Page 2549: ...interior 3 Align mainshaft with the rear output shaft bearing and align shift rail with bore in rear case Then install rear case Fig 80 Verify that the case alignment dowels correctly seat into their...

Page 2550: ...aligned 5 Tighten bolts to 27 34 N m 20 25 ft lbs 6 Install rear output bearing inner snap ring Fig 82 to output shaft OIL PUMP AND REAR EXTENSION 1 Install the oil pump Fig 83 onto the output shaft F...

Page 2551: ...xtension housing Fig 85 onto the rear case half 5 Install rear extension bolts Fig 86 Tighten the bolts to 27 34 N m 20 25 ft lbs 6 Install the extension housing dust boot and seal assembly with Insta...

Page 2552: ...se 7 Connect the shift motor and mode sensor wir ing connectors Secure wire harness to clips on trans fer case 8 Align and connect the propeller shafts 9 Fill transfer case with correct fluid Refer to...

Page 2553: ...NV271 NV273 Handle Universal C 4171 Remover L 4454 Installer Bearing 6953 Installer Pump Housing Seal 7888 Installer Bearing 8128 Cup 8148 Installer 8151 Installer 8152 21 714 TRANSFER CASE NV273 DR T...

Page 2554: ...Installer 8891 Socket 9033 Installer Bearing 9035 Installer Seal 9036 Installer Seal 9037 DR TRANSFER CASE NV273 21 715 TRANSFER CASE NV273 Continued...

Page 2555: ...g 90 3 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT PRO PELLER SHAFT INSTALLATION 4 Verify proper transfer case fluid level 5 Lower vehicle FLUID STANDARD PROCEDURE FLUID...

Page 2556: ...to use Flange puller 8992 to remove the companion flange 6 Using a screw and a slide hammer remove the front output shaft seal INSTALLATION 1 Install the new front output shaft seal with Installer MB9...

Page 2557: ...gnal between 3 8 Volts and 0 8 Volts is considered to be undefined Refer to SECTOR ANGLES vs TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted tra...

Page 2558: ...850 2300 4HI E 3050 5950 2WD Default F 9 5 12 5K In between positions G 15 5K Open For resistances between the ranges B E shown for each valid position T Case NEUTRAL 4LO 4HI 2WD the TCCM may interpre...

Page 2559: ...ft motor Fig 96 consists of a permanent magnet D C motor with gear reduction to convert a high speed low torque device into a low speed high torque device The output of the device is coupled to a shaf...

Page 2560: ...FRONT 15 SPARE TIRE DESCRIPTION DESCRIPTION SPARE TEMPORARY TIRE 15 DESCRIPTION FULL SIZE SPARE WHEEL WITH MATCHING TIRE 15 TIRES WHEELS DIAGNOSIS AND TESTING TIRE AND WHEEL RUNOUT Radial runout is t...

Page 2561: ...effects can be reduced by rotat ing the tires according to the maintenance schedule in the Owners Manual This will improve tread life traction and maintain a smooth quiet ride The recommended method o...

Page 2562: ...valve stem location This reference will ensure that it is remounted in the original position on the wheel 1 Remove the tire and wheel assembly from the vehicle and mount on a service dynamic balance...

Page 2563: ...aluminum wheel use back cone mounting method without cone spring NOTE Static should be used only when a two plane balancer is not available NOTE Cast aluminum and forged aluminum wheels require coate...

Page 2564: ...leration Severe brake applications High speed driving Excessive speeds on turns Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It is important to follow the...

Page 2565: ...e specified on the tire sidewall Vehicles loaded to the maximum capacity should not be driven at continuous speeds above 75 mph 120 km h For emergency vehicles that are driven at speeds over 90 mph 14...

Page 2566: ...AND TESTING DIAGNOSIS AND TESTING PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure After checking the air pressure replace valve cap finger tight DIAGNOSIS AND TESTIN...

Page 2567: ...o the road One side of tread is then worn more than the other Fig 15 Excessive toe in or toe out causes wear on the tread edges and a feathered effect across the tread Fig 15 DIAGNOSIS AND TESTING TIR...

Page 2568: ...Fig 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART DR TIRES WHEELS 22 9 TIRES Continued...

Page 2569: ...repaint if neces sary Install wheel on vehicle and tighten to proper torque specification Refer to 22 TIRES WHEELS WHEELS SPECIFICATIONS SPECIFICATIONS TIRE REVOLUTIONS PER MILE TIRE SIZE SUPPLIER RE...

Page 2570: ...WHEEL INSPECTION Inspect wheels for Excessive run out Dents or cracks Damaged wheel lug nut holes Air Leaks from any area or surface of the rim NOTE Do not attempt to repair a wheel by hammer ing hea...

Page 2571: ...the proper torque specification Fig 22 Fig 23 Never use oil or grease on studs or nuts Wheels must be replaced if they have Excessive runout Bent or dented Leak air through welds Have damaged bolt ho...

Page 2572: ...bered sequential pattern until they are snug tight Then tighten lug nut to specified torque following same number sequence Refer to 22 TIRES WHEELS WHEELS SPECIFICATIONS Tighten lug nuts in same numbe...

Page 2573: ...eel SRW models insert a hub cap remover installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion 2 On 3500 models with dual rear wheels DRW you m...

Page 2574: ...sure that they are properly installed SPARE TIRE DESCRIPTION DESCRIPTION SPARE TEMPORARY TIRE The temporary spare tire is designed for emer gency use only The original tire should be repaired or repla...

Page 2575: ......

Page 2576: ...se when welding Disconnect the negative cable clamp from the battery when servicing electrical components that are live when the ignition is OFF Damage to electrical system can result Do not use abras...

Page 2577: ...ing stopping turning or when on an incline MIRROR INSPECTION METHOD When a leak point area is visually obstructed use a suitable mirror to gain visual access A mirror can also be used to deflect light...

Page 2578: ...E HEAT STAKING 1 Remove trim panel 2 Bend or move the trim panel components at the heat staked joints Observe the heat staked loca tions and or component seams for looseness 3 Heat stake the component...

Page 2579: ...emicals or compounds on undamaged painted surfaces around repair areas Damage to finish can result RIGID SEMI RIGID AND FLEXIBLE PLASTIC PARTS TYPES CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICAT...

Page 2580: ...NDER EXTENSIONS EEBC ETHER ESTER BLOCKED CO POLYMER EEBC BUMPERS EEBC PBTP EEBC POLYBUTYLENE TEREPTHALATE EEBC PBTP BEXLOY BUMPER ROCKER PANELS EMPP ETHYLENE MODIFIED POLYPROPYLENE EMPP BUMPER COVERS...

Page 2581: ...gee For fine texturing a small amount of water can be applied to the filler surface while smoothing The cured filler can be sanded as neces sary and as a final step cleanup can be done with soapy wate...

Page 2582: ...t a true damage assessment Close inspection may require partial removal of interior trim or inner panels Identify the type of repair Puncture or Crack Damage that has penetrated completely through the...

Page 2583: ...of the patch should be the same as the repair area 4 After patch has cured peel waxed paper or plastic from the back of the patch 5 If desired a thin film coat of adhesive can be applied to the back o...

Page 2584: ...ps around the patch Fig 13 With compressed air blow dust from around patch 18 Apply adhesive backed nylon mesh dry wall tape over gaps around patch Fig 14 19 Mix enough adhesive to cover the entire pa...

Page 2585: ...the patched area grind surface down and apply a coat of high quality rigid plastic body filler Prime block sand and paint as required Fig 12 INSTALL SCREWS 1 PATCH 2 GAP Fig 13 GRIND SURFACE 1 PATCH 2...

Page 2586: ...also isolates components Water resistant Between metal and metal metal and plastic vinyl and plastic Examples Pull cups bezels clips ducts top cover to glass cowl panel 40 to 180 Fahrenheit 40 to 82...

Page 2587: ...ss lift plate nuts 10 89 Front door hinge to a pillar nuts 28 21 Front door hinge to door nuts bolts 28 21 Front door inside handle bolt 9 80 Front door latch adjustment screw 3 30 Front door latch as...

Page 2588: ...striker bolts 28 21 Rear door regulator bolts 10 89 Rear door regulator stabilizer nuts 10 89 Rear door remote handle actuator nuts 10 89 Rear fender bottom screws 7 60 Rear fender nuts 7 60 Rear fen...

Page 2589: ...SPECIAL TOOLS BODY Trim Stick C 4755 Torx Bit Set C 4794 B Molding Remover C 4829 23 14 BODY DR BODY Continued...

Page 2590: ...is in clearance hole portion of cable end 4 Separate cable end from stud 5 Remove screw attaching cable to tailgate Fig 2 6 Separate check cable from tailgate INSTALLATION 1 Position check cable on ta...

Page 2591: ...REMOVAL 1 Remove the cover Refer to 23 BODY TAIL GATE COVER REMOVAL 2 Using a grease pencil or equivalent mark the actuator rod for installation 3 Disconnect the actuator rod at the control assembly...

Page 2592: ...3 Connect the actuator rods using the marks made during removal 4 Install the cover Refer to 23 BODY TAIL GATE COVER INSTALLATION TAILGATE REMOVAL 1 Open the tailgate 2 Disconnect the tailgate check c...

Page 2593: ...ALLATION 26 SIDE VIEW MIRROR FLAG REMOVAL 27 INSTALLATION 27 DOOR REMOVAL 1 Disconnect the door wire harness electrical con nector at the A pillar Fig 1 2 Using a grease pencil or equivalent mark the...

Page 2594: ...e door requires the loosening of the door to hinge fasteners it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool NOTE When the up down adjustments are done c...

Page 2595: ...into the window opening 2 Engage the glass into the glass run weather strip 3 Raise the glass within the door opening and connect the window regulator to the lift plate 4 Install the nuts and tighten...

Page 2596: ...he door loosen the upper screw and disengage from the door Fig 6 3 Separate the glass run weatherstrip from the rear channel and remove the channel INSTALLATION FRONT RUN CHANNEL 1 Install the channel...

Page 2597: ...Install the hinges and bolts 2 Tighten bolts to 28 N m 21 ft lbs 3 Install the door Refer to 23 BODY DOOR FRONT DOOR INSTALLATION INSIDE HANDLE ACTUATOR REMOVAL 1 Remove the screw and remove the insi...

Page 2598: ...er to 23 BODY DOOR FRONT LATCH INSTALLATION ADJUSTMENTS ADJUSTMENT 1 Locate access hole and remove the mylar tape covering it Fig 10 2 Insert a 5 32 inch hex wrench through hole and into adjustment sc...

Page 2599: ...switch if equipped lever and retaining clip 3 Install the exterior handle Refer to 23 BODY DOOR FRONT EXTERIOR HANDLE INSTALLATION TRIM PANEL REMOVAL 1 Remove the window crank if equipped Fig 13 2 Rem...

Page 2600: ...2 Secure the waterdam to the inner door panel 3 Install the speaker Refer to 8 ELECTRICAL AUDIO SPEAKER INSTALLATION 4 Install the inside handle actuator Refer to 23 BODY DOOR FRONT INSIDE HANDLE ACTU...

Page 2601: ...e or equivalent 5 Lower the regulator 6 Remove the stabilizer nuts 7 Remove the two lower and loosen the two upper bolts Fig 16 8 Slide the regulator up and out of the keyhole slot 9 Remove the regula...

Page 2602: ...bs and remove the mirror flag INSTALLATION NOTE Clean the excess heat staking off of the studs to aid installation 1 Install the new mirror flag over the tabs and install the screws into the heat stak...

Page 2603: ...poxy bonded washers should not be seperated from the hinge If the washers are removed the door may have to be re adjusted 4 Remove the nuts and bolts attaching the door hinges to the door INSTALLATION...

Page 2604: ...inge to hinge pillar fasteners Refer to 23 BODY DOORS REAR HINGE REMOVAL or loosen the hinge to door fasteners Refer to 23 BODY DOORS REAR DOOR REMOVAL 4 Adjust the door to the correct position Refer...

Page 2605: ...quivalent 5 Install the glass run channels Refer to 23 BODY DOORS REAR GLASS RUN CHANNEL INSTALLATION EXTERIOR HANDLE REMOVAL 1 Remove the front glass run channel Refer to 23 BODY DOORS REAR GLASS RUN...

Page 2606: ...IM REMOVAL 3 Remove the nut and bolt attaching the hinge to the door 4 Remove the two bolts attaching the hinge to the b pillar 5 From the inside of the vehicle remove the remaining bolt attaching the...

Page 2607: ...rical connector and remove the latch INSTALLATION 1 Connect the electrical connector and install the latch assembly 2 Install the bolts and tighten to 10 N m 89 in lbs 3 Connect the actuator rods 4 Ad...

Page 2608: ...2 Remove the interior handle Refer to 23 BODY DOORS REAR INSIDE HANDLE ACTUA TOR REMOVAL 3 Remove the screw near the inside handle Fig 9 CAUTION Trim panel is attached to the door using hooks molded...

Page 2609: ...tion 6 Secure the glass in the up position using a wood wedge or equivalent 7 Lower the regulator 8 Disconnect the electrical connector Fig 12 9 Remove the lower regulator bolt and loosen the upper tw...

Page 2610: ...le in the inner door panel 2 Position the regulator bolts into the keyhole slots and slide into place 3 Install the back regulator bolts and tighten all four to 10 N m 89 in lbs 4 Position the stabili...

Page 2611: ...the top edge of the molding and to one end to use as a guide for installation if neces sary 2 If temperature is below 21 C 70 F warm molding with a heat lamp or gun Do not exceed 52 C 120 F when heati...

Page 2612: ...e bolts 2 Tighten the bolts to 108 N m 80 ft lbs 3 Connect the fuel fill and vent hoses Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL TANK INSTALLATION 4 Connect the tail lamp wire harness CARGO BOX TIE...

Page 2613: ...e for installation if necessary 2 If temperature is below 21 C 70 F warm emblem with a heat lamp or gun Do not exceed 52 C 120 F when heating name plate 3 Using a trim stick C 4755 or equivalent remov...

Page 2614: ...17 N m 13 ft lbs 5 Check the fender positioning and adjust as required by adding shims Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFI CATIONS 6 Install the wheelhouse splash shield Refer to 23...

Page 2615: ...screws 2 Install the grille Refer to 23 BODY EXTERI OR GRILLE INSTALLATION FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1 Remove the three screws at the fender Fig 10 2 Remove the electrical connector push...

Page 2616: ...TRIM PANEL REMOVAL 2 Disconnect the electrical connector and remove the nuts Fig 12 3 Squeeze the electrical connector tabs and remove the mirror Fig 13 INSTALLATION 1 Install the mirror onto the door...

Page 2617: ...VICING THE MIRROR ASSEM BLY FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY FROM BRO KEN GLASS Standard Mirror 1 Position the mirror glass so that it s facing in toward the vehicle as...

Page 2618: ...R HOUSING COVER 1 MIRROR HOUSING COVER 2 RETAINING TABS 3 Fig 18 STANDARD MIRROR RETAINING TAB 1 MIRROR ASSEMBLY 2 MIRROR GLASS LOWER RETAINING TAB Fig 19 TOW PACKAGE MIRROR POSITION 1 MIRROR HOUSING...

Page 2619: ...move the rear inner nuts below the tail lamp Fig 24 6 Remove the two bolts at the rear bottom edge 7 Remove the two bolts at the front bottom edge 8 Remove the four inner nuts front edge Fig 25 9 Loos...

Page 2620: ...amp opening and tighten to 7 N m 60 in lbs 9 Install the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT INSTALLATION Fig 23 TAIL LAMP OPENING 1 TAIL LAMP OPENING 2 FENDER...

Page 2621: ...r to 23 BODY EXTERIOR FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 7 From inside the fender remove the two hinge bolts Fig 2 8 Slide the hinge forward and remove from the fender rail INSTALLATION 1 Install...

Page 2622: ...arks made pre viously and install the bolts 3 Tighten the bolts to 11 N m 8 ft lbs 4 Check hood fit and adjust if required Refer to 23 BODY BODY STRUCTURE GAP AND FLUSH SPECIFICATIONS LATCH RELEASE CA...

Page 2623: ...NOTE The support cylinders can be replaced one at a time 1 Open the hood and support NOTE Lift the clips only enough to release the ball studs Fig 6 2 Using a small flat bladed tool or equivalent rele...

Page 2624: ...sing at the center of the cylinder Press the ends only 2 Install the support cylinder over the ball studs with the thin end connected to the body side of the hinge and the retaining clips snapping int...

Page 2625: ...DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND...

Page 2626: ...NNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISAB...

Page 2627: ...R SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the center be...

Page 2628: ...the box press down on the rearward edge of the bin and raise the glove box fully past the stops 3 Check for proper glove box operation GLOVE BOX LATCH REMOVAL 1 Remove the glove box Refer to 23 BODY...

Page 2629: ...E BEZEL REMOVAL 9 Remove the left side mounting bolts Fig 8 10 Disconnect the wire harness electrical connec tors above the brake pedal Fig 9 11 Loosen the screws and remove the hood release handle fr...

Page 2630: ...22 Remove the right a pillar trim Refer to 23 BODY INTERIOR A PILLAR TRIM GRAB HANDLE REMOVAL 23 Remove the two right side mounting bolts on the a pillar and one right mounting bolt on the cowl side...

Page 2631: ...nd the right side guide hook 4 Install the left side mounting bolts and tighten to 12 N m 9 ft lbs 5 Install the instrument panel drivers side bezel Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL...

Page 2632: ...ERING COLUMN SEAT BELT TENSIONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO...

Page 2633: ...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 2634: ...h electrical connector if equipped 3 Seat the upper attachment clips fully 4 Install the two screws 5 Position the endcap and seat fully 6 Install the drivers side cowl trim panel Refer to 23 BODY INT...

Page 2635: ...move the storage bin if equipped Refer to 23 BODY INSTRUMENT PANEL STORAGE BIN REMOVAL 6 Remove the ash receiver Refer to 23 BODY INSTRUMENT PANEL ASH RECEIVER REMOVAL 7 Remove the steering column ope...

Page 2636: ...ONER OR INSTRU MENT PANEL COMPONENT DIAGNOSIS OR SER VICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING...

Page 2637: ...er bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL REMOVAL 2 Remove the floor console Refer to 23 BODY INTERIOR FLOOR CONSOLE REMOVAL 3 Remove the four screws and remove the bin...

Page 2638: ...ATION 71 INSTALLATION REARVIEW MIRROR SUPPORT BRACKET 71 SUN VISOR REMOVAL 71 INSTALLATION 71 SUN VISOR SUPPORT REMOVAL 72 INSTALLATION 72 BODY VENT REMOVAL 72 INSTALLATION 72 REAR DOOR SILL TRIM COVE...

Page 2639: ...LOWER TRIM REMOVAL 1 Remove the upper b pillar trim Refer to 23 BODY INTERIOR B PILLAR UPPER TRIM REMOVAL 2 Remove the cowl trim Refer to 23 BODY IN TERIOR COWL TRIM REMOVAL STANDARD CAB 1 Remove the...

Page 2640: ...R UPPER TRIM REMOVAL 1 Remove the seat belt turning loop Refer to 8 ELECTRICAL RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER REMOVAL 2 Open the trim plugs and remove the grab han dle bolts if equipped Fi...

Page 2641: ...jack assembly 3 Install the rear cup holder if equipped 4 Install the lower b pillar trim Refer to 23 BODY INTERIOR B PILLAR LOWER TRIM INSTALLATION 5 Install the floor console if equipped Refer to 2...

Page 2642: ...and seat the attachment clips fully C PILLAR LOWER TRIM REMOVAL 1 Remove the upper c pillar trim Refer to 23 BODY INTERIOR C PILLAR TRIM REMOVAL 2 Remove the seat belt anchor bolt Fig 11 3 Using a tr...

Page 2643: ...boot Refer to 23 BODY INTERIOR 4WD FLOOR SHIFT BOOT REMOVAL 2 Using a trim stick C 4755 or equivalent pry up the transmission shifter boot from the console 3 Remove the transmission shifter extension...

Page 2644: ...se the headliner and insert the right side above right side pillar trim pieces 3 Connect the center high mounted stop light electrical connector 4 Install the sun visor supports Refer to 23 BODY INTER...

Page 2645: ...ar trim 2 Route the center belt and trim bezel through the back panel if equipped 3 On standard cab models install the left lower b pillar trim panel Refer to 23 BODY INTERIOR B PILLAR LOWER TRIM INST...

Page 2646: ...Allow the accelerator to dry for five minutes e Do not touch the bracket contact surface after the accelerator has been applied 5 Apply adhesive accelerator to the bracket con tact surface on the wind...

Page 2647: ...the vent hole INSTALLATION 1 Position the vent into the vent hole in the cab back panel 2 Twist the vent and pull it into the hole frame and seat the tabs fully 3 Install the cab back panel trim Refe...

Page 2648: ...N m 18 ft lbs LOAD FLOOR SUPPORT CYLINDER REMOVAL 1 Open the load floor 2 Remove the snap clips and retaining pins Fig 24 3 Remove the support cylinder INSTALLATION 1 Install the support cylinder wit...

Page 2649: ...Timberline Green AGW INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER CODE Taupe L5 Dark Slate Gray DV PAINT CODE DESCRIPTION Exterior vehicle body colors are identified on the Vehicle Safety Certificat...

Page 2650: ...t Do not overlap touch up color onto the original color coat around the scratch or chip Butt the new color to the original color if possible Do not stroke applicator brush on body surface Allow touch...

Page 2651: ...3 SEAT CUSHION COVER FRONT REMOVAL 83 INSTALLATION 83 SEAT TRACK REMOVAL 83 INSTALLATION 83 SEAT REAR REMOVAL 84 INSTALLATION 84 SEAT BACK REAR REMOVAL 84 INSTALLATION 84 SEAT BACK CUSHION COVER REAR...

Page 2652: ...to 28 N m 21 ft lbs CENTER ARMREST SEAT BACK REMOVAL NOTE Do not reuse the seat fasteners always replace with new ones 1 Remove the center seat Refer to 23 BODY SEATS SEAT CENTER REMOVAL 2 Disconnect...

Page 2653: ...zip strip Fig 5 2 Position aside the storage bin cover 3 Remove the pivot bolt 4 Open the hinge cover at the bottom and remove the hinge cover Fig 6 INSTALLATION NOTE Free pivot hinge cover is instal...

Page 2654: ...ness Fig 9 5 Remove the cover from the hinge Inertia Hinge 1 Remove the seat back inertia hinge cover Refer to 23 BODY SEATS CENTER SEAT BACK INERTIA HINGE COVER REMOVAL 2 Remove and discard the inert...

Page 2655: ...LATION CENTER SEAT BACK LID REMOVAL 1 Open the center armrest seat back 2 Remove the four screws attaching the hinge to the storage bin and remove the lid INSTALLATION 1 Position the center seat back...

Page 2656: ...ix screws 2 Install the center seat cushion Refer to 23 BODY SEATS CENTER SEAT CUSHION INSTAL LATION UNDER SEAT STORAGE BIN COVERING REMOVAL 1 Remove the under seat storage bin Refer to 23 BODY SEATS...

Page 2657: ...supply electrical con nector if equipped Fig 13 4 Fold the seat backs forward and roll the seat assembly back in the vehicle 5 Separate the seat assembly by removing and discarding the three nuts on e...

Page 2658: ...er to 23 BODY SEATS SEAT TRACK REMOVAL 5 Disconnect the j straps and remove the seat cushion and cover INSTALLATION 1 Position the seat cushion and cover onto the frame assembly and connect the j stra...

Page 2659: ...Refer to 23 BODY IN TERIOR LOAD FLOOR INSTALLATION SEAT BACK REAR REMOVAL 1 Remove the rear seat Refer to 23 BODY SEATS SEAT REAR REMOVAL 2 Remove the seat back bolts and remove the seat back Fig 17 I...

Page 2660: ...at Refer to 23 BODY SEATS SEAT REAR INSTALLATION SEAT CUSHION FRAME REAR REMOVAL 1 Remove the seat cushion cover Refer to 23 BODY SEATS SEAT CUSHION COVER REAR REMOVAL 2 Remove the bolts and remove th...

Page 2661: ...NTERIOR C PILLAR UPPER TRIM REMOVAL 5 Bend backlite retaining tabs Fig 1 inward against glass 6 Disconnect the rear window defogger electrical connector if equipped 7 Using a suitable pneumatic knife...

Page 2662: ...the vent glass upward to remove from the lower window frame 3 Lower the glass out of the upper window frame and remove INSTALLATION 1 Slide the vent glass upper edge into window frame and insert the l...

Page 2663: ...IP RETAINER REMOVAL 4 Remove the a pillar trim panels Refer to 23 BODY INTERIOR A PILLAR TRIM REMOVAL 5 Remove the headliner and from the inside of the vehicle cut the upper urethane bonding from arou...

Page 2664: ...helper position the wind shield over the windshield opening Align the refer ence marks at the bottom of the windshield to the support spacers 12 Slowly lower windshield glass to the fence opening gui...

Page 2665: ...2 SPACER LOCATION 75 MM 2 95 IN 3 LOWER FOAM SPACERS 3 4 SIDE FOAM SPACERS 4 Fig 8 APPLICATOR TIP 1 APPLICATOR TIP Fig 9 LOWER WINDSHIELD INTO POSITION 1 COMPRESSION SPACER 2 WINDSHIELD 3 ADJUSTABLE S...

Page 2666: ...1 Remove the drip rail weatherstrip retainer Refer to 23 BODY WEATHERSTRIP SEALS DRIP RAIL WEATHERSTRIP REMOVAL 2 Remove the five screws and remove the weath erstip retainer Fig 1 INSTALLATION 1 Insta...

Page 2667: ...at the center of the lower flange Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated Work in one direction smoothing the seal to avoid puckers or...

Page 2668: ...INSTALLA TION REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1 Lower the glass 2 Separate the weatherstrip out of the door frame and remove through the window opening Fig 4 INSTALLATION NOTE A mixture of s...

Page 2669: ...REMOVAL 2 Separate the belt molding from the mounting flange from the back to the front Fig 5 INSTALLATION 1 Position the belt molding and seat onto the mounting flange fully 2 Install the door trim p...

Page 2670: ...ECIFICATIONS BODY OPENING DIMENSIONS 99 SEALER LOCATIONS SPECIFICATIONS 103 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS 113 WELD LOCATIONS SPECIFICATIONS 122 GAP AND FLUSH SPECIFICATIONS GAP FLUSH DI...

Page 2671: ...door to windshield O F 20 5 1 5 Base of windshield O F 9 0 1 5 Top of windshield 6 Roof to front door U F 6 0 1 5 Parallel within 1 5 7 Quarter to front door 5 0 1 5 Parallel within 1 0 0 0 1 5 8 Fron...

Page 2672: ...within 1 5 2 Quarter to rear door 5 0 1 5 Parallel within 2 0 0 0 1 5 3 Rear door to quarter character line alignment Up Down 0 0 1 5 4 Rear door to front door character line alignment Up Down 0 0 1 5...

Page 2673: ...0 1 5 4 Cab to box side 31 0 5 0 Parallel within 3 0 4 0 2 5 Standard Cab O F 5 0 2 5 Quad Cab 5 Cab to box character line alignment Up Down 0 0 3 0 6 Tailgate to outer box 5 0 2 0 Parallel within 1...

Page 2674: ...S BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 4 DOOR OPENING STANDARD CAB 5 DOOR OPENINGS QUAD CAB 6 REAR WINDOW OPENING 7 ENGINE COMPARTMENT FRONT STRUCTURE 8 Fig 4 WINDSHIELD...

Page 2675: ...Fig 5 DOOR OPENING STANDARD CAB Fig 6 DOOR OPENINGS QUAD CAB 23 100 BODY STRUCTURE DR OPENING DIMENSIONS Continued...

Page 2676: ...Fig 7 REAR WINDOW OPENING DR BODY STRUCTURE 23 101 OPENING DIMENSIONS Continued...

Page 2677: ...Fig 8 ENGINE COMPARTMENT FRONT STRUCTURE 23 102 BODY STRUCTURE DR OPENING DIMENSIONS Continued...

Page 2678: ...DASH PANEL LOWER COWL SIDE AND FLOOR PAN SUPPORT 11 ROOF PANEL OUTER BODY SIDE APERTURE AND BACKLITE 12 CAB BACK BODY SIDE APERTURE REAR AND BACKLITE LOWER CORNER 13 LOWER DASH PANEL AND FLOOR PAN 14...

Page 2679: ...Fig 10 DASH PANEL 23 104 BODY STRUCTURE DR SEALER LOCATIONS Continued...

Page 2680: ...Fig 11 LOWER DASH PANEL DR BODY STRUCTURE 23 105 SEALER LOCATIONS Continued...

Page 2681: ...Fig 12 ROOF PANEL 23 106 BODY STRUCTURE DR SEALER LOCATIONS Continued...

Page 2682: ...Fig 13 CAB BACK PANEL DR BODY STRUCTURE 23 107 SEALER LOCATIONS Continued...

Page 2683: ...Fig 14 LOWER DASH PANEL 23 108 BODY STRUCTURE DR SEALER LOCATIONS Continued...

Page 2684: ...Fig 15 FLOOR PAN DR BODY STRUCTURE 23 109 SEALER LOCATIONS Continued...

Page 2685: ...Fig 16 FRONT FLOOR PAN 23 110 BODY STRUCTURE DR SEALER LOCATIONS Continued...

Page 2686: ...Fig 17 FLOOR PAN DR BODY STRUCTURE 23 111 SEALER LOCATIONS Continued...

Page 2687: ...Fig 18 PICKUP BOX 23 112 BODY STRUCTURE DR SEALER LOCATIONS Continued...

Page 2688: ...X SIDE PANEL 23 INNER WHEELHOUSE CROSSMEMBERS AND CROSSMEMBER END SUPPORT BRACKET TO INNER BOX SIDE PANEL 24 INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL 25 INNER DOOR PANEL TO OUTER DOOR PANEL FRONT...

Page 2689: ...Fig 20 FRONT FENDER 23 114 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2690: ...Fig 21 FLOOR PAN DR BODY STRUCTURE 23 115 STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2691: ...Fig 22 INNER WHEELHOUSE Fig 23 INNER BOX SIDE PANEL 23 116 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2692: ...Fig 24 INNER WHEELHOUSE Fig 25 INNER BOX SIDE PANEL DR BODY STRUCTURE 23 117 STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2693: ...Fig 26 INNER DOOR PANEL Fig 27 INNER DOOR PANEL 23 118 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2694: ...Fig 28 REAR DOOR INNER PANEL DR BODY STRUCTURE 23 119 STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2695: ...Fig 29 SILL RAIL STD CAB 23 120 BODY STRUCTURE DR STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2696: ...Fig 30 SILL RAIL QUAD CAB DR BODY STRUCTURE 23 121 STRUCTURAL ADHESIVE LOCATIONS Continued...

Page 2697: ...40 REINFORCEMENT AND HEADLAMP MOUNTING PANEL TO OUTER FENDER PANEL 41 SEAT MOUNTING FRONT BRACKETS TO SEAT MOUNTING FRONT CROSSMEMBER TO FRONT FLOOR PAN 42 AIR BAG MODULE BRACKET SHIFTER MOUNTING PLAT...

Page 2698: ...TER BODY SIDE APERTURE TO A PILLAR REINFORCEMENT 66 OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE 67 B PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 68 UPPER B PI...

Page 2699: ...ETS TO REAR CROSS BOX SILL FRONT WHEELHOUSE LONG AND BRACKET SUPPORT CROSSMEMBERS 93 STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER BOX SIDE PANEL 94 OUTER BOX SIDE REINFORCEMENT BRA...

Page 2700: ...PANEL TO BOX FRONT PANEL 117 BOX FRONT PANEL TO BOX FLOOR PANEL 118 BOX FLOOR PANEL TO INNER BOX SIDE PANEL 119 LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER BOX SIDE PANEL 120 INNER...

Page 2701: ...Fig 31 FENDER BRACE 23 126 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2702: ...Fig 32 STEERING COLUMN SUPPORT DR BODY STRUCTURE 23 127 WELD LOCATIONS Continued...

Page 2703: ...Fig 33 WIPER ATTACHING WELD NUTS Fig 34 DASH PANEL 23 128 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2704: ...Fig 35 DASH PANEL DR BODY STRUCTURE 23 129 WELD LOCATIONS Continued...

Page 2705: ...Fig 36 LOWER PLENUM PANEL 23 130 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2706: ...Fig 37 FRONT FENDER Fig 38 DASH PANEL DR BODY STRUCTURE 23 131 WELD LOCATIONS Continued...

Page 2707: ...Fig 39 FRONT FENDER Fig 40 DASH PANEL 23 132 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2708: ...Fig 41 HEADLAMP MOUNTING PANEL DR BODY STRUCTURE 23 133 WELD LOCATIONS Continued...

Page 2709: ...Fig 42 SEAT MOUNTING FRONT BRACKETS STANDARD CAB 23 134 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2710: ...Fig 43 AIR BAG MODULE BRACKET STANDARD CAB DR BODY STRUCTURE 23 135 WELD LOCATIONS Continued...

Page 2711: ...Fig 44 RIGHT TO LEFT REAR FLOOR CROSSMEMBER STANDARD CAB 23 136 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2712: ...Fig 45 REAR FLOOR CROSSMEMBER STANDARD CAB DR BODY STRUCTURE 23 137 WELD LOCATIONS Continued...

Page 2713: ...Fig 46 SEAT MOUNTING FRONT CROSSMEMBER STANDARD CAB 23 138 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2714: ...Fig 47 FRONT SEAT MOUNTING CROSSMEMBERS STANDARD CAB DR BODY STRUCTURE 23 139 WELD LOCATIONS Continued...

Page 2715: ...Fig 48 REAR FLOOR CROSSMEMBERS STANDARD CAB 23 140 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2716: ...Fig 49 FLOOR SILL STANDARD CAB DR BODY STRUCTURE 23 141 WELD LOCATIONS Continued...

Page 2717: ...Fig 50 AIR BAG MODULE BRACKET QUAD CAB 23 142 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2718: ...Fig 51 REAR SEAT MIDDLE MOUNTING PLATE QUAD CAB DR BODY STRUCTURE 23 143 WELD LOCATIONS Continued...

Page 2719: ...Fig 52 REAR FLOOR CROSSMEMBER QUAD CAB 23 144 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2720: ...Fig 53 LEFT REAR CROSSMEMBER QUAD CAB Fig 54 STORAGE BIN QUAD CAB DR BODY STRUCTURE 23 145 WELD LOCATIONS Continued...

Page 2721: ...Fig 55 RIGHT REAR FRONT SEAT MOUNTING CROSSMEMBER QUAD CAB 23 146 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2722: ...Fig 56 FRONT SEAT MOUNTING FRONT CROSSMEMBER QUAD CAB DR BODY STRUCTURE 23 147 WELD LOCATIONS Continued...

Page 2723: ...Fig 57 FRONT SEAT MOUNTING FRONT CROSSMEMBER 23 148 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2724: ...Fig 58 A PILLAR REINFORCEMENT STANDARD CAB DR BODY STRUCTURE 23 149 WELD LOCATIONS Continued...

Page 2725: ...Fig 59 A PILLAR REINFORCEMENT STANDARD CAB Fig 60 INNER BODY SIDE APERTURE STANDARD CAB 23 150 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2726: ...Fig 61 SHOULDER BELT REINFORCEMENT STANDARD CAB Fig 62 FRONT PILLAR TAPPING PLATES STANDARD CAB DR BODY STRUCTURE 23 151 WELD LOCATIONS Continued...

Page 2727: ...Fig 63 INNER BODY SIDE APERTURE STANDARD CAB 23 152 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2728: ...Fig 64 C PILLAR BAFFLE QUAD CAB DR BODY STRUCTURE 23 153 WELD LOCATIONS Continued...

Page 2729: ...Fig 65 A PILLAR REINFORCEMENT QUAD CAB Fig 66 FRONT EXTENSION PLATE QUAD CAB 23 154 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2730: ...Fig 67 OUTER BODY SIDE APERTURE QUAD CAB Fig 68 B PILLAR REINFORCEMENT QUAD CAB DR BODY STRUCTURE 23 155 WELD LOCATIONS Continued...

Page 2731: ...Fig 69 UPPER TAPPING PLATE QUAD CAB Fig 70 UPPER A PILLAR TAPPING PLATE QUAD CAB 23 156 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2732: ...Fig 71 SEAT BELT MOUNTING PLATES QUAD CAB Fig 72 OUTER BODY SIDE APERTURE QUAD CAB DR BODY STRUCTURE 23 157 WELD LOCATIONS Continued...

Page 2733: ...Fig 73 C PILLAR REINFORCEMENT QUAD CAB Fig 74 SEAT BELT RETRACTOR PLATE STANDARD CAB 23 158 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2734: ...Fig 75 FLOOR SILL STANDARD CAB DR BODY STRUCTURE 23 159 WELD LOCATIONS Continued...

Page 2735: ...Fig 76 BACK REINFORCEMENT STANDARD CAB 23 160 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2736: ...Fig 77 CAB BACK REINFORCEMENT STANDARD CAB DR BODY STRUCTURE 23 161 WELD LOCATIONS Continued...

Page 2737: ...Fig 78 COWL SIDE PANEL STANDARD CAB Fig 79 OUTER ROOF PANEL STANDARD CAB 23 162 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2738: ...Fig 80 FRONT ROOF HEADER STANDARD CAB Fig 81 REAR ROOF HEADER STANDARD CAB DR BODY STRUCTURE 23 163 WELD LOCATIONS Continued...

Page 2739: ...Fig 82 OUTER BODY SIDE APERTURE QUAD CAB 23 164 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2740: ...Fig 83 OUTER BODY SIDE APERTURE QUAD CAB DR BODY STRUCTURE 23 165 WELD LOCATIONS Continued...

Page 2741: ...Fig 84 REAR FLOOR CROSSMEMBER QUAD CAB 23 166 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2742: ...Fig 85 CAB BACK REINFORCEMENT QUAD CAB DR BODY STRUCTURE 23 167 WELD LOCATIONS Continued...

Page 2743: ...Fig 86 CENTER SHOULDER BELT REINFORCEMENT QUAD CAB 23 168 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2744: ...Fig 87 A PILLAR REINFORCEMENT QUAD CAB DR BODY STRUCTURE 23 169 WELD LOCATIONS Continued...

Page 2745: ...Fig 88 B PILLAR REINFORCEMENT QUAD CAB 23 170 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2746: ...Fig 89 FRONT ROOF HEADER QUAD CAB DR BODY STRUCTURE 23 171 WELD LOCATIONS Continued...

Page 2747: ...Fig 90 INNER BODY SIDE APERTURE QUAD CAB 23 172 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2748: ...Fig 91 FRONT CROSSMEMBER SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 173 WELD LOCATIONS Continued...

Page 2749: ...Fig 92 LONG CROSSMEMBER SHORT CARGO BOX ONLY 23 174 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2750: ...Fig 93 TAPPING PLATES SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 175 WELD LOCATIONS Continued...

Page 2751: ...Fig 94 STAKE POCKET REINFORCEMENTS SHORT CARGO BOX ONLY 23 176 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2752: ...Fig 95 OUTER BOX SIDE REINFORCEMENT BRACES SHORT CARGO BOX ONLY Fig 96 OUTER WHEELHOUSE SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 177 WELD LOCATIONS Continued...

Page 2753: ...Fig 97 WELD NUT SHORT CARGO BOX ONLY SHORT CARGO BOX ONLY Fig 98 FRONT BOX PANEL SHORT CARGO BOX ONLY 23 178 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2754: ...Fig 99 FRONT CROSSMEMBER SHORT CARGO BOX ONLY Fig 100 BOX FLOOR PANEL SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 179 WELD LOCATIONS Continued...

Page 2755: ...Fig 101 FRONT CROSSMEMBER SHORT CARGO BOX ONLY 23 180 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2756: ...Fig 102 STAKE POCKET REINFORCEMENT SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 181 WELD LOCATIONS Continued...

Page 2757: ...Fig 103 INNER TAILGATE PILLAR PANEL SHORT CARGO BOX ONLY 23 182 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2758: ...Fig 104 BOX FLOOR SILL CROSSMEMBER SHORT CARGO BOX ONLY Fig 105 INNER TAILGATE PILLAR SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 183 WELD LOCATIONS Continued...

Page 2759: ...Fig 106 BOX SIDE PANEL SHORT CARGO BOX ONLY Fig 107 FRONT BOX PANEL SHORT CARGO BOX ONLY 23 184 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2760: ...Fig 108 INNER BOX SIDE PANEL SHORT CARGO BOX ONLY Fig 109 OUTER WHEELHOUSE PANEL SHORT CARGO BOX ONLY DR BODY STRUCTURE 23 185 WELD LOCATIONS Continued...

Page 2761: ...Fig 110 FRONT CROSSMEMBER LONG CARGO BOX ONLY 23 186 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2762: ...Fig 111 WHEELHOUSE CROSSMEMBER LONG CARGO BOX ONLY DR BODY STRUCTURE 23 187 WELD LOCATIONS Continued...

Page 2763: ...Fig 112 FRONT AND CENTER STAKE POCKET REINFORCEMENTS LONG CARGO BOX ONLY Fig 113 OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT LONG CARGO BOX ONLY 23 188 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2764: ...Fig 114 OUTER WHEELHOUSE LONG CARGO BOX ONLY DR BODY STRUCTURE 23 189 WELD LOCATIONS Continued...

Page 2765: ...Fig 115 TAILGATE BOX SIDE PIVOT REINFORCEMENT LONG CARGO BOX ONLY Fig 116 FRONT BOX SIDE PANEL LONG CARGO BOX ONLY 23 190 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2766: ...Fig 117 FRONT BOX SIDE PANEL LONG CARGO BOX ONLY Fig 118 BOX FRONT PANEL LONG CARGO BOX ONLY DR BODY STRUCTURE 23 191 WELD LOCATIONS Continued...

Page 2767: ...Fig 119 BOX FLOOR PANEL LONG CARGO BOX ONLY Fig 120 LONG CROSSMEMBERS LONG CARGO BOX ONLY 23 192 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2768: ...Fig 121 INNER WHEELHOUSE PANEL LONG CARGO BOX ONLY Fig 122 TAILGATE PILLAR OUTER PANEL LONG CARGO BOX ONLY DR BODY STRUCTURE 23 193 WELD LOCATIONS Continued...

Page 2769: ...Fig 123 REAR SILL CROSS BOX LONG CARGO BOX ONLY 23 194 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2770: ...Fig 124 OUTER BOX SIDE PANEL LONG CARGO BOX ONLY DR BODY STRUCTURE 23 195 WELD LOCATIONS Continued...

Page 2771: ...Fig 125 STAKE POCKET REINFORCEMENTS LONG CARGO BOX ONLY Fig 126 TAILGATE PIVOT REINFORCEMENT LONG CARGO BOX ONLY 23 196 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2772: ...Fig 127 INNER WHEELHOUSE LONG CARGO BOX ONLY Fig 128 OUTER TAILGATE PILLAR LONG CARGO BOX ONLY DR BODY STRUCTURE 23 197 WELD LOCATIONS Continued...

Page 2773: ...Fig 129 INNER DOOR PANEL QUAD CAB 23 198 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2774: ...Fig 130 INNER DOOR PANEL STANDARD CAB DR BODY STRUCTURE 23 199 WELD LOCATIONS Continued...

Page 2775: ...Fig 131 INNER DOOR PANEL QUAD CAB 23 200 BODY STRUCTURE DR WELD LOCATIONS Continued...

Page 2776: ...the air conditioning refrigerant system Unique service port coupler sizes are used on the R 134a system to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong...

Page 2777: ...d the effect that humidity has on the performance of the air condition ing system When humidity is high the evaporator has to perform a double duty It must lower the air temperature and it must lower...

Page 2778: ...Out Pressuree at Service Port High Side 1034 to 1724 kPa 150 to 250 psi 1379 to 2068 kPa 200 to 300 psi 1724 to 2413 kPa 250 to 350 psi 1999 to 2689 kPa 290 to 390 psi 2413 to 2965 kPa 350 to 430 psi...

Page 2779: ...3 Perform blend door actuator diagnosis replace if faulty The low side pressure is normal or slightly low and the high side pressure is too low 1 Low refrigerant system charge 1 See Plumbing Diagnosi...

Page 2780: ...ugh the fixed orifice tube 2 See A C Orifice Tube in this group Replace the liquid line if required 3 Restricted refrigerant flow through the condenser 3 See A C Condenser in this group Replace the re...

Page 2781: ...NTROL If the heater outlet air temperature cannot be adjusted with the temperature control knob on the a c heater control panel the following could require service A faulty a c heater control A faulty...

Page 2782: ...battery negative cable s and test affected systems SPECIFICATIONS A C APPLICATION TABLE Item Description Notes Vehicle DR Ram Truck System R134a w fixed orifice tube Compressor Saden SD 7 SP 15 PAG oi...

Page 2783: ...NER 28 6 21 4 250 50 A C COMPRESSOR TO MOUNTING BRACKET BOLTS 27 20 239 ACCUMULATOR RETAINING BOLT 5 3 7 44 BLEND DOOR ACTUATOR SCREWS 2 4 34 1 8 25 21 3 HVAC HOUSING SCREWS 2 4 34 1 8 25 21 3 HVAC HO...

Page 2784: ...PTION 20 OPERATION 21 REMOVAL 21 INSTALLATION 22 RECIRCULATION DOOR ACTUATOR DESCRIPTION 22 OPERATION 22 REMOVAL 22 INSTALLATION 23 A C COMPRESSOR CLUTCH DESCRIPTION The compressor clutch assembly con...

Page 2785: ...s until the system voltage drops below 12 5 volts a If the clutch coil current reading is four amperes or more the coil is shorted and should be replaced b If the clutch coil current reading is zero t...

Page 2786: ...compressor front housing Fig 6 13 Remove the snap ring from the compressor hub and remove the clutch field coil Fig 7 Slide the clutch field coil off of the compressor hub Fig 2 CLUTCH NUT REMOVE Typi...

Page 2787: ...valent Fig 8 Thread the installer on the shaft then turn the nut until the rotor assembly is seated 5 Install the external front housing snap ring with snap ring pliers The bevel side of the snap ring...

Page 2788: ...mpressor clutch relay Fig 10 is located in the Power Distribution Center PDC Refer to the PDC label for relay identification and location Remove the relay from the PDC to perform the fol lowing tests...

Page 2789: ...he control also has a push button to activate the Optional side view mirrors defroster elements and to turn the A C on The Dual Zone HVAC control panel contains a pair of slider type temperature contr...

Page 2790: ...ignal and a sensor ground to the transducer then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure The PCM is programmed to respond to this and...

Page 2791: ...tors 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 used for the sin...

Page 2792: ...eceptacle Fig 14 4 Remove the screws that secure the blend door actuator to the distribution housing 5 Remove the blend door actuator from the dis tribution housing INSTALLATION 1 Position the blend d...

Page 2793: ...BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSS...

Page 2794: ...SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY S...

Page 2795: ...air door Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle Two integral mounting tabs allow the actuator to be secured with two scr...

Page 2796: ...d using a DRBIIIt scan tool Refer to the appropriate diagnostic information REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING C...

Page 2797: ...or does not require mechanical indexing to the recircu lation air door as it is electronically calibrated by the heater A C control module The recirculation door actuator cannot be adjusted or repaire...

Page 2798: ...necessary rotate the actua tor slightly to align the splines on the actuator out put shaft with those in the recirculation air door 2 Install and tighten the two screws that secure the recirculation d...

Page 2799: ...is retained by a light snap fit INSTALLATION PANEL OUTLETS To install position the grill housing in the panel outlet housing and press firmly until it snaps into place BLEND DOOR REMOVAL WARNING ON VE...

Page 2800: ...R CONDITIONING DISTRI BUTION HVAC HOUSING INSTALLATION 7 Run calibration test BLOWER MOTOR DESCRIPTION The blower motor and blower wheel are located in the passenger side end of the HVAC housing below...

Page 2801: ...possible causes include Foreign material in the HVAC housing Improper blower motor mounting Improper blower wheel mounting Blower motor faulty REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISAB...

Page 2802: ...ng in the vehicle Refer to 24 HEATING AIR CONDITIONING DISTRI BUTION HVAC HOUSING INSTALLATION 5 Run calibration test FLOOR DISTRIBUTION DUCTS REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABL...

Page 2803: ...AIR CONDITIONING DISTRIBUTION BLOWER MOTOR REMOVAL 5 Remove the heater core mounting screws and carefully remove the heater core assembly Refer to 24 HEATING AIR CONDITIONING PLUMBING HEATER CORE REM...

Page 2804: ...plug or remove the tape from the liquid line and the evaporator inlet tube fittings Connect the liquid line coupler to the evaporator inlet tube Refer to 24 HEATING AIR CONDITIONING PLUMB ING STANDARD...

Page 2805: ...C DOOR REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT A...

Page 2806: ...3 7 4 7 and 5 7L ENGINES 39 REMOVAL 5 9L DIESEL ENGINE 40 REMOVAL 8 0L Engine 40 INSTALLATION INSTALLATION 3 7 4 7 and 5 7L ENGINES 41 INSTALLATION 5 9L DIESEL ENGINE 42 INSTALLATION 8 0L Engine 42 A...

Page 2807: ...frigerant lines at least once a year to make sure they are in good condition and properly routed The refrigerant lines and hoses are coupled with other components of the HVAC system with either 3 O ri...

Page 2808: ...twisting of the refrigerant lines or tubes Refrigerant oil will absorb moisture from the atmo sphere if left uncapped Do not open a container of refrigerant oil until you are ready to use it Replace t...

Page 2809: ...recovery recycling charging equipment Fig 1 The service hoses on the gauge set being used should have manual turn wheel or automatic back flow valves at the service port connector ends This will prev...

Page 2810: ...s 4 Close all of the valves and turn off the charg ing station vacuum pump 5 The refrigerant system is now ready to be charged with R 134a refrigerant Refer to 24 HEATING AIR CONDITIONING PLUMBING STA...

Page 2811: ...eading noise when the compressor clutch is engaged which may not occur when the compressor clutch is disen gaged Check the serpentine drive belt condition and tension as described in Cooling before be...

Page 2812: ...ON LINE REMOVAL Refer to 24 HEAT ING AIR CONDITIONING PLUMBING A C DISCHARGE LINE REMOVAL Install plugs in or tape over all of the opened refrigerant fittings 6 Remove the bolts that secure the compre...

Page 2813: ...racket 2 On the 3 7L 4 7L 5 7L and 8 0L gasoline engines install and tighten the bolts in the following sequence Fig 4 The number one bolt rear is hand tightened first then tightened to 55 N m 41 ft l...

Page 2814: ...DESCRIPTION The condenser is located in the air flow next to the engine cooling radiator The condenser is a heat exchanger that allows the high pressure refrigerant gas being discharged by the compre...

Page 2815: ...or tape over all of the opened refrigerant line fittings 5 On diesel engine models a Remove the two screws that secure the brackets on the passenger side end of the con denser to the charge air cooler...

Page 2816: ...RONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTION Refer to 24 HEATING AIR CONDI...

Page 2817: ...er outlet Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE A C LINE COUPLERS 3 Install a new gasket and the discharge line block fitting over the stud on the condenser inlet Tighten th...

Page 2818: ...ING WARNING Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTION 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR COND...

Page 2819: ...line fittings on the discharge line and the condenser inlet tube Connect the discharge line refrigerant line coupler to the condenser inlet tube Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD...

Page 2820: ...cle INSTALLATION WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING Refer to 24 HEAT...

Page 2821: ...ING Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTION 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDI TIONIN...

Page 2822: ...MBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 7 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE A C EVAPORATOR DESCRIP...

Page 2823: ...low pressure liquid as it passes through the metering orifice and diffuser screen of the fixed orifice tube The fixed orifice tube cannot be repaired and if faulty or plugged the liquid line assembly...

Page 2824: ...apor through the inlet tube Any liq uid oil laden refrigerant falls to the bottom of the canister which acts as a separator A desiccant bag is mounted inside the accumulator canister to absorb any moi...

Page 2825: ...to the heater core at all times As the coolant flows through the heater core heat removed from the engine is transferred to the heater core fins and tubes Air directed through the heater core picks u...

Page 2826: ...NT STANDARD PROCEDURE 2 Connect and dispense 0 283 kilograms 0 625 pounds or 10 ounces of R 134a refrigerant into the evacuated refrigerant system Refer to 24 HEAT ING AIR CONDITIONING PLUMBING REFRIG...

Page 2827: ...frigerant system has been tested for leaks and evacuated a refrigerant charge can be injected into the system See Refrigerant Charge Capacity in the Service Procedures section of this group for the pr...

Page 2828: ...located within the cage of the male coupler fitting and that the garter spring is not damaged a If the garter spring is missing install a new spring by pushing it into the coupler cage opening b If th...

Page 2829: ...ry all components except the compressor are refrigerant oil free After the refrigerant system has been charged and operated the refrigerant oil in the compressor is dispersed throughout the refrigeran...

Page 2830: ...g assume the device its associated wiring and driver circuit work cor rectly Connect the DRB scan tool to the data link connector and access the Actuators screen DESCRIPTION DIAGNOSTIC TROUBLE CODES A...

Page 2831: ...the O2S ranges from 0 to 1 volt A good sensor can easily generate any output voltage in this range as it is exposed to different con centrations of oxygen To detect a shift in the A F mixture lean or...

Page 2832: ...e purge flow will be clocked up from some small value in an attempt to see a shift in the 02 control system If fuel vapor indicated by a shift in the 02 control is present the test is passed If not it...

Page 2833: ...wice in a row and turns ON the MIL re running that monitor which previously failed on the next start up and passing the monitor is considered to be a Good Trip These will include the following Oxygen...

Page 2834: ...tions occur when Many of the diagnostic steps required by OBD II must be per formed under specific operating conditions The Task Manager software organizes and prioritizes the diag nostic procedures T...

Page 2835: ...wo trip fault for non fuel system and non misfire Priority 2 One trip failure of a two trip fault for fuel system rich lean or misfire Priority 3 Two trip failure for a non fuel sys tem and non misfir...

Page 2836: ...s and Freeze Frames Forty Warm Up cycles must occur in order for the PCM to self erase a DTC and Freeze Frame A Warm Up Cycle is defined as fol lows Engine coolant temperature must start below and ris...

Page 2837: ...ev Counter Counts 0 4 when in similar conditions Misfire Good Trip Counter Counts up to three to turn OFF the MIL Misfire Data Data collected during test Test Done This Trip Indicates YES when the tes...

Page 2838: ...OUND The PCM cannot determine a poor system ground However one or more diagnostic trouble codes may be generated as a result of this condition The mod ule should be mounted to the body at all times al...

Page 2839: ...vapors into the atmosphere When fuel evaporates in the fuel tank the vapors pass through vent hoses or tubes into the two charcoal filled evaporative canisters The canisters tempo rarily hold the vap...

Page 2840: ...PUMP 3 LIQUID EXPANSION CHAMBER 10 EVAP CANISTERS 2 4 FUEL FILTER FUEL PRESSURE REGULATOR 11 FUEL TANK STRAPS 2 5 QUICK CONNECT FITTING AND FUEL LINE TO ENGINE 12 CHECK VALVE 6 EVAP LINE CONNECTION 1...

Page 2841: ...e two fittings When the engine is operating fresh air enters the engine and mixes with crankcase vapors Manifold vacuum draws the vapor air mixture through the fixed orifice and into the intake manifo...

Page 2842: ...cal cap to be sure of correct system operation CAUTION Remove the fuel tank filler tube cap to relieve fuel tank pressure The cap must be removed prior to disconnecting any fuel system component or be...

Page 2843: ...n by spring pressure as the LDP solenoid turns on and off The LDP also has a magnetic reed switch to signal diaphragm position to the PCM When the diaphragm is down the switch is closed which sends a...

Page 2844: ...ING ACTION Action During portions of this test the PCM uses the reed switch to monitor diaphragm movement The solenoid is only turned on by the PCM after the reed switch changes from open to closed in...

Page 2845: ...firmly connected Check the vapor vacuum lines at the LDP LDP filter and EVAP canister purge solenoid for damage or leaks If a leak is present a Diagnos tic Trouble Code DTC may be set 4 Connect elect...

Page 2846: ...ad valve cover with a hose extending from the valve to the intake manifold Fig 14 Another hose connects the opposite cylinder head valve cover to the air cleaner housing to provide a source of clean a...

Page 2847: ...acuum When the engine is not operating or during an engine pop back the spring forces the plunger back against the seat Fig 16 This will prevent vapors from flowing through the valve Fig 12 LOCATION 5...

Page 2848: ...ld PCV valve 9 Return PCV valve back to oil filler tube by placing valve locating tabs Fig 19 into cam lock Press PCV valve in and rotate valve upward A slight click will be felt when tabs have engage...

Page 2849: ...from valve cover The valve should rattle when shaken Fig 24 Fig 19 PCV VALVE 3 7L V 6 4 7L V 8 1 O RING 2 LOCATING TABS 3 CAM LOCK 4 OIL FILLER TUBE 5 PCV LINE HOSE 6 PCV VALVE Fig 20 CRANKCASE BREATH...

Page 2850: ...side of the valve Fig 25 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 hose Fig 25 by discon necting rubber hose at PCV va...

Page 2851: ...tion VACUUM LINES DESCRIPTION A vacuum schematic for emission related items can be found on the vehicles VECI label Refer to Vehicle Emission Control Information VECI Label for label location VAPOR CA...

Page 2852: ...and system Vehicles equipped with JTEC engine control modules use a leak detection pump Refer to Leak Detection Pump LDP for additional information The Natural Vacuum Leak Detection NVLD sys tem is th...

Page 2853: ...excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative The solenoid actuates the valve to unseal the can ister vent while the engine is ru...

Page 2854: ...uum lines and hoses must be firmly connected Check the vapor vacuum lines at the NVLD pump filter and EVAP canister purge solenoid for damage or leaks If a leak is present a Diag nostic Trouble Code D...

Page 2855: ......

Page 2856: ...ON 5 6 ADJUSTABLE PEDAL SWITCH REMOVAL 5 6 ADJUSTER DIAGNOSIS AND TESTING HYDRAULIC LASH 9 124 9 31 ADJUSTER INSTALLATION SEAT BELT TURNING LOOP 8O 50 ADJUSTER REMOVAL SEAT BELT TURNING LOOP 8O 50 ADJ...

Page 2857: ...DIAGNOSIS AND TESTING 8I 7 ASD SENSE PCM INPUT OPERATION 8I 6 ASH RECEIVER INSTALLATION 23 52 ASH RECEIVER REMOVAL 23 51 AUDIO DESCRIPTION 8A 1 AUDIO DIAGNOSIS AND TESTING 8A 2 AUDIO OPERATION 8A 1 A...

Page 2858: ...MAIN 9 322 BEARING FITTING STANDARD PROCEDURE CONNECTING ROD 9 128 9 251 9 382 BEARING FITTING STANDARD PROCEDURE CRANKSHAFT MAIN 9 253 BEARING FITTING STANDARD PROCEDURE CONNECTING ROD 9 48 BEARING F...

Page 2859: ...VENT INSTALLATION 23 72 BODY VENT REMOVAL 23 72 BOOST PRESSURE DIAGNOSIS AND TESTING TURBOCHARGER 11 10 BOOSTER DESCRIPTION POWER BRAKE 5 25 BOOSTER DIAGNOSIS AND TESTING HYDRAULIC 5 25 BOOSTER DIAGNO...

Page 2860: ...TALLATION RIGHT REAR 5 32 CABLE INSTALLATION SPARK PLUG 8I 35 CABLE INSTALLATION THROTTLE CONTROL 14 51 14 96 CABLE OPERATION 8P 3 CABLE OPERATION ANTENNA BODY 8A 4 CABLE OPERATION SPARK PLUG 8I 33 CA...

Page 2861: ...RATION ELECTRONIC VEHICLE INFO 8M 8 CENTER REMOVAL ELECTRONIC VEHICLE INFO 8M 10 CENTER ANCHOR RIGHT OUTBOARD INSTALLATION 8O 45 CENTER ANCHOR RIGHT OUTBOARD REMOVAL 8O 43 CENTER ARMREST SEAT BACK INS...

Page 2862: ...OVERDRIVE PISTON RETAINER DISASSEMBLY OVERRUNNING 21 238 21 415 CLUTCH CAM OVERDRIVE PISTON RETAINER INSPECTION OVERRUNNING 21 238 21 416 CLUTCH CAM OVERDRIVE PISTON RETAINER OPERATION OVERRUNNING 21...

Page 2863: ...SCRIPTION SIDE IMPACT AIRBAG 8O 53 CONTROL MODULE DESCRIPTION TRANSFER CASE 8E 15 CONTROL MODULE DESCRIPTION TRANSMISSION 8E 19 CONTROL MODULE DIAGNOSIS AND TESTING FRONT 8W 97 5 CONTROL MODULE DIAGNO...

Page 2864: ...SILL TRIM 23 72 COVER REMOVAL SHIFT 21 128 21 86 COVER REMOVAL STEERING COLUMN OPENING 23 61 COVER REMOVAL STRUCTURAL 9 143 9 210 9 56 COVER REMOVAL TIMING CHAIN 9 220 COVER REMOVAL WHEEL 22 14 COVER...

Page 2865: ...ATIC 8N 12 DAY NIGHT MIRROR OPERATION AUTOMATIC 8N 12 DAY NIGHT MIRROR REMOVAL AUTOMATIC 8N 13 DEFINITION DESCRIPTION TRIP 25 4 DEFROST DOOR INSTALLATION 24 27 DEFROST DOOR INSTALLATION FLOOR 24 30 DE...

Page 2866: ...24 17 DOOR ACTUATOR REMOVAL FLOOR DEFROST 24 19 DOOR ACTUATOR REMOVAL MODE 24 21 DOOR ACTUATOR REMOVAL RECIRCULATION 24 22 DOOR AJAR INDICATOR DESCRIPTION 8J 23 DOOR AJAR INDICATOR OPERATION 8J 23 DOO...

Page 2867: ...PROCEDURE REFILLING COOLING SYSTEM 5 9L 8 0L 7 18 ENGINE 5 9L DIESEL DESCRIPTION 9 282 ENGINE 8 0L DESCRIPTION 9 353 ENGINE BLOCK CLEANING 9 127 9 200 9 249 9 38 9 380 ENGINE BLOCK DESCRIPTION 9 126 9...

Page 2868: ...PROCEDURES WATER DRAINING AT FUEL 14 57 FILTER WATER SEPARATOR DESCRIPTION FUEL 14 61 FILTER WATER SEPARATOR INSTALLATION FUEL 14 62 FILTER WATER SEPARATOR OPERATION FUEL 14 61 FILTER WATER SEPARATOR...

Page 2869: ...OVAL 13 23 FRONT DOOR GLASS RUN WEATHERSTRIP INSTALLATION 23 92 FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 23 92 FRONT DOOR INNER BELT MOLDING INSTALLATION 23 93 FRONT DOOR INNER BELT MOLDING REMOVAL 2...

Page 2870: ...NDICATOR OPERATION CHECK 8J 21 GEAR DESCRIPTION CRANKSHAFT 9 322 GEAR INDEPENDENT FRONT SUSPENSION DESCRIPTION 19 16 GEAR INDEPENDENT FRONT SUSPENSION INSTALLATION 19 17 GEAR INDEPENDENT FRONT SUSPENS...

Page 2871: ...HEADLAMP SWITCH INSTALLATION 8L 14 HEADLAMP SWITCH OPERATION 8L 14 HEADLAMP SWITCH REMOVAL 8L 14 HEADLAMP SWITCH BEZEL INSTALLATION INSTRUMENT PANEL 23 57 HEADLAMP SWITCH BEZEL REMOVAL INSTRUMENT PANE...

Page 2872: ...27 HYDRAULIC BOOSTER DIAGNOSIS AND TESTING 5 25 HYDRAULIC LASH ADJUSTER DIAGNOSIS AND TESTING 9 124 9 31 HYDRAULIC LIFTERS CLEANING 9 260 9 388 HYDRAULIC LIFTERS INSTALLATION 9 260 9 388 HYDRAULIC LI...

Page 2873: ...ED REMOVAL FRONT OIL SEAL FRONT COVER 9 384 INSTRUMENT CLUSTER ASSEMBLY 8J 15 INSTRUMENT CLUSTER DESCRIPTION 8J 2 INSTRUMENT CLUSTER DIAGNOSIS AND TESTING 8J 10 INSTRUMENT CLUSTER DISASSEMBLY 8J 14 IN...

Page 2874: ...DURE MODULE 8M 3 LAMP REPLACEMENT STANDARD PROCEDURE READING COURTESY 8M 3 LAMP SWITCH DESCRIPTION BACKUP 8L 7 LAMP SWITCH DESCRIPTION BRAKE 8L 8 LAMP SWITCH DIAGNOSIS AND TESTING BACKUP 8L 8 LAMP SWI...

Page 2875: ...ION DOOR 8N 5 LOCK MOTOR DIAGNOSIS AND TESTING DOOR 8N 5 LOCK MOTOR OPERATION DOOR 8N 5 LOCK SWITCH DIAGNOSIS AND TESTING POWER 8N 4 LOCK SWITCH INSTALLATION POWER 8N 4 LOCK SWITCH REMOVAL POWER 8N 4...

Page 2876: ...ASS REMOVAL SIDE VIEW 23 42 MIRROR SUPPORT BRACKET INSTALLATION REARVIEW 23 71 MIRROR SWITCH DIAGNOSIS AND TESTING POWER 8N 13 MIRROR SWITCH REMOVAL POWER 8N 13 MIRROR SYSTEM DESCRIPTION HEATED 8G 1 M...

Page 2877: ...IAGNOSIS AND TESTING A C COMPRESSOR 24 36 NOISE DIAGNOSIS AND TESTING WIND 23 2 NOISE OR VIBRATION DIAGNOSIS AND TESTING TIRE 22 7 NOISE SUPPRESSION GROUND STRAP DESCRIPTION RADIO 8A 8 NOISE SUPPRESSI...

Page 2878: ...9 151 9 215 9 341 9 70 ON BOARD DIAGNOSTICS OBD DIAGNOSIS AND TESTING 7 5 ONLY ASSEMBLY 5 9L 7 73 ONLY DISASSEMBLY 5 9L 7 73 ON OFF RELAY DESCRIPTION WIPER 8R 25 ON OFF RELAY DIAGNOSIS AND TESTING WIP...

Page 2879: ...SSENGER SEAT SWITCH DIAGNOSIS AND TESTING 8N 17 PASSENGER SEAT SWITCH INSTALLATION 8N 18 PASSENGER SEAT SWITCH OPERATION 8N 17 PASSENGER SEAT SWITCH REMOVAL 8N 17 PATTERNS DIAGNOSIS AND TESTING TIRE W...

Page 2880: ...5 25 POWER DISTRIBUTION DESCRIPTION 8W 97 1 POWER DISTRIBUTION OPERATION 8W 97 1 POWER DISTRIBUTION SYSTEMS SPECIAL TOOLS 8W 97 2 POWER GROUNDS DESCRIPTION 8E 10 POWER LOCK SWITCH DIAGNOSIS AND TESTIN...

Page 2881: ...4 9 344 9 400 9 68 PUMP OPERATION 19 38 PUMP OPERATION FUEL 14 12 PUMP OPERATION FUEL INJECTION 14 64 PUMP OPERATION FUEL TRANSFER 14 76 PUMP OPERATION LEAK DETECTION 25 14 PUMP OPERATION OIL 21 212 2...

Page 2882: ...23 94 REAR DOOR SILL TRIM COVER INSTALLATION 23 72 REAR DOOR SILL TRIM COVER REMOVAL 23 72 REAR DRUM IN HAT BRAKE CLEANING 5 33 REAR DRUM IN HAT BRAKE INSPECTION 5 33 REAR FENDER INSTALLATION 23 44 RE...

Page 2883: ...RY TRANSMITTER SPECIFICATIONS 8N 10 REMOTE SWITCHES DESCRIPTION 8A 10 REMOTE SWITCHES DIAGNOSIS AND TESTING 8A 11 REMOTE SWITCHES INSTALLATION 8A 12 REMOTE SWITCHES OPERATION 8A 10 REMOTE SWITCHES REM...

Page 2884: ...PTION MAINTENANCE 0 6 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 21 175 21 355 21 513 SCHEMATICS SCHEMATICS AND DIAGRAMS HYDRAULIC 21 175 21 355 21 513 SEAL DIAGNOSIS AND TESTING RADIATOR CAP TO FIL...

Page 2885: ...NDICATOR DESCRIPTION 8J 34 SECURITY INDICATOR OPERATION 8J 35 SECURITY SYSTEM DIAGNOSIS AND TESTING VEHICLE THEFT 8Q 3 SELECTION STANDARD PROCEDURE HEAD GASKET 9 330 SELECTOR INDICATOR DESCRIPTION GEA...

Page 2886: ...DESCRIPTION REAR 21 252 21 429 SERVO DISASSEMBLY FRONT 21 208 21 388 SERVO DISASSEMBLY REAR 21 252 21 430 SERVO INSPECTION FRONT 21 208 21 388 SERVO INSTALLATION 8P 7 SERVO OPERATION 8P 7 SERVO OPERA...

Page 2887: ...N FRONT WHEEL 5 41 SPEED SENSOR OPERATION INPUT 21 558 SPEED SENSOR OPERATION OUTPUT 21 567 SPEED SENSOR REMOVAL FRONT WHEEL 5 41 SPEED SENSOR REMOVAL INPUT 21 559 SPEED SENSOR REMOVAL OUTPUT 21 567 S...

Page 2888: ...N 19 SWITCH DESCRIPTION OVERDRIVE 21 218 21 397 21 568 SWITCH DESCRIPTION PASSENGER AIRBAG ON OFF 8O 38 SWITCH DESCRIPTION PASSENGER SEAT 8N 16 SWITCH DESCRIPTION POWER STEERING PRESSURE 19 45 SWITCH...

Page 2889: ...DURE OPEN CIRCUIT VOLTAGE 8F 10 TEST STANDARD PROCEDURE VERIFICATION 8O 8 TEST MODE DESCRIPTION CIRCUIT ACTUATION 25 1 TEST MODE DESCRIPTION STATE DISPLAY 25 1 TESTER STANDARD PROCEDURE USING MICRO 42...

Page 2890: ...TRAC RITE INSPECTION DIFFERENTIAL 3 119 3 146 TRAC RITE OPERATION DIFFERENTIAL 3 118 3 145 TRAILER HITCH INSTALLATION 13 25 TRAILER HITCH REMOVAL 13 25 TRAILER TOW WIRING DESCRIPTION 8L 22 TRANS COOL...

Page 2891: ...TANDARD PROCEDURE SENTRY KEY IMMOBILIZER SYSTEM 8Q 4 TRAY DESCRIPTION BATTERY 8F 17 TRAY INSTALLATION BATTERY 8F 18 TRAY OPERATION BATTERY 8F 17 TRAY REMOVAL BATTERY 8F 17 TREAD WEAR INDICATORS DIAGNO...

Page 2892: ...1 432 VALVE CABLE DESCRIPTION THROTTLE 21 254 21 432 VALVE GUIDE SEALS DESCRIPTION 9 31 9 36 VALVE GUIDES DESCRIPTION 9 106 9 197 VALVE LASH ADJUSTMENT AND VERIFICATION STANDARD PROCEDURE 9 308 VALVE...

Page 2893: ...EMOVAL FRONT DOOR GLASS RUN 23 92 WEATHERSTRIP REMOVAL REAR DOOR GLASS RUN 23 93 WEATHERSTRIP RETAINER INSTALLATION A PILLAR 23 91 WEATHERSTRIP RETAINER INSTALLATION DRIP RAIL 23 92 WEATHERSTRIP RETAI...

Page 2894: ...___________________________________________________ ______________________________________________________________________________________ _____________________________________________________________...

Page 2895: ...Dealer Technical Operations 800 Chrysler Drive CIMS 486 02 76 Auburn Hills MI 48326 2757...

Reviews:

No comments

Related manuals for dakota 2002

Hama Pico Operating Instructions preview
Pico
Brand: Hama Pages: 2
Fabbri BICI OK 2 Quick Start Manual preview
BICI OK 2
Brand: Fabbri Pages: 4
Metra Electronics 99-3103 Installation Instructions preview
99-3103
Brand: Metra Electronics Pages: 2
iDataLink BLADE-AL(TB)-TL2 Install Manual preview
BLADE-AL(TB)-TL2
Brand: iDataLink Pages: 9
Magneti Marelli BCF184 Installation Instructions preview
BCF184
Brand: Magneti Marelli Pages: 2
Chevrolet 2013 Spark Specifications preview
2013 Spark
Brand: Chevrolet Pages: 2
Mazda 1989 323 Manual preview
1989 323
Brand: Mazda Pages: 13
NavLinkz RL2-SC14 Manual preview
RL2-SC14
Brand: NavLinkz Pages: 21
Jeep PATRIOT 2013 Manual preview
PATRIOT 2013
Brand: Jeep Pages: 16
Audi RSE III Quick Start Manual preview
RSE III
Brand: Audi Pages: 4
A-Tach 50092 Quick Start Manual preview
50092
Brand: A-Tach Pages: 2
RAM Truck Diesel Supplement 2012 Owner'S Manual preview
Truck Diesel Supplement 2012
Brand: RAM Pages: 174
AEM 30-3500 Instruction Manual preview
30-3500
Brand: AEM Pages: 27
EUFAB 16458 Operating Instructions Manual preview
16458
Brand: EUFAB Pages: 16
FVC Sprinter Side Ladder Installation Manual preview
Sprinter Side Ladder
Brand: FVC Pages: 8
Audiovox AA-BAT Programming Manual preview
AA-BAT
Brand: Audiovox Pages: 3
Victory 4x4 VRKCAP Install Instructions Manual preview
VRKCAP
Brand: Victory 4x4 Pages: 9
SNIPER V2 Inox Owner'S Manual preview
V2 Inox
Brand: SNIPER Pages: 2

Brands by name

Popular brands

Load more brands