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Dodge RAM 1500 1996, Service Manual

The Dodge RAM 1500 1996 Service Manual is a comprehensive user manual that provides detailed instructions and diagrams for all aspects of your vehicle's maintenance and repair. Available for free download at manualshive.com, this manual ensures effortless troubleshooting and allows you to maintain your truck with confidence.

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Summary of Contents for RAM 1500 1996

Page 1: ...9 SERVICE MANUAL RAM TRUCK 1500 3500 2 WHEEL DRIVE 4 WHEEL DRIVE VOL 1 00 08 ...

Page 2: ...9 SERVICE MANUAL RAM TRUCK 1500 3500 2 WHEEL DRIVE 4 WHEEL DRIVE VOL 2 09 25 ...

Page 3: ... ANY FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corporation reserves the right to m a k e changes in design or to m a k e additions to or improvements in its products without imposing any obli gations upon itself to install them on its products previously manufactured Litho in U S A Copyright ...

Page 4: ...h group The first page of the group has a contents section that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of this manual Use the form to provide Chrysler Corporation with your comments and sugges...

Page 5: ...g Systems 8 P 8 K Wiper and Washer Systems 8 L Lamps 8 M Passive Restraint Systems Power Door Locks 8 R Power Seat Systems 8 S Power Window Systems 8 T Power Mirror Systems 8 U Chime Buzzer Warning Systems 8 V Overhead Console Systems 8 W Wiring Diagrams Q Engine j 1 Exhaust System and Intake Manifold j 3 Frame and Bumpers 14 Fuel System j 9 Steering 21 Transmission and Transfer Case 2 2 Tires and...

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Page 7: ... 17 characters that provide data concerning the vehicle Refer to the VIN decoding chart to determine the identification of a vehicle The Vehicle Identification Number is also imprinted on the Body Code Plate Equipment Identification Plate Vehicle Safety Certification Label Frame rail To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ...

Page 8: ...bel is attached to the left side B pillar Fig 2 The label certifies that the vehicle conforms to Federal Motor Vehicle Safety Standards FMVSS The label also lists the Month and year of vehicle manufacture Gross Vehicle Weight Rating GVWR The gross front and rear axle weight ratings GAWR s are based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number VIN Typ...

Page 9: ...l Roof Code CDoor Combo Code P i l l e t t e Digit 17 Open Space Digit 18 23 Model J901N 20 3 digit numerical code 6 digit SEC code If there is not enough space left in the row for all of the 6 digit SEC code if used The unused space will remain blank The code will be listed in the next row The last nine positions of row 7 will contain a 2 digit code when applicable and a 6 digit gateline serial n...

Page 10: ...3 7 78 0 7 7 7 7 7 Overall Width At Front Wheel Lip 70 4 79 4 79 4 79 51 8 Track Front 68 5 68 5 68 6 63 6 8 Rear 68 0 68 0 73 0 H Tailgate Load Height 3 72 35 6 31 5 35 6 31 5 35 6 31 4 35 6 i Overhang Front 37 9 3 37 9 37 9 J Overhang Rear Without Rear Bumper 47 6 47 6 47 6 47 6 J With Rear Bumper r 51 7 51 7 51 7 5 7 7 f Back Of Cab To Rear Bumper 87 2 107 4 107 4 77 I Front Bumper To Back Of C...

Page 11: ...rii 66 9 68 5 66 9 68 5 68 6 68 9 68 6 68 9 69 8 G Rear 66 9 667 68 0 68 0 73 0 H Tailgate Load Height 31 3 33 9 31 3 34 4 34 4 37 3 33 3 37 2 33 8 37 8 I Overhang Front 37 9 37 9 37 9 37 9 37 9 J Overhang Rear Without rear bumper a s 47 5 A7 5 43 5 5 J With rear bumper 475 51 5 51 5 47 5 51 5 K Back of Cab To Rear Bumper 87 1 107 1 107 1 87 1 107 1 L Front Bumper To Back Of Cab 136 9 136 9 36 9 1...

Page 12: ... 4 51 4 H Rear Track Outside 78 0 94 6 94 6 78 0 94 6 94 6 1 Overhang Front 37 9 37 9 37 9 37 9 37 9 37 9 J Axle To End Of Frame 44 1 44 1 44 1 44 1 44 1 44 1 K Center Of Front Wheel To Back Of Cab 79 0 79 0 79 0 79 0 79 0 79 0 L Frame To Top Of Cab 52 9 52 9 52 9 52 9 52 9 52 9 M Top Of Frame To Ground 29 6 34 3 34 1 34 0 34 3 34 2 N Inside Width Between Frame Rails 31 7 31 7 31 7 31 7 31 7 31 7 ...

Page 13: ... the Thread Notation chart Fig 5 GRADE CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8 The higher the grade number the greater the bolt strength Identification is determined by the line marks on the top of each bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 12 9 ...

Page 14: ... Customary SAE Grade Number 5 8 Bolt Head Markings These are all SAE Grade 5 3 line Bolt Torque Grade 5 Bolt Bolt Torque Grade 8 Bolt Body Size Cast Iron Aluminum Cast Iron Aluminum ft lb N m 1Mb ft lb ft lb 1 4 20 9 7 8 6 15 11 12 9 28 12 9 9 7 18 13 14 10 5 16 18 20 15 16 12 30 22 24 18 24 23 17 19 14 33 24 25 19 3 8 16 40 30 25 20 55 40 40 30 24 40 30 35 25 60 45 45 35 7 16 14 60 45 45 35 90 65...

Page 15: ...olt j j No mark 4T Stud bolt 61 Hexagon flange bolt w washer hexagon bolt j No mark 4 T Stud bolt Grooved 61 Hexagon head bolt TWO j 1 protruding lines 51 Stud bolt Grooved 61 Hexagon flange bolt w washer hexagon bolt T w o j 1 J protruding lines 61 Stud bolt 61 Hexagon flange bolt w washer hexagon bolt T w o j 1 J protruding lines 61 Welded bolt 41 Hexagon head bolt f f T h r e e IL jj protruding...

Page 16: ...rt to convert torque values listed in metric Newton meters N m Also use the chart to convert between millimeters mm and inches in CONVERSION FORMULAS AND EQUIVALENT VALUES Multiply By ToGaf Multiply By To Get in lbs x 0 11298 Newton Meters N m x 8 851 in lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7376 ft lbs Inches Hg 60 F x 3 377 Kilopascafs kPa kPa x 0 2961 Inches Hg psi x 6 895 Kilopascals k...

Page 17: ...6 63 4303 7 9 4907 27 36 6071 47 63 7234 67 90 8398 87 117 9562 7 5 1629 27 19 9142 47 34 6654 67 49 4167 87 64 1679 8 10 8465 28 37 9629 48 65 0793 68 92 1956 88 119 3120 8 5 9005 28 20 6517 48 35 4030 68 50 1542 88 64 9545 9 12 2024 29 39 3187 49 66 4351 69 93 5514 89 120 6678 9 6 6381 29 21 3893 49 36 1405 69 50 8918 89 65 6430 10 13 5582 30 40 6745 50 67 7909 70 94 9073 90 122 0236 10 7 3756 3...

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Page 19: ...ules that show proper service based on the conditions that the vehi cle is subjected to Schedule A lists scheduled maintenance to be performed when the vehicle is used for general trans portation Schedule B lists maintenance intervals for vehi cles that are operated under the conditions listed at the beginning of the Maintenance Schedule section Use the schedule that best describes your driving co...

Page 20: ... produce deposits on valves that can progress to guttering and valve burning A maximum sulfated ash content of 1 85 mass is recommended for all oil used in the engine Refer to Group 9 Engine for diesel engine oil spec ification GEAR LUBRICANTS SAE ratings also apply to multiple grade gear lubricants In addition API classification defines the lubricants usage LUBRICANTS AND GREASES Lubricating grea...

Page 21: ...2 0 L 4 2 pts NV4500 3 8 L 8 0 pts TRANSFER CASE NV231 HD 1 2 L 2 5 pts N V 2 4 1 2 7 L 5 0 pts NV241 HD 3 5 L 6 5 pts NV241 HD W PTO 4 9 L 9 0 pts POWER TAKE OFF ADAPTER N V 0 2 1 2 1 L 4 6 pts FRONT AXLE Dana 44 3 2 L 6 8 pts Dana 60 3 6 L 7 6 pts REAR AXLE 9 1 4 inch 2 3 L 4 8 pts Dana 60 2WD 3 0 L 6 3 pts Dana 60 4WD 3 4 L 7 3 pts Dana 70 2WD 3 3 L 7 0 pts Dana 70 4WD 3 6 L 7 8 pts Dana 80 2WD...

Page 22: ...e best vehicle performance and reliability More frequent maintenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving UNSCHEDULED INSPECTION At Each Stop For Fuel Check engine oil level and add as required Check windshield washer solvent and add as required page LIGHT DUTY SCHEDULE B 5 UNSCHEDULED INSPECTION 4 Once A Month Check tire pressur...

Page 23: ...ince last change 90 000 Miles 144 000 km or at 72 months Change engine oil Replace engine oil filter Replace engine air cleaner element Replace spark plugs Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings 97 500 Miles 156 000 km or at 78 months Change engine oil 105 000 Miles 168 000 km or at 84 months Change engine oil Replace engine oil filter Flush and replace...

Page 24: ...ck if required 4x2 45 000 Miles 72 000 km Change engine oil Inspect engine air cleaner element replace as necessary 48 000 Miles 77 000 km Change engine oil Replace engine oil filter Drain and refill automatic transmission fluid Replace filter and adjust bands Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings 51 000 Miles 82 000 km Change engine oil Flush and replace engine ...

Page 25: ...e engine oil Inspect engine air cleaner element replace as necessary Inspect front wheel bearings Clean and repack if required 4x2 108 000 Miles 173 000 km Change engine oil Replace engine oil filter Drain and refill automatic transmission fluid Replace filter and adjust bands Drain and refill transfer case fluid Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings 111 000 Mile...

Page 26: ...rovide the best vehicle performance and reliability More frequent mainte nance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving UNSCHEDULED INSPECTION At Each Stop For Fuel Check engine oil level and add as required Check windshield washer solvent and add as required page MEDIUM DUTY SCHEDULE B 9 UNSCHEDULED INSPECTION 8 Once A Month Check t...

Page 27: ...000 miles 48 000 km or 24 months since last change 84 000 Miles 134 000 km or at 84 months Replace engine oil and filter Flush and replace engine coolant i f it has been 30 000 miles 48 000 km or 24 months since last change 90 000 Miles 144 000 km or at 90 months Replace engine oil and filter Replace engine air cleaner element Replace spark plugs Inspect brake linings 96 000 Miles 154 000 km or at...

Page 28: ...epack if required 4x2 Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings Flush and replace engine coolant 51 000 Miles 82 000 km Replace engine oil and filter 54 000 Miles 86 000 km Replace engine oil and filter 57 000 Miles 91 000 km Replace engine oil and filter 60 000 Miles 96 000 km Replace engine oil and filter Replace engine air cleaner element Replace ignition cables R...

Page 29: ...eplace engine oil and filter Drain and refill automatic transmission fluid Replace filter and adjust bands Drain and refill transfer case fluid Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings Flush and replace engine coolant 111 000 Miles 178 000 km Replace engine oil and filter 114 000 Miles 183 000 km Replace engine oil and filter 117 000 Miles 187 000 km Replace engine ...

Page 30: ... the best vehicle performance and reliability More frequent mainte nance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving UNSCHEDULED INSPECTION At Each Stop For Fuel Check engine oil level and add as required Check windshield washer solvent and add as required page INTRODUCTION 12 UNSCHEDULED INSPECTION 12 Once A Month Check tire pressure a...

Page 31: ...Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change 66 000 Miles 106 000 km or at 66 months Change engine oil Replace engine oil filter 8 0L only 72 000 Miles 115 000 km or at 72 months Change engine oil Replace engine oil filter Replace engine air cleaner element and air pump filter Drain and refill automatic transmission fluid Replace filter and ...

Page 32: ...ce engine oil filter Replace engine air cleaner element and air pump filter Drain and refill automatic transmission fluid Replace filter and adjust bands Change rear axle fluid Change front axle fluid 4x4 Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings 27 000 Miles 43 000 km Change engine oil Replace engine oil filter 8 0L only 30 000 Miles 48 000 km Change engi...

Page 33: ...ce filter and adjust bands Drain and refill transfer case fluid Change rear axle fluid Change front axle fluid 4x4 Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings 75 000 Miles 120 000 km Change engine oil Replace engine oil filter 8 0L only 78 000 Miles 125 000 km Change engine oil Replace engine oil filter Flush and replace engine coolant 81 000 Miles 130 000 k...

Page 34: ...efill transfer case fluid Change rear axle fluid Change front axle fluid 4x4 Inspect brake linings Flush and replace engine coolant Requires Service Reminder Indicator Light If so equipped these parts are to be replaced at the indi cated mileage or when the service reminder indicator light remains on continuously with the key in the ON position whichever occurs first Off the highway operation trai...

Page 35: ...ant reservoir brake master cylinder power steering and transmission Add fluid as required Check all lights and all other electrical items for correct operation Drain water from fuel filter Check Filter Minder Replace filter if nec essary page SCHEDULE B 18 UNSCHEDULED INSPECTION 17 At Each Oil Change Inspect exhaust system Inspect brake hoses Rotate the tires at each oil change interval shown 6 00...

Page 36: ...2 Inspect brake linings 78 000 Miles 125 000 km or at 78 months Change engine oil and filter Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change 84 000 Miles 134 000 km or at 84 months Change engine oil and filter Inspect water pump weep hole for blockage Replace fuel filter Flush and replace engine coolant if it has been 30 000 miles 48 000 km or ...

Page 37: ...km Change engine oil and filter 45 000 Miles 72 000 km Change engine oil and filter 48 000 Miles 77 000 km Change engine oil and filter Adjust valve lash clearance Inspect fan hub Inspect damper Inspect water pump weep hole for blockage Replace fuel filter Drain and refill automatic transmission fluid Replace filter and adjust bands Change rear axle fluid Change front axle fluid 4x4 Inspect front ...

Page 38: ...s 149 000 km Change engine oil and filter 96 000 Miles 154 000 km Change engine oil and filter Adjust valve lash clearance Inspect fan hub 9 Inspect damper Inspect water pump weep hole for blockage Replace fuel filter Drain and refill automatic transmission fluid Replace filter and adjust bands Change rear axle fluid Change front axle fluid 4x4 Inspect front wheel bearings Clean and repack if requ...

Page 39: ...ator if equipped Low battery fluid level Generator drive belt condition and tension Fuel fumes or leakage correct if necessary CAUTION If the cause of starting problem on dis abled vehicle is severe damage to booster vehicle charging system can result 2 When using another vehicle as a booster source turn off all accessories place gear selector in page J U M P STARTING PROCEDURE 21 TOWING RECOMMEND...

Page 40: ... allow anyone under the disabled vehicle while It is lifted by the towing device Do not allow passengers to ride In a vehicle being towed Always observe state and local laws regarding towing regulations B R W H E E L LIFT FLAT BED J 9 5 0 0 6 Fig 3 Tow Vehicles With Approved Equipment Do not tow a vehicle in a manner that could jeopardize the safety of the operator pedestrians or other motorists D...

Page 41: ...A Wheel lift or Sling type device can be used provided all the wheels are lifted off the ground using tow dollies HOISTING RECOMMENDATIONS Refer to the Owner s Manual for emergency vehicle lifting procedures WARNING THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHI CLE WHEN A CHASSIS OR DRIVETRAIN COMPO NENT IS REMOVED FROM A VEHICLE THE CENTER OF GRAVITY IS ALTERED MAKING SOME...

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Page 43: ...lation to the vehicle The positioning is accomplished through suspension and steering linkage adjustments An alignment is con sidered essential for efficient steering good direc tional stability and to maximize tire wear The most important measurements of front end alignment are caster camber and toe position Fig 1 and Fig 2 NOTE Routine inspection of the front suspension and steering components i...

Page 44: ...Refer to Group 22 Wheels and Tires for diagnosis information 2 Inspect front wheel bearings for wear or adjust ment 3 Inspect front wheels for excessive radial lat eral runout and unbalance Refer to Group 22 Wheels and Tires for diagnosis information POSITIVE NEGATIVE POSITIVE NEGATIVE STEERING AXIS INCLINATION J9402 56 Fig 1 Aiignment Angles IFS 4 Inspect ball studs linkage pivot points and steer...

Page 45: ...t 1 Adjust or replace wheel bearings 2 Replace worn bushings or suspension components 3 Replace or balance tires as needed 4 Align front end VEHICLE INSTABILITY 1 Loose or worn front wheel bearings 2 Alignment 3 Loose or worn suspension bushings or components 4 Weak or broken spring 5 Tire pressure 1 Adjust or replace wheel bearings 2 Align front end 3 Replace worn bushings or suspension component...

Page 46: ... POSITION The wheel toe position adjust ment should be the final adjustment 1 Start the engine and turn wheels both ways before straightening the wheels Center and secure the steering wheel and turn off engine 2 Loosen the tie rod adjustment sleeve clamp bolts nuts NOTE Each front wheel should be adjusted for one half of the total toe position specification This will ensure the steering wheel will...

Page 47: ... tightening 5 Verify the right toe setting CAB CHASSIS CASTER CORRECTION MEASURMENT To determine the correct caster alignment angle for Cab Chassis vehicles the following procedure must be performed 1 Take a height measurement to the center of the front gauge hole in the frame Take another mean surement to the center of the rear spring hanger bolt Fig 6 Take these measurements on both sides of the...

Page 48: ...ter Gauge Hole Correction Gauge Hole Correction pitches degrees inches degrees 5 00 0 23 5 00 0 19 4 75 0 11 4 75 0 09 4 50 0 01 4 50 0 01 4 25 0 14 4 25 0 11 4 00 0 26 4 00 0 21 3 75 0 38 3 75 0 31 3 50 0 50 3 50 0 41 3 25 0 62 3 25 0 51 3 00 0 75 3 00 0 61 2 75 0 87 2 75 0 71 2 50 0 99 2 50 0 81 2 25 1 11 2 25 0 91 2 00 1 24 2 00 1 01 1 75 1 36 1 75 1 11 1 50 1 48 1 50 1 21 1 25 1 60 1 25 1 31 1...

Page 49: ...0 4x2 8800 154 7 3 65 0 50 4x2 10500 134 7 3 25 0 50 4x2 10500 154 7 3 45 0 50 4x4 6400 118 7 3 35 not set 4x4 6400 134 7 3 45 not set 4x4 6400 138 7 3 40 not set 4x4 6400 154 7 3 55 not set 4x4 7500 134 7 3 00 not set 4x4 8800 134 7 3 10 not set 4x4 8800 154 7 3 25 not set 4x4 10500 134 7 2 90 not set 4x4 10500 154 7 3 00 not set 4x2 4x4 4x2 4x4 4x2 4x4 8800 11000 11000 134 7 138 7 162 7 USE CAB ...

Page 50: ...g on the vehicle build location there are two different coatings applied to BR frames Stabilizer bar VEHICLE BUILD LOCATION 11th POSITION VIN CHARACTER FRAME COATING St Louis North J E Coat Dodge City S Wax Coat Saltillo Mexico G Wax Coat Lago Alberto Mexico M Wax Coat Replacement fasteners and torque values for frame attached components may wary depending on frame coatings Ensure the replacement ...

Page 51: ... the center of the tire Measure the axial movement of the knuckle with respect to the suspension arm 5 I f the travel of the suspension arm is 0 030 inch 0 8 mm or more replace the ball joint UPPER BALL STUD 1 Position a floor jack under the lower suspension arm Raise the wheel and allow the tire to lightly contact the floor vehicle weight relieved from the tire 2 Mount a dial indicator on the upp...

Page 52: ...suspension arm mount Install shock bolt and tighten to specifications 3 Install steering knuckle on lower ball stud Install lower ball stud nut and tighten to specifica tions Replace cotter pin and remove jack 4 Install stabilizer bar link on lower suspension arm Install grommet retainer and nut and tighten to specifications 5 Install tie rod on steering knuckle and tighten nut to specifications 6...

Page 53: ...tall replacement cotter pin 3 Remove jack from lower suspension arm 4 Install tire and wheel assembly 5 Remove support and lower vehicle 6 Align front suspension STABILIZER BAR REMOVAL 1 Raise and support the vehicle 2 Disconnect the link from lower suspension arm and stabilizer bar Fig 6 3 Disconnect the stabilizer bar clamps from the frame rails Remove the stabilizer bar Fig 6 STABILIZER BAR INS...

Page 54: ...er tight and install the nut lock Install a new cotter pin 7 The adjustment above should have 0 001 to 0 003 inch 0 254 to 0 0762 mm end play 8 Clean the dust cap and apply a coating lubri cant to the internal surface Do not fill the dust cap with lubricant Install the cap 9 Install disc brake caliper refer to Group 5 Brakes 10 Install the wheel and tire assembly WHEEL STUDS REMOVAL 1 Remove wheel...

Page 55: ...engine oil from each bearing Pack each bearing with multi purpose NLGI grade 2 EP type lubricant or an equivalent lubricant NOTE Ensure that lubricant is forced into all the cavities between the bearing cage and rollers SPECIAL TOOL C4212F J9402 35 Fig 10 Upper Ball Stud Installation S P E C I F I C A T I O N S IFS SUSPENSION WAX COAT FRAME DESCRIPTION TORQUE Shock Absorber Upper Nut 41 N m 30 ft ...

Page 56: ...2 14 SUSPENSION S P E C I A L T O O L S Installer Ball Stud 6761 ...

Page 57: ...ng Refer to the Torque Specifications Chart at the end of each group to determine the correct torque value D E S C R I P T I O N A N D O P E R A T I O N FRONT SUSPENSION LINK COIL The Ram Truck Link coil suspension allows each wheel to adapt to different road surfaces The sus pension is comprized of Fig 1 Shock absorbers Coil springs Upper and lower suspension arms Stabilizer bar Track bar Fig 1 L...

Page 58: ...between mounting bushings and metal brackets or attaching components This noise can usually be stopped by tightening the attaching nuts If the noise persists inspect for damaged and worn bushings and attaching components Repair as nec essary if any of these conditions exist The shock absorbers are not refillable or adjust able If a malfunction occurs the shock absorber must be replaced To test a s...

Page 59: ...cations Install new cotter pin 7 Remove the supports and lower the vehicle 8 Tighten the following suspension components to specifications Link to stabilizer bar nut Lower shock bolt Track bar bolt at axle shaft tube bracket Upper suspension arm nut at axle bracket Upper suspension nut at frame bracket Align lower suspension arm reference marks and tighten cam nut Lower suspension nut at frame bra...

Page 60: ...emove the supports and lower the vehicle TRACK BAR REMOVAL 1 Raise and support the vehicle 2 Remove the cotter pin and nut from the ball stud end at the frame rail bracket Fig 7 3 Remove ball stud from bracket with Puller C 3894 A 4 Remove the bolt and flag nut from the axle bracket and remove the track bar Fig 7 AXLE BRACKET fify FRAME BRACKET TRACK BAR FLAG NUT J9402 53 STABILIZER BAR RETAINER G...

Page 61: ... vehicle WHEEL MOUNTING STUDS REMOVAL 1 Raise and support vehicle 2 Remove wheel and tire assembly 3 Remove brake caliper and rotor refer to Group 5 Brakes for procedure 4 Remove stud from hub with Remover C 4150A Fig 9 HUB FLANGE REMOVER Fig 9 Wheel Stud Removal DESCRIPTION TORQUE Shock Absorber Upper Nut 41 N m 30 ft lbs Lower Bolt 135 N m 100 ft lbs Bracket 75 N m 55 ft lbs Suspension Arm Upper...

Page 62: ...2 20 SUSPENSION SPECIAL TOOLS LINK COIL SUSPENSION Remover C 4150A ...

Page 63: ...ar helps to control the vehicle body in relationship to the sus pension The bar extends across the underside of the page REMOVAL AND INSTALLATION LEAF SPRING 22 SHOCK ABSORBER 22 SPECIFICATIONS REAR SUSPENSION E COAT FRAME 23 REAR SUSPENSION WAX COAT FRAME 23 body and is attached to the body rails with grom mets Links at the end of the bar are attached to the leaf spring brackets Jounce Bumpers Th...

Page 64: ... nut from the frame crossmember bracket 3 Remove the bolt and nut from the axle bracket 4 Remove the rear shock absorber from the vehi cle INSTALLATION 1 Position shock absorber in brackets 2 Install bolts through the brackets and shock Install flag nut on top bolt and nut on lower bolt 3 Tighten upper and lower bolts to specifications 4 Remove the support and lower vehicle LEAF SPRING REMOVAL 1 R...

Page 65: ... Cab Chassis 163 N m 120 ft lbs Spring Front and Rear Eye Bolt Nut 6 010 7 500 GVW 203 N m 150 ft lbs Bolt Nut 8 800 1 100 GVW 285 N m 210 ft lbs Jounce Bumper Bolts 45 N m 33 ft lbs REAR SUSPENSION E C0AT FRAME SPRING SHACKLE J9403 62 Fig 3 Rear Spring Cab Chassis 11000 GVW INSTALLATION 1 Install shackle on rear spring eye and install bolt and nut 2 Position spring on axle shaft tube so spring ce...

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Page 67: ...the propeller shaft must be able to change angles when going over various roads This is accomplished through universal joints which permit the propeller shaft to operate at different angles The slip joints or yokes permit contraction or expansion page REAR PROPELLER SHAFT 7 TWO PIECE PROPELLER SHAFT REAR 8 DISASSEMBLY AND ASSEMBLY CENTER BEARING 8 DOUBLE CARDAN CV 10 SINGLE CARDAN 9 CLEANING AND I...

Page 68: ...s systems are used Single cardan universal joint Fig 2 Double cardan universal joint Fig 3 LUliiCATlON The slip yoke on the Type 1 front shaft is equipped with a lubrication fitting Use a multi purpose NLGI Grade 2 EP lubricant The factory installed U joints are lubricated for the life of the vehicle and do not need lubrication All U joints should be inspected for leakage and damage each time the ...

Page 69: ...nts are not worn are properly installed and are correctly aligned with the shaft Check the universal joint clamp screws torque 1 Raise the vehicle 2 Remove the wheel and tires assembly Install the wheel lug nuts to retain the brake drums 3 Mark and number the shaft six inches from the yoke end at four positions 90 apart 4 Run and accelerate the vehicle until vibration occurs Note the intensity and...

Page 70: ...unout exceeds the limit RUNOUT SPECIFICATIONS S E R V I C E P R O C E D U R E S UNIVERSAL JOINT ANGLE INFORMATION When two shafts come together at any common joint the bend that is formed is called the operating angle The larger the angle the larger the amount of acceleration and deceleration of the joint This speed ing up and slowing down of the joint must be can celled to produce a smooth power ...

Page 71: ... PROPELLER SHAFT ANGLE MEASUREMENT To accurately check driveline alignment raise and support the vehicle at the axles as level as possible Allow the wheels and propeller shaft to turn Remove any external bearing snap rings if equipped from universal joint so protractor base sits flat 1 Rotate the shaft until transmission transfer case output yoke bearing is facing downward Always make measurements...

Page 72: ...ment raise and support the vehicle at the axles as level as possible Allow the wheels and propeller shaft to turn Remove any external bearing snap rings if equipped from universal joint so protractor base sits flat 1 Rotate the shaft until transmission transfer case output yoke bearing is facing downward 2 Place Inclinometer on yoke bearing A parallel to the shaft Fig 13 Center bubble in sight gla...

Page 73: ...on the propeller shaft with the yoke ref erence marks aligned Install the propeller shaft Fig 14 Replacement U joint straps and bolts must be installed 2 Tighten the U joint strap bolts at the pinion shaft to 19 N m 14 ft lbs torque Tighten the transfer case bolts to 88 N m 65 ft lbs torque 3 Install skid plates if equipped refer to Group 13 Frames Remove support and lower the vehicle REAR PROPELL...

Page 74: ... lbs torque Replacement U joint straps and bolts must be installed 3 Tighten the U joint strap bolts to Dana Axle 29 N m 22 ft lbs torque 9 1 4 Axle 19 N m 14 ft lbs torque 4 Lower the vehicle D I S A S S E M B L Y A N D A S S E M B L Y CENTER BEARING Vehicles equipped with a two piece rear propeller shaft have a rubber insulated center bearing The bearing supports the shafts where they join toget...

Page 75: ...loosen snap ring 4 Remove snap rings from both sides of yoke Fig 17 J9316 19 Fig 17 Remove Snap Ring 5 Set the yoke in an arbor press or vise with a large socket beneath it Position the yoke with the grease fitting pointing up if equipped Place a smaller socket on the upper bearing assembly and press it through to release the lower bearing assem bly Fig 18 6 If the bearing assembly will not pull o...

Page 76: ...ring On Trunnion 4 Press the bearing assembly into the cross hole enough to install a snap ring Install a snap ring 5 Repeat steps 3 and 4 to install the opposite bearing assembly If the joint is stiff strike the yoke with a soft hammer to seat the needle bearings Install a snap ring 6 Add grease to lube fitting if equipped 7 Install the propeller shaft DOUBLE CARDAN CV REMOVAL Cardan universal jo...

Page 77: ...llet and drift to dislodge from the yoke Fig 24 6 Flip assembly and repeat steps 4 and 5 for removing the opposite side bearing This will then allow removal of the cross centering kit assembly and spring Fig 25 J9316 8 Fig 25 Remove Centering Kit 7 Press the remaining bearing assemblies out the other cross as described above to complete the disas sembly INSTALLATION During installation ensure that...

Page 78: ...bly Be sure to remove any lube fittings that may interfere with removal 5 Fit the center yoke on the remaining two trun Fig 27 Install Bearing Assembly n i o n s a n d p r e s s b e a r i n g a s s e m b l i e s i n p l a c e b o t h 3 Press the bearing assembly in place and install sides Fig 30 Install a snap ring a snap ring Fig 28 Fig 28 Press In Bearing Assembly 4 Flip the tube yoke and bearin...

Page 79: ...oss 8 Press the remaining two bearing assemblies into place and install snap rings Fig 33 9 Tap the snap rings to allow them to seat into the grooves Fig 34 10 Check for proper assembly Flex the CV joint beyond center it should snap over center in both directions when correctly assembled Fig 35 11 Install the propeller shaft Fig 33 Press in Bearing Assembly J9316 17 Fig 84 Seat Snap Rings In Groov...

Page 80: ...is a symp tom associated on vehicles using a two piece prop shaft To decreased shudder lowering the center bearing in 1 8 inch increments Use shim stock or fabricated plates Fig 37 Plate stock must be used to maintain compression of the rubber insulator around the bearing Do not use washers Replace the original bolts with the appropriate increased length bolts J9316 25 Fig 37 Angle Adjustment at C...

Page 81: ...mblies and tone rings are pressed on the axle shaft Use care when removing axle shafts as NOT to dam age the tone wheel or the sensor page FINAL ASSEMBLY 38 HUB BEARING AND AXLE SHAFT 26 INTERMEDIATE AXLE SHAFT 32 PINION GEAR 34 PINION SHAFT SEAL REPLACEMENT 28 RING GEAR 34 STEERING KNUCKLE 44 AXLE 26 STEERING KNUCKLE 60 AXLE 26 VACUUM SHIFT MOTOR 24 ISASSEMBLY AND ASSEMBLY AXLE SHAFT CARDAN U JOI...

Page 82: ... pinion gears are mounted on a pinion mate shaft and are free to rotate on the shaft The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts In operation power flow occurs as follows Pinion gear rotates the ring gear Ring gear bolted to the differential case rotates the case Differential pinion gears mounted on the pinion mate shaft in the...

Page 83: ...ult in noisy operation after repair Axle gear problem conditions are usually the result of Insufficient lubrication Incorrect or contaminated lubricant Overloading excessive engine torque Exceeding vehicle weight capacity Incorrect clearance or backlash adjustment Insufficient lubrication is usually the result of a housing cover leak It can also be from worn axle shaft or pinion gear seals Check f...

Page 84: ...r to pinion bearing The pitch of differential bearing noise is also constant and varies only with vehicle speed Axle shaft bearings produce noise and vibration when worn or damaged The noise generally changes when the bearings are loaded Road test the vehicle Turn the vehicle sharply to the left and to the right This will load the bearings and change the noise level Where axle bearing damage is sl...

Page 85: ...d erratic use of clutch 4 Replace broken axle shaft Inspect clutch and make necessary repairs or adjustments DIFFERENTIAL CASE CRACKED 1 Improper adjustment of differential bearings 2 Excessive ring gear backlash 3 Vehicle overloaded 4 Erratic clutch operation 1 Replace cracked case examine gears and bearings for possible damage At reassembly adjust differential bearings properly 2 Replace cracked...

Page 86: ...er adjustments 1 Replace gears Examine other gears and bearings for possible damage 2 Replace gears and examine the remaining parts for possible damage Avoid erratic clutch operation j 3 Replace gears Examine the remaining parts for possible damage Replace parts as required 4 Replace gears Examine other parts for possible damage Ensure ring gear backlash is correct AXLE NOISE 1 Insufficient lubric...

Page 87: ...NECT AXLE SHIFT MOTOR DIAGNOSIS VACUUM CONTROL SYSTEM The disconnect axle control system consists of Shift motor Indicator switch Vacuum switch Vacuum harness Fig 6 Refer to Group 21 Transmissions for addi tional information CHECK VALVE SHIFT MOTOR J9202 55 Fig 6 Vacuum Control System ...

Page 88: ... NEUTRAL DICONNECT THE SHIFT MOTOR VACUUM HOSES TEST FOR VACUUM IN VACUUM HOSE THAT CONNECTS TO INBOARD SHIFT MOTOR PORT VACUUM SHOULD BE BETWEEN 10 20 IN HG CHECK TRANSFER CASE REPAIR AS NECESSARY NO VACUUM OR LOW VACUUM 1 INSPECT INTAKE MANIFOLD VACUUM SUPPLY HOSE CONNECTION TRANSFER CASE VACUUM SWITCH CONNECTION VACUUM RESERVOIR AND SHIFT SYSTEM VACUUM HOSES FOR PROPER CONNECTION RESTRICTION AI...

Page 89: ...FT MOTOR SHOULD BE BETWEEN 10 20 IN HG NO VACUUM OR LOW VACUUM STOP ENGINE K VACUUM OK INSPECT INTAKE MANIFOLD VACUUM SUPPLY HOSE CONNECTION TRANSFER CASE VACUUM SWITCH CONNECTION VACUUM RESERVOIR AND SHIFT SYSTEM VACUUM HOSES FOR PROPER CONNECTION RESTRICTION LEAKS AND DAMAGE REPAIR OR REPLACE AS NECESSARY CONNECT A VACUUM PUMP TO THE OUTBOARD SHIFT MOTOR PORT APPLY 15 INCHES HG VACUUM AND ROTATE...

Page 90: ...plied 7 Install the cover and any identification tag Tighten the cover bolts in a criss cross pattern to Model 44 41 N m 30 ft lbs torque Model 60 47 N m 35 ft lbs torque 8 Refill differential with the specified quantity of Mopar Hypoid Gear Lubricant CAUTION Overfilling the differential can result in lubricant foaming and overheating R E M O V A L A N D I N S T A L L A T I O N VACUUM SHIFT MOTOR ...

Page 91: ...normal height It is important to have the springs supporting the weight of the vehicle when the fasteners are tightened If springs are not at their normal ride position vehicle ride comfort could be affected and premature bush ing wear may occur Rubber bushings must never be lubricated 1 Install the springs retainer clip and bolts 2 Support the axle on a hydraulic jack under the differential Posit...

Page 92: ...ass ham mer to loosen Remove knuckle from axle tube yokes KNUCKLE INSTALLATION 1 Position the steering knuckle on the ball studs 2 Install and tighten lower ball stud nut to 108 N m 80 ft lbs torque Advance nut to next slot to line up hole and install new cotter pin 3 Install and tighten upper ball stud nut to 101 N m 75 ft lbs torque Advance nut to next slot to line up hole and install new cotter...

Page 93: ... shown to install ball stud Fig 12 L O W E R B A L L STUD REPLACEMENT 1 Position tools as shown to remove ball stud Fig 13 2 Position tools as shown to install ball stud Fig 14 BALL STUDS 60 AXLE UPPER BALL STUD REPLACEMENT 1 Position tools as shown to remove ball stud Fig 15 2 Position tools as shown to install ball stud Fig 16 J9402 48 Fig 12 Upper Ball Stud Install SPECIAL TOOL C 4212F J9402 51...

Page 94: ...tall ball stud Fig 18 PINION SHAFT SEAL REPLACEMENT REMOVAL 1 Raise and support the vehicle 2 Remove wheel and tire assemblies 3 Mark the drive shaft yoke and pinion yoke for installation alignment reference KNUCKLE Jf402 38 Fig 15 Upper Ball Stud Remove LOWER BALL STUD REPLACEMENT 1 Position tools as shown to remove ball Fig 17 stud ...

Page 95: ...n reference It must be known to prop erly adjust the pinion gear bearing preload torque after seal installation 7 Remove the pinion yoke nut and washer Use Remover C 452 and Wrench C 3281 to remove the pinion yoke Fig 19 8 Mark the positions of the yoke and pinion gear for installation alignment reference SPECIAL TOOL C 3281 Fig 20 Seal Removal INSTALLATION 1 Apply a light coating of gear lubrican...

Page 96: ...tation preload torque is attained 8 Align the installation reference marks and attach the drive shaft to the yoke 9 Add API grade GL 5 hypoid gear lubricant to the differential housing if necessary 10 Install wheel and tire assemblies 11 Lower the vehicle PINION FLANGE HOLDING TOOL 6719 Fig 23 Tightening Pinion Shaft Nut DIFFERENTIAL REMOVAL To service the differential the axle shafts must be remo...

Page 97: ... tool dowel pins seated in the locating holes Fig 25 Install the hold down clamps and tighten the tool turnbuckle finger tight 2 Install a pilot stud at the left side of the differ ential housing Attach Dial Indicator to housing pilot stud Load the indicator plunger against the opposite side of the housing Fig 25 and zero the indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is ...

Page 98: ...rential side bearings Fig 30 2 Install differential in axle housing HANDLE C 4171 DIFFERENTIAL BEARING Fig 30 Install Differential Side Bearings AXLE SHAFT OIL SEAL 1 Remove the axle shaft seal from the differential housing with a long drift or punch Be careful not to damage housing 2 Clean the inside perimeter of the differential housing with fine crocus cloth 3 Apply a light film of oil to the i...

Page 99: ...STALLATION 1 Position the bearing on installation tool Seat the bearing in the housing bore Fig 34 2 Clean the inside perimeter of the axle shaft tube with fine crocus cloth 3 Apply a light film of oil to the inside lip of the new axle shaft seal 4 Install the inner axle seal Fig 35 or Fig 36 The inner axle seal position is different on a 44 then a 60 axle Be sure to use the correct Fig 34 Interme...

Page 100: ...oper pro cedure REMOVAL 1 Remove differential from axle housing 2 Place differential case in a suitable vise with soft metal jaw protectors Fig 37 3 Remove bolts holding ring gear to differential case 4 Using a soft hammer drive ring gear from dif ferential case Fig 37 Fig 37 Ring Gear Removai RING GEAR INSTALLATION CAUTION Do not reuse the bolts that held the ring gear to the differential case Th...

Page 101: ...th a slide ham mer or pry out with bar 5 Remove oil slinger front bearing 6 Remove the front pinion bearing cup and seal with Remover D 147 for model 44 or D 158 for model 60 and Handle C 4171 Fig 41 Fig 42 Rear Bearing Cup Removal 8 Remove the collapsible preload spacer Fig 43 REAR BEARING OIL SLINGER COLLAPSIBLE SPACER SHOULDER PINION GEAR J9302 66 HANDLE REMOVER J9302 22 Fig 41 Front Bearing Cu...

Page 102: ...aring Cup Installation 3 Install pinion front bearing oil slinger Apply a light coating of gear lubricant on the lip of pinion seal Install seal with Installer D 163 and Handle C 4171 Fig 47 INSTALLER J9502 1 Fig 47 Pinion Seal Installation NOTE Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh If the factory installed ri...

Page 103: ...inion gear Tighten the nut to 258 N m 190 ft lbs for model 44 or 291 N m 215 ft lbs for model 60 minimum Do not over tighten Maximum torque is 380 N m 280 ft lbs CAUTION Never loosen pinion gear nut to decrease pinion gear bearing preload torque and never exceed specified preload torque If preload torque is exceeded a new collapsible spacer must be installed The torque sequence will have to be rep...

Page 104: ...l can result in lubricant foaming and overheating 4 Refill the differential housing with the speci fied quantity of Mopar Hypoid Gear Lubricant 5 Install the fill hole plug and tighten to 34 N m 25 ft lbs torque D I S A S S E M B L Y A N D A S S E M B L Y AXLE SHAFT CARDAN U JOINT DISASSEMBLY Single cardan U joints are not serviceable If defec tive they must be replaced as a unit If the bearings s...

Page 105: ...s enough to Install the retaining clips 5 Install the bearing cap retaining clips 6 Install the axle shaft refer to Hub Bearing and Axle Shaft installation STANDARD DIFFERENTIAL DISASSEMBLE 1 Remove pinion gear mate shaft 2 Rotate the differential side gears and remove the pinion mate gears and thrust washers Fig 56 THRUST WASHER MATE GEAR SIDE GEAR J9203 61 Fig 56 Pinion Mate Gear Removal 3 Remov...

Page 106: ... face of the pinion is 109 5 mm 4 312 inches for Model 44 axles and 127 mm 5 in for Model 60 axles The standard depth provides the best teeth contact pattern Refer to Backlash and Contact Pattern Analysis Paragraph in this section for additional information PRODUCTION NUMBERS DRIVE PINION GEAR DEPTH VARIANCE GEAR MATCHING NUMBER SAME AS RING GEAR NUMBER J9003 100 Fig 57 Pinion Gear ID Numbers NOTE...

Page 107: ...al indicator to measure dif ference in height of the arbor and the pinion block Fig 60 1 Assemble Pinion Gauge Set Pinion Block and pinion bearings Install assembly into differential pinion gear bore and hand tighten cone Fig 61 2 Place Arbor Disc 6732 on Arbor D 115 3 and position in the bearing cradles Fig 62 Install dif ferential bearing caps on Arbor Discs and tighten caps snug only Arbor Disc...

Page 108: ...RBOR SCOOTER BLOCK DIFFERENTIAL CASE J9003 27 J9403 38 Fig 63 Pinion Gear Depth Measurement Typical 6 Remove the measurement tools from the differ ential housing Fig 64 Differential Bearing Shim Installation 4 Install the marked bearing caps in their correct positions Install and snug the bolts 5 Attach a dial indicator to the housing Position the indicator plunger so that it contacts the ring gea...

Page 109: ...arious thicknesses Adjust the backlash accord ingly Fig 67 Do not increase the total shim pack thickness excessive bearing preload and damage will occur The ring gear teeth contact patterns will show if the pinion gear depth shim s have the correct thick ness It will also show if the ring gear backlash has been adjusted correctly The backlash must be main DIFFERENTIAL AND DRIVELINE 3 43 Fig 66 Rin...

Page 110: ...OAST SIDE OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH Fig 68 Gear...

Page 111: ...ring 2 3 4 5 N m 20 40 in lbs TORQUE MODEL 44 AXLE DESCRIPTION TORQUE Plug Fill Hole 34 N m 25 ft lbs Bolt Diff Cover 42 N m 31 ft lbs Bolt Bearing Cap 108 N m 80 ft lbs Nut Pinion 258 393 N m 190 290 ft lbs Bolt Ring Gear 95 122 N m 70 90 ft lbs Bolt Shift Motor 11 N m 8 ft lbs Nut Axle 237 N m 175 ft lbs Bolt Wheel Brg 170 N m 125 ft lbs Nut Lower Ball Stud 108 N m 80 ft lbs Nut Upper Ball Stud ...

Page 112: ...Driver C 3716 A ...

Page 113: ...DIFFERENTIAL AND DRIVELINE 3 47 Press Ball Joint Remover Installer G 4212 F ...

Page 114: ...3 48 DIFFERENTIAL AND DRIVELINE S P E C I A L T O O L S Continued Remover Installer Set D 354 Puller Head 938 ...

Page 115: ...ND DRIVELINE 3 49 Splitter Bearing 1130 Receiver Bail Stud 6289 1 Receiver Bail Joint 289 6 Adapter Bail Stud installer 6289 12 Holder 6719 6730 PINION HEIGHT SET 6733 734 6735 6736 6737 6738 Remover Ball Stud 6289 8 Set Pinion Depth Setting 6730 ...

Page 116: ...3 50 DIFFERENTIAL AND DRIVELINE S P E C I A L T O O L S Continued Remover 7794 A Installer Ball Joint 6758 ...

Page 117: ...l stamped metal axle gear ratio identifica tion tag is attached to the housing cover The Rear Wheel Anti lock RWAL brake speed sen sor is attached to the top forward exterior of the dif ferential housing A seal is located between the sensor and the wire harness connector The seal must be in place when the wire connector is connected to the sensor The RWAL brake exciter ring is press fitted onto th...

Page 118: ...3 52 DIFFERENTIAL AND DRIVELINE BR DIAGNOSIS AND T E S T I N G Continued HUB AXLE DIFFERENTIAL SHAFT HOUSING Fig 1 9 1 4 Axle ...

Page 119: ...erential and pinion gear bear ings can all produce noise when worn or damaged Bearing noise can be either a whining or a growling sound Pinion gear bearings have a constant pitch noise This noise changes only with vehicle speed Pinion bearing noise will be higher because It rotates at a faster rate Drive the vehicle and load the differen tial If bearing noise occurs the pinion rear bearing is the ...

Page 120: ... until the reference marks are facing downward Measure the distance between the outside edges of the two pieces of tape Record this measurement as the Bottom Of Tire BTR measurement 7 Average the FTR and the RTR distance mea surements Subtract the BTR measurement from this average distance to obtain the camber The accept able amount of camber is 1 16 inch to 3 32 inch 1 6 to 2 4 mm NOTE FTR RTR Di...

Page 121: ...ic use of clutch 4 Replace broken axle shaft Inspect clutch and make necessary repairs or adjustments DIFFERENTIAL CASE CRACKED 1 Improper adjustment of differential bearings 2 Excessive ring gear backlash 3 Vehicle overloaded 4 Erratic clutch operation 1 Replace cracked case examine gears and bearings for possible damage At reassembly adjust differential bearings properly 2 Replace cracked case e...

Page 122: ...djustments 1 Replace gears Examine other gears and bearings for possible damage 2 Replace gears and examine the remaining parts for possible damage Avoid erratic clutch operation 3 Replace gears Examine the remaining parts for possible damage Replace parts as required 4 Replace gears Examine other parts for possible damage Ensure ring gear backlash is correct AXLE NOISE 1 Insufficient lubricant 2 ...

Page 123: ...in front and rear of both front wheels 3 Raise one rear wheel until it is completely off the ground 4 Remove wheel and bolt Special Tool 6790 to studs 5 Use torque wrench on special tool to rotate wheel and read rotating torque Fig 2 6 If rotating torque is less than 22 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the unit should be service S E R V I C E P R O C E D U R E S DRAIN ...

Page 124: ...and brake drums 4 Disconnect the brake fluid tube fittings from the wheel cylinders Cap the fittings to prevent loss of brake fluid 5 Remove the vent hose from the brake tee nip ple 6 Remove the brake tee bolt Carefully detach the brake fluid tubes from the clips 7 Disconnect the parking brake cables and unbolt backing plates Mark the U joint pinion yoke and pinion shaft for reference 8 Disconnect...

Page 125: ... dull gray and it could appear to be lightly dented DIFFERENTIAL AND DRIVELINE 3 59 SEAL AND BEARING REMOVAL 1 Remove the axle shaft seal with a small pry bar Fig 7 Fig 7 Axle Seal Removal 2 Remove the axle bearing with Remover 0 4828 Fig 8 Fig 8 Bearing Removal 3 Inspect the axle shaft seal surface and tube bore for roughness and burrs Polish each axle shaft with No 600 crocus cloth This will rem...

Page 126: ...ead of sealant and install cover 5 Install the brake drum 6 Install wheel and tire assembly and lower the vehicle 7 Raise or lower the hoist until the vehicle is level 8 Remove the fill hole plug and fill the differen tial housing with lubricant Refer to the Specifica tions chart for the type and the quantity Install the fill hole plug PINION SEAL CAUTION The following procedures must be used so t...

Page 127: ...lers are seated 9 Use a Newton meter or an inch pound torque wrench to measure the pinion bearing preload torque DIFFERENTIAL AND DRIVELINE 3 61 DIFFERENTIAL Fig 12 Tightening Pinion Shaft Nut CAUTION Never loosen pinion gear nut to decrease pinion gear bearing preload torque and never exceed specified preload torque If preload torque is exceeded a new collapsible spacer must be installed The torq...

Page 128: ...housing and the differen tial bearing caps for installation reference Fig 14 6 Remove bearing threaded adjuster lock from each bearing cap Loosen the bolts but do not remove the bearing caps 7 Loosen the threaded adjusters with Wrench C 4164 Fig 15 8 Hold the differential case while removing bear ing caps and adjusters 9 Remove the differential case Each differential bearing cup and threaded adjus...

Page 129: ... 102 N m 75 ft lbs torque When installing differential in axle housing after ring and pinion gear replacement pinion depth side bearing preload and gear lash will require adjust ment EXCITER RING REMOVAL The ring gear must be removed before the RWAL ABS brake exciter ring can be replaced 1 Remove exciter ring with a hammer and drift INSTALLATION 1 Heat the replacement exciter ring with a heat lamp...

Page 130: ...d with a special sealant An additional appli cation of sealant is not required 5 Lubricate the pinion gear front and rear bear ings with gear lubricant 6 Install new collapsible spacer on pinion gear shaft Install pinion gear in housing CAUTION Use care to prevent over collapsing pre load spacer during installation of the yoke and seat ing the front bearing 7 Install the pinion yoke with Installer...

Page 131: ... bearing The correct pre load torque Is 1 N m 10 in lbs torque plus the torque measured and recorded during disas sembly The bearing preload torque should be con stant during a complete revolution of the drive pinion gear shaft If preload torque varies while rotating the shaft there is an internal binding that must be corrected before assem bly 14 If specified torque is not obtained tighten the nu...

Page 132: ...Tool Set 6960 Refer to Model 35 Axle section in this Group for Differential Removal and Installa tion 1 Clamp Side Gear Holding Tool 6965 in a vise 2 Position the differential case on the holding tool Fig 25 Place shop towels under the differen tial to avoid damage if removal of the ring gear is required Fig 25 3 If ring gear replacement is required remove and discard the bolts holding the ring ge...

Page 133: ...B R DISASSEMBLY AND A S S E M B L Y Continued DIFFERENTIAL AND DRIVELINE 3 67 Fig 28 Mate Shaft Removal ...

Page 134: ... Rotate case with tool until pinion gears can be removed Fig 33 13 Remove top side gear and clutch pack Keep plates in correct order during removal Fig 34 Fig 33 Pinion Gear Removal SIDE GEAR DIFFERENTIAL AND CLUTCH DISC CASE Fig 34 Side Gear Clutch Disc Removal 14 Remove case from fixture Remove remaining clutch pack 15 Remove clutch pack retaining clips Mark each clutch pack for installation ref...

Page 135: ...ith holes in case 11 Tighten forcing screw to 122 N m 90 ft lbs to compress the Belleville springs Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver Insert mate shaft into each pinion gear to verify alignment 12 Remove forcing screw threaded adapter and step plate Install pinion gear mate shaft align holes in shaft and case 13 Install the pinion m...

Page 136: ...grees opposite the flange runout mark 5 Remove the differential bearing cap bolts Remove the differential case from the differential housing TRAC LOK 1 Clean all components in cleaning solvent Dry components with compressed air 2 Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one compo nent in either pack is damaged 3 Inspect side and pinion gears Replace an...

Page 137: ...housands of an inch deviation from the standard If the number is negative add that value to the required thickness of the depth shim s If the number is positive subtract that value from the thickness of the depth shim s If the number is 0 no change is necessary After selecting the proper pinion depth shim s remove the measurement tools from the axle hous ing PINION GEAR DEPTH VARIANCE Original Pin...

Page 138: ...aded Adjuster Toot 2 Install Dial Indicator Fig 42 Position the plunger against the drive side of a ring gear tooth Measure the backlash at 4 positions 90 degrees apart around the ring gear Locate and mark the area of minimum backlash 3 Rotate the ring gear to the position of the least backlash Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed Fig...

Page 139: ...er to the pinion gear teeth Insufficient backlash is corrected by moving the ring gear away from the pinion gear 1 Apply yellow ferrous Iron oxide compound to both drive and coast sides of ring gear teeth 2 Rotate the ring gear one complete revolution in both directions 3 Note patterns In compound Refer to chart for Interpretation of contact patterns and adjust accord ingly 4 Install the axle shaf...

Page 140: ...OTH PATTERN SHOULD BE CENTERED O N THE COAST SIDE O F TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP O F THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRE...

Page 141: ...ing the side gear from sliding on the axle shaft 5 If there Is no side gear clearance remove the C clip lock from the axle shaft Use a micrometer to measure the thrust washer thickness Record the SIDE GEAR CLEARANCE 0 007 THRUST WASHER THICKNESS 0 033 TOTAL 0 040 I 0 040 REPLACEMENT WASHER THICKNESS 0 0 3 7 NEW SIDE GEAR CLEARANCE 0 003 J9203 31 Fig 44 Side Gear Calcuiations thickness and install ...

Page 142: ...3 76 DIFFERENTIAL AND DRIVELINE Installer C 3980A ...

Page 143: ...B R S P E C I A L TOOLS Continued DIFFERENTIAL AND DRIVELINE 3 Remover Installer Bearing Set C 4306 ...

Page 144: ...3 78 DIFFERENTIAL AND DRIVELINE S P E C I A L T O O L S Continued B R Wrench 6719 Fixture Tool 6965 ...

Page 145: ...AXLE ASSEMBLY 91 DIFFERENTIAL SIDE BEARINGS 92 page DIFFERENTIAL 91 EXCITER AND RING GEAR 94 PINION GEAR 95 PINION SEAL MODEL 70 80 90 PINION SHAFT SEAL 89 DISASSEMBLY AND ASSEMBLY POWER LOK MODEL 70 TRAC LOK MODEL 80 104 STANDARD DIFFERENTIAL 99 TRAC LOK DIFFERENTIAL 100 CLEANING AND INSPECTION AXLE COMPONENTS 107 TRAC LOK AND POWER LOK 107 ADJUSTMENTS DIFFERENTIAL BEARING PRELOAD AND GEAR LASH 1...

Page 146: ...SIDE GEAR GASKET OR SEALER WASHER EXCITOR RING CONE FLANGE AND AXLE SHAFT GASKET OIL SEAL X WASHER 3 80 differential and driveline General Information continued BOLT J9203 54 Fig 1 Model 60 70 and 80 Rear Axle 09 3B ...

Page 147: ...system divides the torque between the axle shafts It allows the axle shafts to rotate at different speeds when turning corners Each differential side gear is splined to an axle shaft The pinion gears are mounted on a pinion mate shaft and are free to rotate on the shaft The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts In operation p...

Page 148: ...qual traction Trac Lok operation is normal In extreme cases of dif ferences of traction the wheel with the least traction may spin D I A G N O S I S A N D T E S T I N G GENERAL INFORMATION Axle bearing problem conditions are usually caused by Insufficient or incorrect lubricant Foreign matter water contamination Incorrect bearing preload torque adjustment Incorrect backlash to tight When serviced ...

Page 149: ... is heard during a coast front bearing is the source Worn damaged differential bearings usually pro duce a low pitch noise Differential bearing noise is similar to pinion bearing The pitch of differential bearing noise is also constant and varies only with vehicle speed Axle shaft bearings produce noise and vibration when worn or damaged The noise generally changes when the bearings are loaded Roa...

Page 150: ...ments Subtract the BTR measurement from this average distance to obtain the camber The accept able amount of camber is 1 16 inch to 3 32 inch 1 6 to 2 4 mm If the BTR distance measurement is less than the average FTR and RTR distance measurement the camber will be positive If the BTR distance measurement is greater than the average FTR and RTR distance the camber will be negative If the toe positi...

Page 151: ...d erratic use of clutch 4 Replace broken axle shaft Inspect clutch and make necessary repairs or adjustments DIFFERENTIAL CASE CRACKED 1 Improper adjustment of differential bearings 2 Excessive ring gear backlash 3 Vehicle overloaded 4 Erratic clutch operation Replace cracked case examine gears and bearings for possible damage At reassembly adjust differential bearings properly Replace cracked cas...

Page 152: ...oper adjustments 1 Replace gears Examine other gears and bearings for possible j damage 2 Replace gears and examine the remaining parts for possible damage Avoid erratic clutch operation 3 Replace gears Examine the remaining parts for possible damage Replace parts as required 4 Replace gears Examine other parts for possible damage Ensure ring gear backlash is correct AXLE NOISE 1 Insufficient lubr...

Page 153: ...l and park ing brake off 2 Place blocks in front and rear of both front wheels 3 Raise one rear wheel until it is completely off the ground 4 Remove wheel and bolt Special Tool 6790 to studs 5 Use torque wrench on special tool to rotate wheel and read rotating torque Fig 5 6 If rotating torque is less than 22 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the unit should be service ...

Page 154: ...eel bearing locknut 8 Tighten the adjustment nut to 163 190 N m 120 140 ft lbs while rotating the wheel 9 Loosen the adjustment nut 1 8 of a turn 120 degrees to provide 0 001 inch to 0 010 inch wheel bearing end play B R 10 Tap the locking wedge into the spindle key way and adjustment nut 11 Install the axle shaft R E M O V A L A N D I N S T A L L A T I O N AXLE ASSEMBLY REMOVAL It is not necessar...

Page 155: ...Fig 7 5 Using an inch pound torque wrench check rotation resistance of the pinion and record the results to aid installation 6 Mark the positions of the yoke and pinion gear for installation alignment reference C 452 J9102 31 Fig 7 Pinion Yoke Removal 7 Use Remover C 748 to remove the pinion gear seal Fig 8 INSTALLATION 1 Apply a light coating of gear lubricant on the lip of pinion seal Install th...

Page 156: ... Fig 10 C 452 J9102 31 Fig 10 Pinion Yoke Removal 6 Use Remover 7794A and slide hammer to remove pinion seal Fig 11 SPECIAL TOOL 7794A PINION SEAL J9402 59X Fig 11 Pinion Seal Removal INSTALLATION 1 Apply a light coating of gear lubricant on the lip of pinion seal Install the new seal with Installer D 187B 2 Align the installation reference marks and position the yoke on the pinion gear 3 Install ...

Page 157: ...e U joint pinion yoke and pinion shaft for reference 8 Disconnect the drive shaft from the pinion yoke Secure the drive shaft in an upright position to prevent damage to the rear U joint 9 Remove the shock absorber lower attaching nuts and bolts 10 Support axle and remove rear spring U bolts and the spring brackets WARNING AXLE MAY ROTATE ON SUPPORT WHEN SPRING CLAMP BOLTS ARE REMOVED ENSURE A1LE ...

Page 158: ...holes Fig 16 Install the hold down clamps and tighten the tool turnbuckle finger tight 2 Install a pilot stud at the left side of the differ ential housing Attach Dial Indicator to housing pilot stud Load the indicator plunger against the opposite side of the housing Fig 16 and zero the indicator DIFFERENTIAL PRY BAR Fig 17 Differential Removal CAUTION Do not spread over 0 38 mm 0 015 in If the ho...

Page 159: ...B R DIFFERENTIAL AND DRIVELINE 3 93 REMOVAL AND INSTALLATION Continued Fig 21 Install Differential Side Bearings ...

Page 160: ...r ring after removal Fig 23 Exciter Ring Removal EXCITER AMD RING GEAR INSTALLATION 1 I f exciter ring was removed align exciter ring tab with slot in differential case Fig 24 Fig 24 Exciter Ring Alignment 2 Invert the differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignment 3 Press the exciter ring onto the differential case using the ring gear as a ...

Page 161: ...Handle C 4171 Fig 28 REMOVER HANDLE J9302 22 Fig 26 Pinion Yoke Removal 3 Remove the pinion gear from housing Fig 27 Catch the pinion with your hand to prevent it from falling and being damaged Fig 28 Front Bearing Cup Removal 7 Remove the rear bearing cup from housing Fig 29 Use Remover D 159 for model 80 or D 162 for model 60 70 and Handle C 4171 RAWHIDE HAMMER DRIVER HANDLE J9302 25 Fig 27 Remo...

Page 162: ...e preload shims on model 70 80 Fig 10 Remove the depth shims from the pinion gear 30 or collapsible spacer on model 60 axles Fig 31 shaft Record the thickness of the depth shims 9 Remove the inner bearing from the pinion with Splitter 1130 and Bridge 938 Fig 32 Fig 31 Collapsible Preload Spacer Model 60 Fig 82 inner Bearing Removal ...

Page 163: ...nd pinion gear mesh If the factory installed ring and pinion gears are reused the pin ion depth shim should not require replacement Refer to Pinion Gear Depth paragraph in this sec tion to select the proper thickness shim before installing rear pinion bearing cone The shims are between the rear pinion bearing cone and pinion gear on model 60 axle and in the axle housing behind the rear bearing cup...

Page 164: ...hten Maximum torque is 380 N m 280 ft lbs REAR BEARING OIL SLINGER COLLAPSIBLE SPACER SHOULDER PINION GEAR J9302 66 Fig 37 Collapsible Preload Spacer Model 60 NOTE On model 60 and 70 axles install yoke washer with concave surface against the yoke PINION YOKE WASHER SLINGER PINION PRELOAD SHIMS FRONT BEARING CUP PINION NUT PINION OIL SEAL PINION PRELOAD SPACER FRONT BEARING CONE SHOULDER FOR PINION...

Page 165: ...axles 80a0c4f5 Fig 40 Tightening Pinion Nut 12 Check bearing preload torque with an inch pound torque wrench Fig 41 The torque necessary to rotate the pinion gear should be Original Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 to 5 N m 15 to 35 in lbs To achieve proper pinion bearing preload on model 70 80 axles remove pinion gear from axle housing Increase shim thickness If rotation torque ...

Page 166: ...pin in two places 180 degrees apart Fig 45 Mate Shaft Pin instaiiation If replacement gears and thrust washers were installed it is not necessary to measure the gear backlash Correct fit is due to close machining tolerances during manufacture TRAC LOI DIFFERENTIAL The Trac Lok limited slip differential compo nents are illustrated in Fig 46 Refer to this illus tration during repair service DISASSEM...

Page 167: ...B R DIFFERENTIAL AND DRIVELINE 3 DISASSEMBLY AND A S S E M B L Y Continued J8903 43 Fig 47 Differential Case Holding Tool ...

Page 168: ...stall and lubricate Step Plate C 4487 I Fig 51 7 Assemble Threaded Adapter C 4487 3 into top side gear Thread forcing Screw C 4487 2 into adapter until it becomes centered in adapter plate 8 Position a small screw driver in slot of Threaded Adapter C 4487 3 Fig 52 to prevent adapter from turning SPECIAL TOOL C 4487 1 DIFFERENTIAL CASE LOWER SIDE GEAR J9203 4 Fig 51 Step Plate Tool Installation SOC...

Page 169: ...ate case with tool until pinion gears can be removed Fig 55 13 Remove top side gear and clutch pack Keep plates in correct order during removal Fig 56 Fig 55 Pinion Gear Removal SIDE GEAR DIFFERENTIAL AND CLUTCH DISC CASE RE Fig 56 Side Gear Clutch Disc Removal 14 Remove case from fixture Remove remaining clutch pack 15 Remove clutch pack retaining clips Mark each clutch pack for installation refe...

Page 170: ...s in pinion gears align with holes in case 11 Tighten forcing screw to 122 N m 90 ft lbs to compress the Belleville springs Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver Insert mate shaft into each pinion gear to verify alignment 12 Remove forcing screw threaded adapter and step plate Install pinion gear mate shaft align holes in shaft and cas...

Page 171: ...Remove the case attaching bolts and remove the button cover half Fig 61 J9203 73 Fig 61 Cover Half Removal 3 Remove the pinion mate gear side gear clutch ring and clutch pack cross shaft Fig 62 Fig 63 Keep these parts with the button cover half for cor rect installation in their original positions 4 Remove the same parts listed above from the ring gear flange half of the case Keep these parts with...

Page 172: ...tallation 1 Saturate the clutch plates with Hypoid Gear Lubricant or Additive Assemble clutch packs into the side gear plate in exactly the same position as removed Fig 62 Fig 63 or Fig 64 CLUTCH PLATES PINION MATE CROSS SHAFT BUTTON HALF J9203 74 Fig 63 Power Lok Components 2 Line up the plate ears and install the assem bled pack into the flange half Fig 65 Make sure the clutch plate lugs enter t...

Page 173: ...r the roller contact sur faces Bearing cups must not be distorted or cracked Machined surfaces should be smooth and with out any raised edges DIFFERENTIAL AND DRIVELINE 3 107 Fig 87 Case Half installation Raised metal on shoulders of cup bores should be removed with a hand stone Wear and damage to pinion gear mate shaft pinion gears side gears and thrust washers Replace as a matched set only Ring ...

Page 174: ...p and housing Fig 70 The second method is selective shim between the pinion gear head and bearing cone If new gear set is being installed note the depth variance etched into original and new pinion gear Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances Refer to the Depth Variance charts For example if old pinion is plus 1 and the new ...

Page 175: ...6730 Use Pinion Block 6734 for Model 44 and 6736 for model 60 axle Use Dial Indicator C 3339 dial indicator to measure dif ference in height of the arbor and the pinion block Fig 71 DIAL INDICATOR PINION HEIGHT BLOCK CONE SCREW PINION BLOCK SCOOTER BLOCK ARBOR DISC J9403 45 Fig 71 Pinion Gear Depth Gauge Tools Typical 1 Assemble Pinion Gauge Set Pinion Block and pinion bearings Install assembly in...

Page 176: ... This procedure requires tool kit 6770 to determine the proper differential side gear preload DIFFERENTIAL SHIM PACK MEASUREMENT NOTE It is recommended whenever bearings are removed that they be replaced 1 Install dummy side bearings D 343 on differen tial 2 Install the differential case in the axle housing 3 Install the outboard shim spacer selected thick ness on each side between bearing cup and...

Page 177: ...ash at three equally spaced locations around the perimeter of the ring gear with a dial indicator Fig 77 Fig 77 Ring Gear Backlash Measurement The ring gear backlash must be within 0 12 0 20 mm 0 005 0 008 in It cannot vary more than 0 05 mm 0 002 in between the points checked If backlash must be adjusted spacers are available in various thicknesses Adjust the backlash accord ingly Fig 78 Do not i...

Page 178: ...AST SIDE O F TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP O F THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH IS PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH J 9 0 0...

Page 179: ...ad Original Bearing 1 3 N m 10 20 in lbs New Bearing 2 5 N m 20 40 in lbs MODEL 80 AXLE DESCEIPTION SPEC Axle Type Hypoid Lubricant Thermally Stable SAE 80W 90 Lube Capacity 4x2 3 22 L 6 8 pts 4x4 4 79 L 10 1 pts Axle Ratio 3 54 4 10 Ring Gear Diameter 279 4 mm 11 00 in Backlash 0 13 0 23 mm 0 005 0 009 in Pinion Std Depth 124 625 mm 5 812 in Pinion Bearing Preload Original Bearing 1 3 N m 10 20 i...

Page 180: ...3 114 DIFFERENTIAL AND DRIVELINE B R Puller C 452 ...

Page 181: ...B R S P E C I A L T O O L S Continued DIFFERENTIAL AND DRIVELINE 3 Installer Differential Bearing iC 4190 ...

Page 182: ...3 116 DIFFERENTIAL AND DRIVELINE S P E C I A L T O O L S Continued Handle Drive C 4735 Remover Pinion Bearing Cup D 159 ...

Page 183: ...B R S P E C I A L T O O L S Continued DIFFERENTIAL AND DRIVELINE 3 Installer Pinion Seal D 187B Spreader Differential W 129B ...

Page 184: ......

Page 185: ...ROCEDURES BRAKE BLEEDING 15 BRAKE DRUM MACHINING 16 BRAKE FLUID LEVEL 14 BRAKE LINE 16 DISC ROTOR MACHINING 15 MASTER CYLINDER BLEEDING 14 REMOVAL AND INSTALLATION BRAKE PEDAL 17 BRAKE SUPPORT PLATE 34 page BRAKESHOE 11 INCH BRAKE 30 BRAKESHOE 13 INCH BRAKE 32 DISC BRAKE CALIPER 24 DISC BRAKE ROTOR WITH TAPERED BEARINGS 28 DISC BRAKE ROTOR WITH UNIT BEARINGS 29 DISC BRAKESHOE 25 FRONT PARKING BRAK...

Page 186: ...ALED BAGS OR CONTAINERS TO MINIMIZE EXPOSURE TO YOURSELF AND OTH ERS FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINIS TRATION AND THE ENVIRONMENTAL PROTECTION AGENCY FOR THE HANDLING PROCESSING AND DISPOSITION OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS CAUTION Never use gasoline kerosene alcohol motor oil transmission fluid or any fluid containing mineral oil to cl...

Page 187: ...aphragms The outer edge of each diaphragm is attached to the booster housing The diaphragms are in turn con nected to the booster push rod Two push rods are used to operate the booster One push rod connects the booster to the brake pedal The second push rod at the forward end of the housing strokes the master cylinder pistons The rear push rod is connected to the two diaphragms in the booster hous...

Page 188: ... removed in order to service either pump However the power steering pump can be removed and serviced separately when necessary The vacuum pump is not a serviceable component If diagnosis indicates a pump malfunction the pump must be replaced as an assembly Do not disassemble or attempt to repair the pump The combined vacuum and steering pump assem bly must be removed for access to either pump How ...

Page 189: ...ble compo nent The valve is available only as part of a com plete cylinder body assembly APPLICATION Three master cylinders are used in BR models The differences between them concern cylinder bore size and fluid reservoir capacity The master cylinder in 1500 models has a 28 6 mm 1 125 in bore The master cylinder in 2500 and 3500 models has a 31 8 mm 1 252 in bore Although the master cylinders used...

Page 190: ...applied to the piston Is transmitted directly to the inboard brakeshoe This forces the shoe lining against the inner surface of the disc brake rotor At the same time fluid pressure within Fig 7 Brake Caliper Operation the piston bore forces the caliper to slide Inward on the mounting bolts This action brings the outboard brakeshoe lining into contact with the outer surface of the disc brake rotor ...

Page 191: ...ing The adjuster lever on the 13 inch brake is also equipped with a lever and tension spring The adjuster mechanism performs two important functions First is in maintaining proper brakeshoe operating clearance And second is to maintain brake pedal height The mechanism does so by adjusting the shoes In small increments to compensate for lin ing wear The adjustment process is continuous throughout t...

Page 192: ...tion Verify that pedal does not bind and has adequate free play If pedal lacks free play check pedal and power booster for being loose or for bind condition Do not road test until condition is corrected 6 If components checked appear OK road test the vehicle ROAD TESTING 1 I f complaint involved low brake pedal pump pedal and note if it comes back up to normal height 2 Check brake pedal response w...

Page 193: ... frequently misdiagnosed pull condi tion is where direction of pull changes after a few stops The cause is a combination of brake drag fol lowed by fade at one of the brake units As the dragging brake overheats efficiency is so reduced that fade occurs Since the opposite brake unit is still functioning normally Its braking effect is magnified This causes pull to switch direction in favor of the no...

Page 194: ...ONTINUITY TEST 1 Check continuity between terminal pins 5 and 6 as follows a Pull plunger all the way out to fully extended position b Attach test leads to pins 5 and 6 and note ohmmeter reading c If continuity exists proceed to next test Replace switch if meter indicates lack of continuity shorted or open TERMINAL PINS J9405 88 Fig 9 Stoplamp Switch Terminal Identification 2 Check continuity betw...

Page 195: ... action again Booster should provide two or more vac uum assisted pedal applications If vacuum assist Is not provided booster is faulty POWER BOOSTER VACUUM TEST 1 Connect vacuum gauge to booster check valve with short length of hose and T fitting Fig 10 2 Start and run engine at curb idle speed for one minute 3 Observe the vacuum supply If vacuum supply is not adequate repair vacuum supply 4 Clam...

Page 196: ...If the valve is operating correctly the stem will extend slightly when the brakes are applied and retract when the brakes are released If the valve is faulty replace the entire combination valve as an assembly Pressure Differential Switch 1 Have helper sit in drivers seat to apply brake pedal and observe red brake warning light 2 Raise vehicle on hoist 3 Connect bleed hose to a rear wheel cylinder...

Page 197: ... the maximum allowable diameter BRAKE LINE AND HOSES Flexible rubber hose is used at both front brakes and at the rear axle junction block Inspect the hoses whenever the brake system is serviced at every engine oil change or whenever the vehicle is in for service Inspect the hoses for surface cracking scuffing or worn spots Replace any brake hose immediately if the fabric casing of the hose is exp...

Page 198: ...gm seal is firmly seated in the reservoir cover If the seal is improp erly seated it will shift out of position when the cover is installed resulting in fluid leakage and eventual contamination 1ASTER CYLINDER BLEEDING An overhauled or new master cylinder should always be bled before installation in the vehicle This practice saves time during brake bleeding because air in the cylinder will not be ...

Page 199: ...with Mopar or equivalent quality DOT 3 brake fluid 2 If calipers or wheel cylinders were overhauled open all caliper and wheel cylinder bleed screws Then close each bleed screw as fluid starts to drip from it Top off master cylinder reservoir once more before proceeding 3 Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid Fig 17...

Page 200: ...line Special bending tools are needed to avoid kink ing or twisting metal brake line In addition special flaring tools are needed to provide the Inverted type double flare required on metal brake lines FLARING PROCEDURE 1 Cut off damaged tube with Tubing Cutter 2 Ream cut edges of tubing to ensure proper flare 3 Install replacement tube nut on section of tube to be repaired 4 Insert tube In flarin...

Page 201: ...Align tab on switch with notch in switch bracket Fig 21 Then insert switch in bracket and turn it clockwise about 30 to lock it in place TAB N O T C H I N BRACKET J9505 141 Fig 21 Stop Lamp Switch 6 Release brake pedal Then lightly pull pedal fully rearward Pedal will adjust switch plunger to correct position as pedal is moved to rear CAUTION Do not use excessive force to move the pedal rearward f...

Page 202: ... bracket 4 Slide pedal shaft into bracket and through pedal from passenger side 5 Push pedal shaft out driver side of mounting bracket just enough to allow Installation of retaining E clip 6 Push pedal shaft back toward passenger side of bracket and install remaining E clip on pedal shaft 7 Install booster push rod on brake pedal Secure push rod to pedal with washer and retaining clip 8 Install st...

Page 203: ...itch 10 Fill and bleed brake system MASTER CYLINDER Exercise care when removing installing the master cylinder combination valve and antilock valve connecting lines The threads in the cylinder and valve fluid ports can be dam aged if care is not exercised Use a flare nut wrench to loosen or tighten the fittings and start all brake line fittings by hand to avoid cross threading REMOVAL 1 Remove bra...

Page 204: ...nation valve and from RWAL valve 2 Disconnect brake line from combination valve to front brakes or ABS valve Then disconnect brake line from RWAL valve to rear brakes 3 Remove nuts attaching master cylinder and valves to power brake booster studs Then remove master cylinder and valves as assembly Fig 30 Fig 30 Master Cylinder Valve Assembly 4 Disconnect vacuum hose at booster check valve 5 Remove ...

Page 205: ... mounting nuts to 23 34 N m 200 300 in lbs 7 Connect front rear brake lines to combination valve and RWAL valve Tighten brake line fittings to 16 23 N m 140 200 in lbs 8 Connect harness wires to RWAL valve and pressure differential switch on combination valve 9 Fill and bleed brake system Refer to proce dures in appropriate antilock brake section POWER BRAKE VACUUM PUiP DIESEL ENGINE REMOVAL 1 Dis...

Page 206: ...SEMBLY BOTTOM INBOARD ADAPTER BRACKET NUT J9105 97 Fig 36 Adapter And Pump Mounting Fastener Location 8 Remove upper bolt that attaches pump assem bly to engine block Fig 37 9 Remove pump assembly from vehicle Fig 37 Pump Assembly Upper Mounting Bolt 10 Remove nuts attaching vacuum pump to adapter Fig 38 J9105 98 Fig 38 Pump Assembly Removal 11 Remove vacuum pump from adapter Fig 39 Turn pump gear...

Page 207: ...nstall coupling on pump shaft Be sure cou pling is securely engaged in shaft drive tangs 7 Install vacuum pump on adapter Rotate drive gear until tangs on pump shaft engage in coupling Verify that pump is seated before installing attaching nuts I R M E S I 23 Fig 41 Steering Pump Mounting Stud Spacer Locations 8 Install and tighten vacuum pump attaching nuts 9 Inspect adapter O ring and replace O ...

Page 208: ... feed line to vacuum pump connec tor and tighten line fitting 20 Install oil pressure sender and connect sender wires 21 Connect steering pump pressure and return lines to pump Tighten pressure line fitting to 30 N m 22 ft lbs 22 Connect vacuum hose to vacuum pump 23 Connect battery cables if removed 24 Fill power steering pump reservoir 25 Purge air from steering pump lines Start engine and slowl...

Page 209: ... Mopar multi mileage grease or Dow GE silicone grease to slide surfaces 2 Install caliper over rotor and seat it on steering knuckle mounting arms 3 Start caliper mounting bolts by hand to avoid cross threading Then tighten mounting bolts to 51 N m 38 ft lbs 4 Connect brake hose to caliper Fig 49 and Fig 50 Inure brake hose fitting is correctly J9405 28 Fig 48 Caliper Removal lnstallation seated a...

Page 210: ...liper INBOARD J9405 49 Fig 51 inboard Brakeshoe Removal 8 Secure caliper to convenient chassis or suspen sion component with wire CAUTION Do not allow the brake hose to support the caliper Suspending the caliper by the brake hose can damage the hose and fitting joints Use 3 R Fig 52 Outboard Brakeshoe Removal wire to support and secure the caliper to a chassis or suspension component If the brakes...

Page 211: ... 3 Install inboard brakeshoe in caliper Be sure spring clip on shoe is properly aligned and seated in caliper piston Fig 56 CALIPER PISTON INBOARD SHOE J9405 34 Fig 56 Inboard Brakeshoe Installation 4 Install outboard brakeshoe in caliper Be sure spring ends are seated in dimples in caliper Fig 57 OUTBOARD BRAKESHOE SPRING CLIP INBOARD BRAKESHOE RETAINING SPRING J9405 29 Fig 57 Brakeshoe Position ...

Page 212: ... tem perature bearing grease Apply grease to bearing races as well Then install inner bearing in hub and install new grease seal GREASE SEAL INNER BEARING AND RACE ROTOR OUTER BEARING AND RACE COTTER PIN AND NUT WASHER CAP J9405 178 Fig 59 Rotor And Hub Assembly With Tapered Bearings 2 Apply liberal coat of bearing grease to spindle interior of rotor hub grease seal lip and seal surface of spindle...

Page 213: ...m inboard back side of steering knuckle Fig 61 Fig 61 Rotor And Hub Attaching Bolts 8 Remove rotor and hub assembly Fig 62 Replace bearing assembly if damaged 9 Remove hub spacer from steering knuckle Fig 63 Note spacer position for installation reference INSTALLATION 1 Apply liberal quantity of Mopar or Permatex anti seize compound to splines of front drive shaft Fig 64 2 Replace grease seal in s...

Page 214: ...in order to separate the rotor from the hub bearing for replace ment BRAKESHOE 11 INCH BRAKE REMOVAL 1 Raise vehicle 2 Remove rear wheels 3 Remove brake drums 4 Remove primary front brakeshoe return spring Fig 65 and Fig 66 Use brake spring pliers to unseat and remove spring from anchor pin 5 Remove primary shoe holddown spring pin and retainers Use brake spring tool to rotate retainers and diseng...

Page 215: ...nstall spring retainer with shoulder on in lever and Into shoe 8 Position secondary brakeshoe on support plate Use new holddown spring pin and retainer to secure shoe and adjuster lever 9 Attach shoe spring to secondary brakeshoe Connect long end of spring in secondary shoe 10 Engage parking brake strut In secondary brakeshoe and install oval shaped spring on opposite end of strut spring end of st...

Page 216: ...ainers with holddown spring tool 6 Disconnect shoe spring and remove primary brakeshoe and parking brake lever strut 7 Remove adjuster screw assembly 8 Remove secondary brakeshoe holddown spring pin and retainers Then remove adjuster lever spring and spring retainer assembly It is not necessary to disassemble adjuster lever components unless they are worn or damaged 9 Disconnect parking brake cabl...

Page 217: ...h support plate b Position secondary brakeshoe on support plate and insert pin through shoe c Position adjuster lever on brakeshoe and insert holddown spring inner retainer into lever and shoe Inner retainer has shoulder on it which seats in lever and shoe Fig 70 Assembling Adjuster Lever Spring And Retainer d Install holddown spring over pin and seat it in inner retainer Then install and seat hol...

Page 218: ...4 Tighten brake line fitting to 13 N m 115 in lbs 5 Install brakeshoe components 6 Adjust brakeshoes to drum using brake gauge 7 Install brake drum 8 Fill and bleed brake system 9 Install wheel and tire assemblies and lower vehicle BRAKE SUPPORT PLATE REMOVAL 1 Remove wheel and tire assemblies 2 Remove brake drums 3 Remove axle shaft refer to Group 3 for proce dures 4 Remove brakeshoes and hardwar...

Page 219: ... 170 Fig 74 Cable Attachment At Foot Pedal REAR PARK BRAKE CABLE REMOVAL 1 Raise vehicle and remove necessary wheel and brake drum 2 Remove secondary brakeshoe and disconnect cable from parking lever attached to secondary shoe 3 Compress rear cable retainer with hose clamp or pliers and pull cable out of support plate 4 Remove one or both cables reaction bracket on left rear fame rail 5 Disengage ...

Page 220: ... tighten to 21 34 N m 200 300 in lbs 3 Connect front cable to arm on pedal assembly 4 Connect wires to brakelamp switch 5 Install knee bolster 6 Raise vehicle 7 Adjust parking brake cable tensioner Refer to procedure in this section J 9 4 0 5 1 7 5 ITEM TORQUE A 21 34 N m 200 300 in lbs Fig 76 Parking Brake Pedal Mounting D I S A S S E M B L Y A N D A S S E M B L Y MASTER CYLINDER DISASSEMBLY The ...

Page 221: ...ary piston spring by tilting the cylinder body downward so the spring slides out of bore CYLINDER lODY J9405 10 Fig 80 Master Cylinder 10 Remove seal retainer from secondary piston Then remove front and rear seals from piston Fig 81 Discard seals spring and retainer after these parts are not reusable SPRING PISTON J9405 11 Fig 81 Secondary Piston Components CLEANING AND INSPECTION Clean the cylind...

Page 222: ... piston in cylinder bore spring end first Do not force piston into bore Work it into place with a twisting turning motion 6 Insert piston retaining snap ring in cylinder body Then push pistons inward with wood dowel and seat snap ring CAUTION Be very sure the piston retaining snap ring is fully seated Recheck snap ring installation before proceeding 7 Install new grommets on cylinder body 8 Remove...

Page 223: ...workbench is clean and dry This is important as dust dirt for eign material oil or solvents can damage seals harm piston surfaces and contaminate fluid 1 Clean the caliper and piston with Mopar brake cleaner clean brake fluid or denatured alcohol Do not use any other cleaning agents 2 Inspect condition of the caliper piston bore The piston must be free of corrosion rust pitting or scor ing replace...

Page 224: ...or torn 6 Lubricate caliper piston piston seal and piston bore with liberal quantity of clean fresh brake fluid 7 Lightly lubricate lip of new boot with Dow or GE silicone grease Install boot on piston and work boot lip into the groove at the top of piston Fig 87 8 Stretch boot rearward to straighten boot folds then move boot forward until folds snap into place Fig 87 9 Install new piston seal int...

Page 225: ...act pads on the support plate with fine sandpaper INSPECTION As a general rule riveted brakeshoes should be replaced when worn to within 0 78 mm 1 32 in of the rivet heads Bonded lining should be replaced when worn to a thickness of 1 6 mm 1 16 in Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered The lining should exhibit contact across its entire width S...

Page 226: ...ation The cylinder bore can be lightly polished but only with crocus cloth Replace the cylinder if the bore is scored pitted or heavily corroded Honing the bore to restore the surface is not recommended Inspect the cylinder pistons The piston surfaces should be smooth and free of scratches scoring and corrosion Replace the pistons if worn scored or cor roded Do attempt to restore the surface by sa...

Page 227: ... one reverse stop Repeat procedure 8 10 times to operate automatic adjusters and equalize adjustment NOTE Bring vehicle to complete standstill at each stop Incomplete roiling stops will not activate automatic adjusters ADJUSTMENT WITH ADJUSTING TOOL 1 Be sure parking brake lever is fully released 2 Raise vehicle so rear wheels can be rotated freely 3 Remove plug from each access hole In brake supp...

Page 228: ... adjustment is complete 11 Raise vehicle again 12 Mark tensioner rod 6 5 mm 1 4 in from edge of tensioner bracket Fig 95 13 Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket Fig 95 CAUTION Do not loosen or tighten the tensioner adjusting nut for any reason after completing adjustment 14 Release parking brake and verify rear wheels rotate fre...

Page 229: ... Ton Model 23 8 mm 0 937 in 1 Ton Model 27 mm 1 06 in Master Cylinder Bore Size 1 2 Ton Model 28 6 mm 1 125 in Installer Brake Caliper Dust Boot 6754 3 4 Ton Model 31 8 mm 1 25 In 1 Ton Model 31 8 mm 1 25 in v Brake Booster V 1 2 Ton Model Dual Diaphragm 3 4 Ton Model Dual Diaphragm High Output 1 Ton M o d e l Dual Diaphragm High Output TORQUE CHART DESCRIPTION TORQUE Booster Mounting Nuts 23 34 N...

Page 230: ...virtually all types of road surfaces Antilock brak ing is desirable because a vehicle which is stopped without locking the wheels will retain directional sta bility and some steering capability This allows the driver to retain greater control of the vehicle during braking The RWAL brake system operates by using a Con troller Antilock Brake CAB to constantly monitor rear wheel speed through the rea...

Page 231: ...vehicle speed EXCITER RING Attached to the ring gear inside the differential housing Provides a means to pull the magnetic field across the wheel speed sensor s windings RED BRAKE WARNING LAMP Located in the instrument cluster Provides the driver with a indicator of park brake engagement hydraulic brake malfunction or ABS malfunction Also is used to identify any diagnostic trouble codes AMBER A B ...

Page 232: ...igni tion key has been turned OFF The exception to this is codes 9 and 11 which are erased any time the key has been turned OFF Also code 11 will be removed from memory when the ignition is in the RUN or ACC positions if the malfunction that caused the code has been eliminated For both codes 9 and 11 if the malfunction remains the DTC will be reset on the next ignition key cycle to ON Cab Inputs T...

Page 233: ...ring passes the tip of the WSS the magnetic lines of force of the sensor are cut causing the magnetic field to be moved across the sensor s windings This in turn causes current to flow through the WSS circuit Fig 8020cd59 Fig 5 Operation of the Wheel Speed Sensor The signal strength of any magnetic induction sen sor is directly affected by Magnetic field strength the stronger the mag netic field t...

Page 234: ...l be set and stored in the CAB memory i f during an antilock stop the driver releases the brake pedal the reset switch contacts will open This signal to the CAB is an indication that pressure has equalized across the RWAL valve The CAB will then reset the dump cycle counter in anticipation of the next antilock stop Additionally any fluid stored in the accumulator will force its way past the dump v...

Page 235: ...ing Mode If the CAB senses that rear wheel speed decelera tion is excessive it will energize the isolation sole BRAKES 5 51 noid This prevents a further increase of driver induced brake pressure to the rear wheels If this ini tial action is not enough to prevent rear wheel lock up the CAB will momentarily energize a dump solenoid This opens the dump valve to vent a small amount of isolated rear br...

Page 236: ...en there is a need for pressure increase during a long antilock stop Remember the sequence of antilock events is to isolate decrease and then increase pres sure to maintain brake effectiveness At the point when the system is in the increase mode is when the pedal will drop slightly Tire Noise And Marks Although the RWAL system prevents complete rear wheel lock up some wheel slip is desired to obta...

Page 237: ...e warning lamp and ABS warning lamp are illuminated To retrieve a DTC place the ignition key in the RUN position Then momentarily ground pin 13 of the Data Link Connector When the ground is removed the ABS and Brake Warning Lamp will begin to flash The initial flash will be a long flash followed by one or more short flashes The long flash indicates the beginning of the DTC number The short flashes...

Page 238: ...STEP ACTION YES and NO You will be guided through each test by the ACTION The ACTION questions will all have bullets in front of them Answer all questions either with a YES or NO statement The YES or NO columns will guide you to the next appropriate test Start RWAL Diagnosis Verifying the Customer s Concern Start the engine and monitor the brake warning lamp and ABS warning lamp Both lamps will il...

Page 239: ...en performed Perform step 2 Perform RWAL DIAGNOSIS 2 The ignition switch should be in the run position prior to starting Are both brake warning and ABS warning lamps illuminated Perform step 6 Perform step 3 3 Is the ABS warning lamp illuminated only Perform RWAL DIAGNOSTIC PROCEDURES TEST 3 Perform step 4 4 Is the brake warning lamp illuminated only Perform RWAL DIAGNOSTIC PROCEDURE TEST 4 Perfor...

Page 240: ...he CAB 14 way connector Turn the ignition switch to the RUN position Is are the warning lamp s still flashing Perform step 13 Perform step 2 13 Turn the ignition key to the OFF position Disconnect and inspect the CAB 14 way connector for indications of poor connections Are there any connections that appear inadequate Repair as necessary and perform the Verification Test Perform step 14 Connect a v...

Page 241: ... short to battery voltage Was there a short to battery voltage at the wiring connectors or brake switch Repair the short as necessary and perform the Verification Test Replace the brake switch and perform the Verification Test 6 Remove RWAL speed sensor from differential housing Inspect the exciter ring Is the exciter ring present Perform step 7 Install a exciter ring and perform Verification Test...

Page 242: ...uired and perform the Verification Test Replace the RWAL j speed sensor and perform the Verification Test 14 Inspect the rear brakes for mechanical problems such as brakes grabbing locking or vehicle lead during braking Do the rear brakes have any mechanical problems Repair the rear brakes as necessary and perform the Verification Test The RWAL brake system is operationa at this time 15 Inspect th...

Page 243: ...perform the Verification Test Repair the RWAL speed sensor circuit for an open or high resistance between terminal 13 of the CAB and terminal 1 of the RWAL speed sensor s connector Then perform the Verification Test CHECKING RWAL SPEED SENSOR AIR GAP 1 Remove sensor from differential 2 Measure and record the distance from the underside of the sensor flange to the end of the sen sor pole piece Fig ...

Page 244: ...al Perform step 6 Replace the bulb and restart the test at the RWAL DIAGNOSIS section 4 Disconnect the RWAL 14 way connector and the connector to the brake warning lamp bulb Refer to section 8W for proper brake warning lamp wiring Connect an ohmmeter between terminal 5 of the RWAL 14 way connector and the brake warning lamp bulb s ground circuit Refer to section 8W for proper brake warning lamp wi...

Page 245: ...OFF position Disconnect the CAB 14 way connector WARNING NOTE Vehicles with diesel engines must also have the vacuum sensor disconnected Turn the ignition key to the RUN position Is the brake warning lamp illuminated Repair the brake warning lamp ground control circuit for a short to ground and perform the Verification Test Replace the CAB and perform the Verification Test 6 Is the ABS warning lam...

Page 246: ...m the fuse to the warning lamp circuit and perform the verification Test RWAL DIAGNOSTIC PROCEDURES TEST 6 are able to retrieve a DTC from the CAB s memory This procedure starts with both the brake warning then perform RWAL DIAGNOSTIC PROCEDURES lamp illuminated and ABS warning lamp illuminated TEST 1 and RWAL diagnostics cannot be performed If you Step Action Yes No 1 Turn the ignition key to the...

Page 247: ... to ground of the diagnostic terminal circuit and perform the verification test Perform step 10 10 Install a voltmeter between terminal 3 of the CAB s 14 way connector and ground Turn the ignition key to the RUN position Is the voltage greater than 9 volts Perform step 11 Perform step 13 11 Install a voltmeter between terminal 9 of the CAB s 14 way connector and ground Is the voltage greater than ...

Page 248: ...CAB connector Poor connections in the RWAL valve s 4 way connector CAB Check resistance of the isolation solenoid and circuit Resistance of the solenoid should be approximately 3 6 ohms 3 This code identifies an open in the dump valve circuit Components and circuits involved include o Open circuit from terminal 8 of the 14 way connector to the RWAL valve Ground connection for the RWAL valve Open c...

Page 249: ...enoid and circuit Resistance of the solenoid should be approximately 3 6 ohms WARNING CAUTION It I s important to r e m e m b e r t h a t the short to ground m u s t be r e p a i r e d prior t o i n s t a l l i n g a CAB for t h i s DTC 8 This code identifies a short in the dump valve circuit Components and circuits involved include Short to ground from terminal 8 in the 14 way connector to the RW...

Page 250: ...sual brake operating conditions such as vehicle lead during braking brakes grabbing brakes drag ging noise low brake pedal etc If the brake warn ing lamp and or the ABS warning lamps illuminate or flash during the test drive proceed to the RWAL DIAGNOSTICS PROCEDURES TEST 1 section in this group If the warning lamps remain extin guished and the brakes respond normally then the previous malfunction...

Page 251: ...mbination valve is held open A spring clip tool is best for securing the valve stem in an open position R E M O V A L A N D I N S T A L L A T I O N RWAL VALVE COMBINATION VALVE REMOVAL 1 Disconnect ground wire and harness wires from combination valve switch and RWAL valve Fig 11 Fig 11 Valve Harness 2 Disconnect lines to front and rear brakes from RWAL and combination valves Fig 12 FRONT BRAKES J9...

Page 252: ...tached to panel flange Fig 14 Fig 14 Knee Bolster 2 Remove module lower attaching screws Fig 15 Screws are partially hidden by air duct but can be removed with long shank number 2 Phillips screwdriver as shown Fig 15 RWAL Module Lower Attaching Screws 3 Remove module upper attaching screw Fig 16 Fig 16 RWAL Module Upper Attaching Screw 4 Remove module and bracket from underside of instrument panel...

Page 253: ...ing 2 Position cover over sensor and install cover and sensor attaching screw and tighten to 24 N m 18 ft lbs 3 Connect harness wires to sensor and lower vehicle 4 Lower vehicle EXCITER RING The exciter ring is mounted on the differential case If the ring is damaged refer to Group 3 Differ ential and Driveline for service procedures RRAINING k SCREW CABLE CLAMP BRAKE UNE COVER SENSOR j 1 AXLE HOUS...

Page 254: ...in electri cally operated solenoid valves The solenoid valves modulate brake fluid apply pressure during antilock page REMOVAL AND INSTALLATION CONTROLLER ANTILOCK BRAKE CAB 75 EXCITER RING 77 FRONT SPEED SENSOR 76 FRONT TONE WHEEL 77 FRONT WHEEL SPEED SENSOR 4WD 76 HYDRAULIC CONTROL UNIT CONTROLLER ANITLOCK BRAKE 75 REAR WHEEL SPEED SENSOR 77 RWAL VALVE COMBINATION VALVE 74 SPECIFICATIONS TORQUE ...

Page 255: ...CAB controls the antilock valve sole noid operation during all phases of antilock braking HYDRAULIC CONTROL UNIT HCU The HCU mounted on the driver side inner fender panel Fig 2 The HCU consist of the front antilock valve assem bly and pump motor unit FRONT ANITLOCK VALVE The front brake antilock valve consists of a sole noid valve body The antilock valve provides two channel pressure control of th...

Page 256: ... point the metering valve opens completely permitting full fluid apply pressure to the front disc brakes AIS RELAYS Two relays are use on the ASB system An ABS warning lamp relay is used to activate the amber ABS warning lamp When the lamp is lit the voltage at the CAB monitoring point will be 0 volts The volt age at the monitoring point will be 12 volts when the CAB energizes the relay turning th...

Page 257: ...nd free of bubbles NEW FRONT ANT1L0C1 W A L W E If a new front antilock valve assembly was installed bleed new valve as follows 1 Loosen bleed plug on new front valve about 1 4 to one full turn Fig 3 Plug must be open to fully bleed upper and lower sections of front antilock valve 2 Remove cap from bleed valve stem Fig 3 3 Install Valve Depressor Tool 6670 on bleed valve stem by sliding notched si...

Page 258: ...hout a proper master cylin der adapter The wrong adapter can lead to leakage or drawing air back into the system Make sure the front brake metering valve in the combination valve is held open A spring clip tool is best for securing the valve stem in an open position 1E1 RWAL VALVE COMBINATION VALVE REMOVAL 1 Disconnect ground wire and harness wires from combination valve switch and RWAL valve Fig ...

Page 259: ...Connect harness wires to RWAL valve and to combination valve switch 10 Fill and bleed brake system CONTROLLER ANTILOCK BRAKE CAB REMOVAL 1 Remove and isolate negative battery cable 2 Release CAB connector locking handle and remove connector Fig 8 3 Remove the 2 CAB mounting bolts and remove CAB from bracket INSTALLATION 1 Install CAB in mounting bracket 2 Install mounting bolts 3 Connect harness a...

Page 260: ...to bore with pry tool 4 Remove brake caliper bolts and lift caliper from knuckle and rotor Secure caliper to frame or chassis component with wire Do not allow brake hose to support caliper weight 5 Remove rotor refer to Group 5 Brakes 6 Remove bolts attaching sensor to steering knuckle Fig 12 Retain bolts They are special and must be reused if in good condition 7 Disconnect sensor wire and remove ...

Page 261: ...ront Tone Wheel 2WD REAR WHEEL SPEED SENSOR REMOVAL 1 Raise vehicle on hoist 2 Clean sensor cover and sensor mounting area of axle housing Fig 14 3 Disconnect harness wires from sensor Fig 14 4 Remove screw that secures brake cable brake line sensor cover and sensor in axle housing 5 Remove sensor and cover 6 Cover sensor opening in axle housing to pre vent dirt entry INSTALLATION 1 Insert sensor ...

Page 262: ...5 78 BRAKES S P E C I A L T O O L S ABS BRAKES Depressor Brake Valve 6670 ...

Page 263: ... disc and cover The transmission input shaft is supported in the crankshaft by a bearing A sleeve type release bear ing is used to engage and disengage the clutch cover pressure plate The release bearing is operated by a release fork in the clutch housing The fork pivots on a ball stud mounted inside the housing The release fork is actu ated by a hydraulic slave cylinder mounted in the housing The...

Page 264: ...g 3 Clutch Disc 10 Engine Fig 4 Clutch Disc Diesel Engine All the discs have damper springs in the hub The 281 mm discs have four springs while the 312 5 mm disc has five springs The damper springs provide smoother torque transfer and disc engagement CLUTCH COWEFt APPOCAT10I Two clutch covers are used for all applications The 281 mm cover Fig 5 is used for 3 9L 5 2L and 5 9L gas engine application...

Page 265: ... J9406 15 Fig 8 Clutch Hydraulic Linkage The clutch master cylinder is connected to the clutch pedal and the slave cylinder is connected to the clutch release fork The master cylinder is mounted on the drivers side of the dash panel adja cent to the brake master cylinder CLUTCH LINKAGE FLUID The clutch fluid reservoir master cylinder slave cylinder and fluid lines are prefilled with fluid at the f...

Page 266: ...m area CLUTCH PROBLEM CAUSES CONTAMINATION Fluid contamination is one of the more common causes of clutch malfunctions Oil water or clutch fluid on the clutch contact surfaces will result in faulty operation The usual result is chatter slip or grab During inspection note if any components are con taminated with oil hydraulic fluid or water road splash Oil contamination indicates a leak at either t...

Page 267: ...to specified torque CLUTCH HOUSING MISALIGNMENT AND RUNOUT Clutch housing alignment is important to proper operation The housing bore maintains alignment between the crankshaft and transmission input shaft Misalignment can cause noise incomplete clutch release and chatter It can also result in premature wear of the pilot bearing cover release fingers and clutch disc In severe cases misalignment ca...

Page 268: ... Replace bearing only if seized noisy or damaged 11 Check clutch cover diaphragm spring and release fingers Replace cover if spring or fingers are bent warped broken cracked Do not tamper with factory spring setting as clutch problems will result 12 Check condition of clutch cover Replace clutch cover if plate surface is deeply scored warped worn or cracked Be sure cover is correct size and proper...

Page 269: ...place bearing and transmission front bearing retainer if sleeve surface is damaged FLYWHEEL HEIGHT INCORRECT 1 Flywheel surface improperly machined Too much stock removed or surface is tapered 1 Replace flywheel WRONG DISC OR PRES SURE PLATE INSTALLED 1 Incorrect parts order or model number 1 Replace with correct parts Compare old and new parts before installation CLUTCH DISC COVER AND OR DIAPHRAG...

Page 270: ...cuum may form in pockets over rivet heads in clutch disc Occurs as clutch cools down after use 1 Drill 1 16 inch diameter hole through rivets and scuff sand disc facing with 180 grit paper CLUTCH DISC TOO THICK 1 Wrong disc installed 1 Replace disc PILOT BEARING SEIZED LOOSE OR ROLLERS ARE WORN 1 Bearing cocked during installation Bearing defective Bearing not lubricated Clutch misalignment 1 Lubr...

Page 271: ...rn or corroded 1 Replace both cylinders as assembly and reservoir NO FAULT FOUND WITH CLUTCH COMPONENTS 1 Problem actually related to suspension or driveline component 2 Engine related problem 1 Further diagnosis required Check engine transmission mounts propeller shafts and U joints tires suspension attaching parts and other driveline components as needed 2 Check EFI and ignition systems PARTIAL ...

Page 272: ...olts to specified torque Replace any clutch bolts that are damaged Components appear overheated Hub of disc cracked or torsion damper springs are distorted or broken 1 Frequent high load full throttle operation 1 Replace parts as needed Alert driver to condition causes Contact surface of release bearing damaged 1 Clutch cover incorrect or release fingers are bent or distorted causing damage 2 Rele...

Page 273: ...points 45 apart around the bore Fig 10 and Fig 11 Repeat the measurement at least twice for accuracy 9 Subtract each reading from the one 180 oppo site to determine magnitude and direction of runout Refer to Fig 12 and following example Bore runout example 0 000 0 007 0 007 in 0 002 0 010 0 012 in 0 004 0 005 0 009 in 0 001 0 001 0 002 in 0 002 inch In the above example the largest difference is 0...

Page 274: ...ck bore runout again Rotate the dowels until the TIR is less than 0 010 in if necessary If a TIR of 0 0 5 3 in or greater is encountered it may be necessary to replace the clutch housing Measuring Clutch Housing Face Runout NV4500 1 Reposition the dial indicator plunger on the housing face Fig 14 Place the indicator plunger at the rim of the housing bore as shown 2 Rotate the crankshaft until the ...

Page 275: ...g Face Measurement Points And Sample Readings be serviced separately The linkage cylinders and connecting lines are sealed units They are pre filled with fluid during manufacture and must not be disassembled nor disconnected Linkage Removal 1 Raise vehicle 2 On diesel models remove slave cylinder shield from clutch housing if equipped 3 Remove nuts attaching slave cylinder to studs on clutch housi...

Page 276: ...eat seal if necessary Then lock cylinder after ward 6 Position clutch fluid reservoir on dash panel and install reservoir screws Tighten screws to 5 N m 40 in lbs torque 7 Install reservoir mounting bracket on dash panel if removed 8 Install replacement bushing on clutch pedal pin if necessary 9 Install clutch master cylinder push rod on clutch pedal pin Secure rod with wave washer flat washer and...

Page 277: ...d gear for alignment ref erence on the flywheel Use a scriber for this pur pose 2 Wear protective goggles or approved safety glasses Also wear heat resistant gloves when han dling a heated ring gear 3 Remove the old gear by cutting most of the way through it at one point with an abrasive cut off wheel Then complete removal with a cold chisel or punch 4 The ring gear Is a shrink fit on the flywheel...

Page 278: ...6 Insert clutch alignment tool in clutch disc and into pilot bushing Tool will hold disc in place when cover bolts are removed FLYWHEEL ALIGNMENT MARKS SCRIBE OR PAINT CLUTCH COVER J9406 17 Fig 24 Marking Clutch Cover Position 7 If clutch cover will be reused loosen cover bolts evenly only few threads at a time and in a diagonal pattern Fig 25 This relieves cover spring tension evenly to avoid war...

Page 279: ...Cower Alignment Installation 6 Position clutch cover over disc and onto fly wheel Fig 27 7 Align and hold clutch cover in position and Install cover bolts finger tight 8 Tighten cover bolts evenly and a few threads at a time Cover bolts must be tightened evenly and to specified torque to avoid distorting cover Tighten 5 16 in diameter bolts to 23 N m 17 ft lbs Tighten 3 8 in diameter bolts to 41 N...

Page 280: ...lutch master cylinder CLUTCH HOUSING REPLACEMENT NV4500 Only the NV4500 clutch housing is serviced sepa rately The NV3500 clutch housing is part of the transmission front case and is therefore serviced only as part of the case assembly 1 Raise vehicle and remove transmission and transfer case if equipped 2 Remove clutch housing bolts and remove hous ing from engine Fig 33 and Fig 34 3 Clean housin...

Page 281: ... 1 REMOVAL 1 Remove transmission 2 On models with gas engine and new style release fork remove clutch housing for access to release fork and release bearing retainer springs 3 Disconnect release bearing from release fork and remove bearing Fig 35 RELEASE BEARING RELEASE AND SLEEVE FORK RN1232 Fig 35 dutch Release Components RELEASE BEARING INSTALLATION 1 Inspect bearing slide surface on transmissi...

Page 282: ...utch cover and disc 5 Install clutch housing transmission and trans fer case on 4 wheel drive models CLUTCH PEDAL REMOVAL 1 Remove retaining ring flat washer and wave washer that secure brake and clutch pedals to push rods Fig 38 2 Remove knee bolster Fig 39 for access to pedal pivot shaft 3 Remove brake light switch Turn switch clock wise about 30 to release it then remove switch from bracket 4 R...

Page 283: ...ess for brake pedal 4 Slide pedal shaft through support and install shaft retainer 5 Secure push rods to clutch and brake pedals 6 Install brake light switch In bracket Rotate switch into place to lock it in bracket 7 Install knee bolster S P E C I F I C A T I O N S TORQUE DESCEIPTION TORQUE Nut slave cylinder 19 26 N m 170 230 in lbs Bolt clutch cover 5 16 in 23 N m 17 ft lbs Bolt clutch cover 3 ...

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Page 285: ... 6 REMOVAL AND INSTALLATION COOLANT PERFORMANCE 9 AIR TO OIL COOLER 3 9L 5 2L 5 9L ENGINES 50 COOLANT RESERVE OVERFLOW SYSTEM 11 AIR TO OIL COOLER 5 9L DIESEL ENGINE 52 COOLANT SELECTION ADDITIVES 10 AIR TO OIL COOLER 8 0L V 10 ENGINE 51 COOLING SYSTEM HOSES AND CLAMPS 11 AUTOMATIC BELT TENSIONER 57 ENGINE BLOCK HEATERS 9 COOLANT RESERVE OVERFLOW TANK 35 RADIATOR PRESSURE CAP 10 COOLING SYSTEM FAN...

Page 286: ... equipped The cooling system Is pressurized and uses a centrifugal water pump on all engines to circulate coolant throughout the system An optional factory installed maximum duty cool ing package Is available for some engines on most models This package will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures COOLING SY...

Page 287: ...As coolant flows toward the ther mostat it provides cooling for the injector nozzle Also refer to Thermostat Operation 5 9L Diesel Engine This can be found In the Thermostat section of this group Flow Diesel Powered Engine COOLANT RESERVE OVERFLOW SYSTEM The coolant reserve overflow system works In con junction with the radiator pressure cap It utilizes thermal expansion and contraction of coolant...

Page 288: ...al side tanks Aluminum cores with plastic side tanks are used on all 3 9L V 6 and 5 2 5 9L V 8 engines Copper brass cores are used with the 8 0L V 10 and diesel engines The radiator supplies sufficient heat transfer to cool the engine and automatic transmission if equipped THERMOSTAT The thermostat on all gas powered engines is located beneath the thermostat housing at the front of the intake mani...

Page 289: ...y reduced generator output rate and greatly reduced belt life It is not necessary to adjust belt tension on any engine All engines are equipped with an automatic belt tensioner The tensioner maintains correct belt tension at all times For other tensioner information and removal installation procedures refer to Auto matic Belt Tensioner proceeding in this group Due to use of this belt tensioner do ...

Page 290: ...t on all gas powered models equipped with an automatic transmission The internal radiator oil cooler is not used with the diesel engine Transmission oil is cooled when it passes through this separate cooler In case of a leak in the internal radiator mounted transmission oil cooler engine cool ant may become mixed with transmission fluid or transmission fluid may enter engine cooling system Both co...

Page 291: ...uto matic transmission Transmission oil is cooled when it passes through these coolers The main water to oil transmission oil cooler is mounted to a bracket on the turbocharger side of the engine Fig 12 The air to oil cooler is located in front of and to the left side of the radiator Fig 13 The diesel engine is not equipped with an internal radiator mounted oil cooler AUTOMATIC BELT TENSIONER Driv...

Page 292: ...ry A C com pressor power steering pump water pump idler pul ley or generator A pulley on an engine accessory being loose MOUNT BOLT 3 8 SQUARE HOLE ACCESSORY DRIVE BELT AUTOMATIC BELT TENSIONER J9307 59 Fig 16 Belt Tensioner 5 9L Diesel Typical non A C shown TENSIONER ASSEMBLY TENSIONER MOUNTING NUT INDEXING ARROW INDEXING MARK J9207 17 Fig 17 indexing Marks 3 9L V 6 or 5 2 5 9L V 8 LDC Gas Engine...

Page 293: ...k heater located on the right side of engine next to the oil filter Fig 18 The 8 0L V 10 engine has the block heater located on the right side of engine next to the engine oil dip stick tube Fig 19 The 5 9L diesel engine has the block heater located on the right side of the engine below the exhaust manifold Fig 20 Fig 18 Engine Block Heater 3 9U5 2U5 9L Gas Powered Engine Fig 19 Engine Block Heate...

Page 294: ...l based coolants are mixed in the vehicle conventional methods of determining freeze point will not be accurate Both the refractive index and spe cific gravity differ between ethylene glycol and propy lene glycol CAUTION Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyl ene glycol COOLANT SELECTION ADDITIVES The prese...

Page 295: ...ARNING 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 SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 Fig 23 SNAP ON CLAMP TOOL NUMBER HPC 20 MAY BE USED FOR LARGER CLAMPS ALWAYS WEAR SAFETY GLASSES WHEN SERVIC ING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant...

Page 296: ...OUNTING BOLTS 2 TANK MOUNTING BOLTS 3 J948D 21 Fig 26 Coolant Reserve Overflow TankS OL V 10 Engine Refer to Coolant Level Check Service Deaeration and Radiator Pressure Cap sections in this group for coolant reserve overflow system operation and service Should the reserve overflow tank become coated with corrosion it can be cleaned with detergent and water Rinse tank thoroughly before refilling c...

Page 297: ...Some engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives They are marked with the word REVERSE to designate their usage Installation of the wrong fan or viscous fan drive can result in engine overheating CAUTION If the viscous fan drive is replaced because of mechanical damage the cooling fan blades should also be inspected Inspect for fatigue cracks loos...

Page 298: ...PCM In either case other DTCs may have been erased If the lamp flashes 1 time pauses and flashes 7 more times a flashing Diagnostic Trouble Code DTC number 17 is indicated After any stored DTC information has been observed the display will end with a flashing DTC number 55 This will indicate the end of all stored information ERASING TROUBLE CODES After the problem has been repaired use the DRB sca...

Page 299: ...GH OR ENGINE COOLANT WARNING LAMP ILLUMINATES COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbed vehicle is operated in slow moving traffic or engine is being idled with very high ambient outside temperatures and the air conditioning is on Higher altitudes could aggravate these conditions 2 Is temperature gauge if equipped reading c...

Page 300: ...eck condition of radiator filler neck If neck is bent or damaged replace radiator c Check the condition of the hose from the radiator to the coolant tank It should fit tight at both ends without any kinks or tears Replace hose if necessary d Check coolant reserve overflow tank and tank hoses for blockage Repair as necessary 8 Check antifreeze Refer to Coolant section of this group Adjust antifreez...

Page 301: ... Gauges 3 A normal condition No correction is necessary Gauge reading should return to normal range after vehicle is driven 4 A normal condition No correction is necessary The gauge should return to normal range after a few minutes of engine operation 5 Check and correct coolant leaks Refer to Testing Cooling System For Leaks in this group 6 a Check for cylinder head gasket leaks with a commercial...

Page 302: ...5 A certain amount of fan noise roaring may be evident on models equipped with a thermal viscous fan drive Some of this noise is normal 1 Replace fan blade assembly Refer to Cooling System Fans in this group 2 Locate point of fan blade contact and repair as necessary 3 Remove obstructions and or clean debris or insects from radiator or A C condenser 4 Replace fan drive Bearing is not serviceable R...

Page 303: ...umps in this group Repair as necessary If a slipping belt is detected refer to Engine Accessory Drive Belts in this group Repair as necessary HEAT ODOR 1 Various heat shields are used at certain drive line components One or more of these shields may be missing 2 Is temperature gauge reading above the normal range 3 Is cooling fan operating correctly 4 Has undercoating been applied to any unnecessa...

Page 304: ...an or airflow to blow it away 1 Occasional steam emitting from this area is normal No repair is necessary COOLANT COLOR 1 Coolant color is not necessarily an indication of adequate corrosion or temperature protection Do not rely on coolant color for determining condition of coolant 1 Refer to Coolant in this group for antifreeze tests Adjust antifreeze to water ratio as necessary COOLANT LEVEL CHA...

Page 305: ...cessary Refer to Group 24 Heating and Air Conditioning for procedures TEMPERATURE GAUGE READS HIGH COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbed vehicle is operated in slow moving traffic or engine is being idled with very high ambient outside temperatures and the air conditioning is on Higher altitudes could aggravate these co...

Page 306: ...or Cap in this group Replace cap if necessary b Check condition of radiator filler neck If neck is bent or damaged replace radiator c Check the condition of the hose from the radiator to the coolant tank It should fit tight at both ends without any kinks or tears Replace hose if necessary d Check coolant reserve overflow tank and tank hoses for blockage Repair as necessary 7 Check antifreeze Refer...

Page 307: ... necessary Refer to Group 8E Instrument Panel And Gauges 3 A normal condition No correction is necessary Gauge reading should return to normal range after vehicle is driven 4 A normal condition No correction is necessary The gauge should return to normal range after a few minutes of engir 5 operation 5 Check and correct coolant leaks Refer to Testing Cooling System For Leaks in this group 6 a Chec...

Page 308: ...Refer to Cooling System Fans in this group 2 Locate point of fan blade contact and repair as necessary 3 Remove obstructions and or clean debris or insects from radiator or A C condenser 4 Replace fan drive Bearing is not serviceable Refer to Viscous Fan Drive in this group 5 Refer to Viscous Fan Drive in this group for an explanation of normal fan noise INADEQUATE AIR CONDITIONER PERFORMANCE COOL...

Page 309: ...to Thermostats in the manual text for information See Thermostat Diagnosis Diesel Engine 2 Refer to Testing Cooling System For Leaks in the manual text Repair as necessary 3 Remove heater hoses at both ends and check for obstructions Repair as necessary 4 Locate kinked area and repair as necessary 5 Refer to Water Pumps in this group Repair as necessary If a slipping belt is detected refer to Engi...

Page 310: ... or airflow to blow it away 1 Occasional steam emitting from this area is normal No repair is necessary COOLANT COLOR 1 Coolant color is not necessarily an indication of adequate corrosion or temperature protection Do not rely on coolant color for determining condition of coolant 1 Refer to Coolant in this group for antifreeze tests Adjust antifreeze to water ratio as necessary COOLANT LEVEL CHANG...

Page 311: ...ace as necessary Observe gauge pointer and determine condition of cooling sys tem according to following criteria Holds Steady I f pointer remains steady for two minutes serious coolant leaks are not present in sys tem However there could be an internal leak that does not appear with normal system test pressure If it is certain that coolant is being lost and leaks can Fig 32 Pressure Testing Cooli...

Page 312: ...rs instructions when using this product COMBUSTION LEAKAGE TEST WITHOUT PRESSURE TESTER DO NOT WASTE reusable coolant If solution is clean drain coolant into a clean container for reuse WARNING DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAIN COCK WITH SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR Drain sufficient coolant to allow thermostat removal Refer to T...

Page 313: ...ncrease in fan flow noise roaring The timing light also will indi cate an increase in the speed of the fan non diesel only 7 When the air temperature reaches 88 C 190 F remove the plastic sheet Fan drive disengage ment should have started to occur at between 57 to 79 C 135 to 175 F A definite decrease of fan flow noise roaring should be noticed If not replace the defective viscous fan drive unit C...

Page 314: ...ed and hardened from heat and excessive slippage 1 Replace automatic belt tensioner 2 Replace belt 3 Replace belt and clean pulleys 4 Replace fauity component bearing 5 Replace belt GROOVE JUMPING BELT DOES NOT MAINTAIN CORRECT POSITION ON PULLEY 1 Belt tension either too high or too low 2 Incorrect belt 3 Pulley s not within design tolerance 4 Foreign object s in grooves 4 Pulley misalignment 5 B...

Page 315: ...as been removed exam ine the thermostat and inside of thermostat housing for contaminants I f contaminants are found the thermostat may already be in a stuck open position Flush the cooling system before replacing thermostat Refer to Cooling System Cleaning Reverse Flushing in this group for additional information 3 Place the thermostat into a container filled with water 4 Place the container on a...

Page 316: ...ealing surfaces are clean Moisten rubber gasket with water and install cap on pressure tester 7700 or an equiv alent Fig 35 Operate tester pump to bring pressure to 104 kPa 15 psi on gauge If pressure cap fails to hold pres sure of at least 97 kPa 14 psi replace cap Refer to CAUTION below The pressure cap may test properly while posi tioned on tool 7700 or equivalent It may not hold pressure or va...

Page 317: ... the radiator WARNING DO NOT OPEN RADIATOR DRAINCOCK WITH ENGINE RUNNING OR WHILE ENGINE IS HOT AND COOLING SYSTEM IS UNDER PRESSURE When vehicle servicing requires a coolant level check in the radiator drain several ounces of coolant from the radiator drain cock Do this while observing the coolant reserve overflow system tank The coolant level in the reserve overflow tank should drop slightly I f...

Page 318: ...ery dirty systems with evidence of partial plugging REVERSE FLUSHING RADIATOR Disconnect radiator hoses from radiator inlet and outlet Attach a section of radiator hose to radiator bottom outlet fitting and insert flushing gun Con nect a water supply hose and air supply hose to flushing gun CAUTION Internal radiator pressure must not exceed 138 kPa 20 psi as damage to radiator may result Allow rad...

Page 319: ... 50 in lbs torque 3 Connect overflow hose to radiator WATER PUMP V 6 AND V 8 ENGINES REMOVAL The water pump on all models can be removed without discharging the air conditioning system if equipped The water pump on all gas powered engines is bolted directly to the engine timing chain case cover On all 3 9L 5 2L 5 9L gas powered engines a gas ket is used as a seal between the water pump and timing ...

Page 320: ...an Wrench number SP346 from Snap On Cummins Diesel Tool Set number 2017DSP can be used Place a bar or screwdriver between the water pump pulley bolts Fig 41 to prevent the pulley from rotating 8 If water pump is being replaced do not unbolt fan blade assembly Fig 41 from the thermal control fan drive 9 Remove fan blade fan drive and fan shroud as an assembly from vehicle 10 After removing fan blad...

Page 321: ...n the clamp at the water pump end of bypass hose Fig 41 Slip the bypass hose from the water pump while removing pump from vehicle Do not remove the clamp from the bypass hose 20 Discard old gasket CAUTION Do not pry the water pump at timing chain case cover The machined surfaces may be damaged resulting in leaks INSTALLATION 1 Clean gasket mating surfaces 2 Using a new gasket install water pump to...

Page 322: ... length must be used 11 Position fan shroud and fan blade viscous fan drive assembly to vehicle as a complete unit 12 Install fan shroud 13 Install fan blade viscous fan drive assembly to water pump shaft 14 Fill cooling system Refer to Refilling Cooling System in this group 15 Connect negative battery cable 16 Start and warm the engine Check for leaks WATER PUMP 8 0L 10 ENGINE R E M O V A L The w...

Page 323: ...4 If replacement is necessary use only an original equipment clamp with a matching number or letter FAN SHROUD MOUNTING BOLTS J9407 37 Fig 50 Typical Fan Shroud Mounting 5 Remove upper radiator hose at radiator 6 The thermal viscous fan drive is attached threaded to the water pump hub shaft Fig 51 Remove the fan fan drive assembly from water pump by turning the mounting nut counterclockwise as vie...

Page 324: ...g 52 Belt Tensioner 8 0L V 10 Engine 10 Remove the four water pump pulley to water pump hub bolts Fig 51 and remove pulley from vehicle 11 Remove the lower radiator hose at water pump 12 Remove heater hose at water pump fitting 13 Remove the seven water pump mounting bolts Fig 53 14 Loosen the clamp at the water pump end of bypass hose Slip the bypass hose from the water J9407 18 Fig 54 Water Pump...

Page 325: ...Guide water pump fitting into bypass hose as pump is being installed Install water pump bolts Fig 53 Tighten water pump mounting bolts to 40 N m 30 ft lbs torque 5 Position bypass hose clamp to bypass hose 6 Spin water pump to be sure that pump impel ler does not rub against timing chain case cover 7 Connect radiator lower hose to water pump 8 Connect heater hose and hose clamp to heater hose fitt...

Page 326: ...TION 1 Install new O ring seal in groove on water pump Fig 59 2 Install water pump Tighten mounting bolts to 24 N m 18 ft lbs torque 3 Install accessory drive belt Refer to the Engine Accessory Drive Belt section of this group 4 Install the bolt retaining the wiring harness near top of water pump 5 Fill cooling system Refer to Refilling Cooling System in this section 6 Connect both battery cables ...

Page 327: ...cessary Also discharging the A C system is not necessary Do not remove any refriger ant lines from A C compressor WARNING THE A C SYSTEM IS UNDER PRES SURE EVEN WITH THE ENGINE OFF REFER TO REFRIGERANT WARNINGS IN GROUP 24 HEATING AND AIR CONDITIONING 1 Disconnect negative battery cable from battery 2 Partially drain cooling system Refer to Drain ing Cooling System in this group 3 Do not waste reu...

Page 328: ...t and position generator and A C compres sor along with their common mounting bracket to gain access to bypass hose A block of wood may be used to hold assembly in position 17 Loosen and position both hose clamps to the center of bypass hose A special clamp tool Fig 23 must be used to remove the constant tension clamps Remove hose from vehicle INSTALLATION 1 Position bypass hose clamps to the cent...

Page 329: ...e Fig 69 in tensioner mounting bracket Tighten bolt to 41 N m 30 ft lbs torque BELT TENSIONER DOWEL PIN J9307 63 Fig 68 Tensioner Dowel Pin 5 9L HDC Gas Engine Fig 69 Tensioner Mounting Bracket Dowel Hole 5 9L HDC Gas Engine 11 Install drive belt Refer to Belt Removal In stallation in the Engine Accessory Drive Belt section of this group CAUTION When installing the serpentine acces sory drive belt...

Page 330: ... must be removed Refer to Belt Removal Installation in the Engine Accessory Drive Belt section of this group c The generator must be partially removed Remove the two generator mounting bolts Do not remove any wiring at generator If equipped with 4WD unplug the 4WD indicator lamp wiring har ness located near rear of generator d Remove generator Position generator to gain access for thermostat gaske...

Page 331: ...olts to 54 N m 40 ft lbs torque CAUTION When installing the serpentine acces sory drive belt the belt must be routed correctly If not the engine may overheat due to the water pump rotating in the wrong direction Refer to Belt Schematics in the Engine Accessory Drive Belt sec tion of this group for correct engine belt routing The correct belt with the correct length must be used 8 Fill cooling syst...

Page 332: ...e intake manifold Fig 73 Fig 75 The thermostat should fit snugly into the rubber seal 3 If seal replacement is necessary coat the outer metal portion of the seal with Mopar Gasket Maker Install the seal into the manifold using Spe cial Seal Tool number C 3995 A with handle tool number C 4171 4 Install thermostat into recessed machined groove on intake manifold Fig 75 5 Install gasket on intake man...

Page 333: ...onstant tension clamps 5 Remove the hose clamp and check valve hose at thermostat housing Fig 76 HOUSING HOSE LIFT BRACKET HOUSING BOLTS OUTER THERMOSTAT SEAL INNER SEAL J9507 22 Fig 76 Thermostat Removal 5 9L Diesei 6 Remove the two upper generator bracket mounting bolts Fig 77 7 Remove the upper generator mounting bracket Fig 77 8 Loosen but do not remove the generator lower pivot bolt 9 Positio...

Page 334: ...h cooling system and transmission should be drained and inspected in case of oil cooler leakage 1 Disconnect negative battery cable at battery 2 Drain cooling system Refer to Draining Cool ing System 3 Place a drain pan under the oil cooler lines 4 Disconnect the two transmission oil cooler line quick connect fittings at the radiator Refer to Group 21 Transmissions for procedures Plug cooler lines...

Page 335: ...level in the automatic trans mission Refer to Group 21 Transmissions for proce dures A1R T0 01L COOLER 8 J L 4 0 ENGINE REM0WAL and transmission should be drained and inspected in case of oil cooler leakage 1 Place a drain pan under the oil cooler lines 2 Disconnect the two transmission oil cooler line quick connect fittings from the transmission oil cooler lines Fig 81 Refer to Group 21 Transmis ...

Page 336: ...o both batter ies 6 Fill cooling system Refer to Refilling Cooling System in this section 7 Check transmission oil level and fill as neces sary 8 Install air cleaner assembly and air cleaner intake hoses Refer to Group 14 Fuel System for pro cedures REMOVAL 1 Remove front bumper Refer to Group 23 Body 2 Place a drain pan under the oil cooler 3 Raise the vehicle 4 Disconnect the oil cooler quick co...

Page 337: ...ssary use only an original equipment clamp with a matching number or letter 5 Remove hose clamps and hoses from radiator 6 All engines Remove coolant reserve overflow tank hose from radiator filler neck nipple 7 All engines except 8 0L V 10 Remove the cool ant reserve overflow tank from the fan shroud pull straight up The tank slips into T slots on the fan shroud 8 Disconnect electrical connectors...

Page 338: ...overflow tank hose to radiator filler neck nipple 12 All Engines Except 8 0L V 10 Install coolant reserve overflow tank to fan shroud fits into T slots on shroud 13 Connect throttle cable to fan shroud 14 Install negative battery cable to battery 15 Diesel Engine Install positive battery cable to top of radiator Tighten radiator to battery cable mounting nuts 16 Position heater controls to full he...

Page 339: ...ed from front until tension has been relieved from belt 3 Remove belt from idler pulley first 4 Remove belt from vehicle Fig 88 Belt Tensioner 3 9L V 6 or 5 2 5 9L V 8 LDC Gas Engines IISTALLATIOI CAUTION When installing serpentine accessory drive belt the belt must be routed correctly If not engine may overheat due to water pump rotating in wrong direction Refer to Fig 89 for correct engine belt ...

Page 340: ...Refer to Fig 91 Fig 92 for cor rect engine belt routing The correct belt with cor rect length must be used CAUTION If the pulley is to be removed from the tensioner its mounting bolt has left hand threads 1 Position drive belt over all pulleys except ten sioner pulley 2 Attach a socket wrench to pulley mounting bolt of automatic tensioner Fig 90 3 Rotate socket wrench counterclockwise Install belt...

Page 341: ...tensioner 3 Rotate ratchet and belt tensioner counterclock wise Place belt over water pump pulley Let ten sioner rotate back into place Remove ratchet Be sure belt is properly seated on all pulleys POWER STEERING PUMP IS NOT BELT DRIVEN Fig 94 Belt Routing 5 9L Diesei Engine With A C AUTOMATIC BELT TENSIONER NOTE On 3 9L V 6 or 5 2 5 9L V 8 LDC gas engines the tensioner is equipped with an indexin...

Page 342: ...rque 2 Install tensioner assembly to mounting bracket An indexing tab is located on back of ten sioner Align this tab to slot in mounting bracket Tighten nut to 67 N m 50 ft lbs torque 3 Connect all wiring to ignition coil 4 Install coil to coil bracket If nuts and bolts are used to secure coil to coil bracket tighten to 11 N m 100 in lbs torque If coil mounting bracket has been tapped for coil mo...

Page 343: ...t Fig 97 and remove tensioner WARNING BECAUSE OF HIGH SPRING PRES SURE DO NOT ATTEMPT TO DISASSEMBLE AUTO MATIC TENSIONER UNIT IS SERVICED AS AN ASSEMBLY EXCEPT FOR PULLEY INSTALLATION 1 Install pulley to tensioner 2 Install tensioner assembly to mounting bracket A dowel is located on back of tensioner Align this dowel to hole in tensioner mounting bracket Tighten bolt to 41 N m 30 ft lbs torque 3...

Page 344: ...serpentine drive belts have reverse rotating fans and viscous fan drives They are marked with the word REVERSE to designate their usage Installation of the wrong fan or viscous fan drive can result in engine overheating fffSFALLATfOfi 1 Install fan blade assembly to viscous fan drive Tighten bolts Fig 100 to 23 N m 17 ft lbs torque 2 Position fan shroud and fan blade viscous fan drive assembly to ...

Page 345: ...s NOTE Viscous Fan Drive Fluid Pump Out Require ment After installing a new viscous fan drive bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes This will ensure proper fluid distribution within the drive C L E A N I N G AND I N S P E C T I O N RADIATOR CAP INSPECTION Hold cap at eye level right side up The vent valve Fig 102 at bottom of cap should open If ...

Page 346: ...s should not exceed 2 0 mm 090 inch Test all blades In this manner WARNING DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI FICATIONS 4 Inspect fan assembly for cracks bends loose rivets or broken welds Replace fan if any damage is found CAUTION If fan blade assembly is replaced because of mechanical damage water pump and viscous fan drive should also be inspected These componen...

Page 347: ... G a s Engines 61 N m 4 5 ft lbs 8 8 N m 6 5 f t lbs 6 7 N m 5 0 f t lbs 41 N m 30 ft lbs 6 N m 50 in lbs 16 N m W i n lbs 4 N m 3 4 in lbs 61 N m 45 ft lbs S P E C I A L T O O L S COOLING Description Torqy Radiator Mounting Bolts Thermal Viscous Fan to Hub Diesel Engine Thermostat Housing Bolts All G a s Engines Except 8 0L V 10 Thermostat Housing Bolts 8 0 L V 1 0 Thermostat Housing Bolts Diesel...

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Page 349: ...he PCM Each monitored circuit is assigned a Diagnos tic Trouble Code DTC The PCM will store a DTC in electronic memory for any failure it detects See the On Board Diagnostics Test in Group 80 Charging System for more information INTRODUCTION This section covers battery diagnostic and service pro cedures only For battery maintenance procedures refer to Group 0 Lubrication and Maintenance While bat ...

Page 350: ...e switching of any of the vehicle s electrical components The battery is vented to release excess hydrogen gas that is created when the battery is being charged or dis charged However even with these vents the hydrogen gas can collect in or around the battery If hydrogen gas is exposed to flame or sparks it may ignite If the electrolyte level is low the battery may arc internally and explode if th...

Page 351: ... PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT THE BATTERY CONTAINS SULFURIC ACID WHICH IS POISONOUS AND CAUSTIC AVOID CON TACT WITH THE SKIN EYES OR CLOTHING IN THE EVENT OF CONTACT FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN IF THE BATTERY IS EQUIPPED WITH REMOV ABLE CELL CAPS BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTER...

Page 352: ...CTIONS CLEAN AND TIGHT NO CLEAN AND TIGHTEN AS REQUIRED YES DONE IS BATTERY FULLY CHARGED REFER TO TEST INDICATOR HYDROMETER TEST OR OPEN CIRCUIT VOLTAGE TEST IN THIS GROUP NO CHARGE BATTERY DOES BATTERY ACCEPT A CHARGE REFER TO BATTERY CHARGING IN THIS GROUP NO REPLACE FAILED BATTERY YES YES WILL BATTERY PASS A LOAD TEST REFER TO LOAD TEST IN THIS GROUP NO YES I BATTERY STILL SEEMS WEAK OR DEAD W...

Page 353: ...THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE PER SONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS Before testing visually inspect the battery for any damage a cracked case or cover loose posts etc that would cause the battery to be faulty In order to obtain correct indications from the built in test indi cator it is important that the b...

Page 354: ...emove only enough electrolyte from the battery so that the float is off the bottom of the hydrometer barrel with pres sure on the bulb released CAUTION Exercise care when inserting the tip of the hydrometer into a cell to avoid damaging the plate separators Damaged plate separators can cause early battery failure To read the hydrometer correctly hold it with the top surface of the electrolyte at e...

Page 355: ... must be removed from the battery Turn the headlamps on for 15 seconds then allow up to five minutes for the battery voltage to stabilize NOTE Models equipped with the diesel engine option are equipped with two 12 volt batteries con nected in parallel positive to positive negative to negative The secondary battery on the passenger s side is dedicated to providing current for the operation of the i...

Page 356: ...er The primary battery on the driver s side is dedi cated to all other vehicle electrical requirements In order to ensure accurate diagnostic results these batteries MUST be disconnected from each other as well as from the vehicle electrical system when being tested 1 Disconnect and isolate both battery cables neg ative cable first The battery top and posts should be clean 2 Connect a suitable vol...

Page 357: ...rator Intermittent shorts in the wiring If the IOD is over 20 milliamperes the problem must be found and corrected before replacing a bat tery In most cases the battery can be charged and returned to service DIAGNOSIS CAUTION Testing for high amperage IOD must be performed first to prevent damage to most milliam pere meters NOTE When testing a diesel engine equipped vehi cle dual batteries do not ...

Page 358: ...S SIGNS OF FREEZ ING LEAKING LOOSE POSTS OR LOW ELECTRO LYTE LEVEL DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHI CLE DAMAGE MAY RESULT EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BATTERY PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT THE BATTERY CONTAINS SULFURIC ACID WHICH IS ...

Page 359: ...ons provided with the battery charger to bypass the polarity sensing circuitry 3 Battery chargers vary in the amount of voltage and current they provide The amount of time required for a battery to accept measurable charger current at various voltages is shown in the Charge Rate chart If the charge current is still not measur able at end of the charging time the battery is faulty and must be repla...

Page 360: ...ve any corrosion using a wire brush or a post and terminal cleaning tool and a sodium bicarbonate baking soda and warm water cleaning solution Fig 11 Replace any cable that has damaged or deformed terminal clamps WARNING WEAR A SUITABLE PAIR OF RUBBER GLOVES NOT THE HOUSEHOLD TYPE WHEN REMOVING A BATTERY BY HAND SAFETY GLASSES SHOULD ALSO BE WORN IF THE BAT TERY IS CRACKED OR LEAKING THE ELECTRO L...

Page 361: ...on to remove any acid film Fig 17 Rinse the battery with clean water Ensure that the BATTElf 8A 13 Fig 16 Right Battery Tray Diesel Engine cleaning solution does not enter the battery cells through the vent holes If the battery is being replaced see the Battery Ratings and Classifications chart in Specifications at the back of this group Con firm that the replacement battery is the correct size an...

Page 362: ...he battery pos itive terminal post 13 Install and tighten the battery positive cable terminal clamp Then install and tighten the nega tive cable terminal clamp Tighten both cable termi nal clamp bolts to 8 5 N m 75 in lbs 14 Apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the cable terminal clamps and battery terminal posts S P E C I F I C A T I O N S BATTERY B...

Page 363: ...ure it detects See the On Board Diagnostics Test in Group 80 Charging System for more information INTRODUCTION The starting system consists of Battery Starter relay Starter with an integral solenoid Ignition switch Clutch pedal position switch manual transmission Park neutral position switch automatic trans mission Wiring harness and connections This group covers diagnosis of the complete start in...

Page 364: ...feature makes it possible to reduce the dimensions of the starter At the same time it allows higher armature rotational speed and delivers increased torque through the pinion gear to the starter ring gear on the flywheel manual transmis sion or torque converter automatic transmission The starter motors for all engines are activated by a solenoid mounted to the overrunning clutch housing However th...

Page 365: ...ck OK replace starter assembly STARTER ENGAGES FAILS TO TURN ENGINE 1 Battery discharged or faulty 2 Starting circuit wiring faulty 3 Starter assembly faulty 4 Engine seized 1 Refer to Group 8A Battery Charge or replace battery if required 2 See Cold Cranking Test in this group Test and repair feed and or control circuits if required 3 If all other starting system components and circuits check OK ...

Page 366: ... switch in the Start position Note the cranking voltage and current amperage draw a If the voltage reads above 9 6 volts and the current amperage draw reads above specifica tions see the Feed Circuit Tests in this group FRONT OF ENGINE AIR TEMPERATURE SENSOR SENSOR ELECTRICAL CONNECTOR INTAKE MANIFOLD UPPER HALF FUEL SHUTDOWN SOLENOID SOLENOID ELECTRICAL CONNECTOR J9414 93 Fig 2 Fuel Shutdown Sole...

Page 367: ...t Battery Negative Connection Resistance Typical 2 Connect the positive lead of the voltmeter to the battery positive terminal post Connect the nega tive lead of the voltmeter to the battery positive cable clamp Fig 4 Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor contact between the cable clamp and the terminal post 80660061...

Page 368: ...tester Fig 8 There should be continuity If OK go to Step 3 If not OK replace the faulty starter assem bly Fig 8 Continuity Test Between Solenoid Terminal and Field Coil Terminal 3 Check for continuity between the solenoid ter minal and the solenoid case Fig 9 There should be continuity If OK go to Step 4 If not OK replace the faulty starter assembly SOLENOID RR8BD33 Fig 9 Continuity Test Between S...

Page 369: ... is grounded through the park neutral position switch only when the gearshift selector lever is in the Park or Neutral positions On vehicles with a manual transmission it is grounded at all times Check for continuity to ground at the cavity for relay terminal 85 If not OK with an automatic transmission check for an open or short circuit to the park neutral position switch and repair if required If...

Page 370: ...uts from the terminal studs for the starter battery lead and solenoid lead Fig 10 or Fig 11 WIRE NUT AND WASHER 8 0 3 1 5 8 4 2 Fig 10 Starter Connector Remove Install V 6 V 8 Engine 4 Remove the hardware securing the starter to the bellhousing Fig 11 or Fig 12 5 Move the starter forward to clear the lower mounting stud V 6 V 8 engine and for the starter gear housing nose to clear the bellhousing ...

Page 371: ...Fig 15 Starter Mounting Bolt Diesei Engine 6 Remove the starter motor 7 Reverse the removal procedures to install Tighten the starter hardware as follows Starter mounting bolts 43 N m 32 ft lbs Solenoid lead nut 6 N m 55 in lbs Battery lead nut 10 N m 90 in lbs Fig 14 Starter Connectors Remove lnstaii Diesel Engine ...

Page 372: ...SYSTEM Starter and Solenoid Engine Application 3 9L 5 2L 5 9L Gas 8 0L 5 9L Diesel Manufacturer Nippon Denso Nippon Denso Nippon Denso Part Number 56027702 56004757 47410 Power Rating i 4 Kilowatt 1 4 Kilowatt 2 7 Kilowatt Voltage 12 Volts 12 Volts 12 Volts Number of Fields 4 4 4 Number of Poles 4 4 4 Number of Brushes 4 4 4 Drive Type Reduction Gear Train Reduction Gear Train Conventional Gear Tr...

Page 373: ... for any failure it detects See the On Board Diagnostics Test in Group 8C Charging System for more information page CHARGING SYSTEM 2 CURRENT OUTPUT TEST 3 ON BOARD DIAGNOSTIC SYSTEM TEST 6 REMOVAL AND INSTALLATION BATTERY TEMPERATURE SENSOR 8 GENERATOR 7 SPECIFICATIONS GENERATOR RATINGS 9 TORQUE SPECIFICATIONS 9 DESCRIPTION AND OPERATION CHARGING SYSTEM OPERATION The charging system consists of G...

Page 374: ...sted fan drive belt loose mounting bolts a misaligned drive pulley or a defective stator or diode BATTERY TEMPERATURE SENSOR The battery temperature sensor is used to deter mine the battery temperature and control battery charging rate This temperature data along with data from monitored line voltage Is used by the PCM to vary the battery charging rate System voltage will be higher at colder tempe...

Page 375: ... See Group 8A Battery for more information 2 Check condition of battery cables at battery Clean if necessary 3 Start the engine and allow it to reach normal operating temperature 4 Shut engine off 5 Connect an engine tachometer 6 Fully engage the parking brake T E S T 1 Start engine 2 Place heater blower in high position 3 Turn on headlamps and place in high beam position 4 Turn vehicle interior l...

Page 376: ...OUP 7 COOLING SYSTEM FOR ACCESSORY DRIVE BELTS CHECK GENERATOR GROUND PATH CLEAN MOUNTING SURFACES YES TIGHTEN FASTENERS TO SPECIFIED TORQUE CHECK ON BOARD DIAGNOSTIC TROUBLE CODES DTC f PERFORM OUTPUT VOLTAGE TEST REFER TO YES OVERCHARGE TEST REFER TO LOW OR NO VOLTAGE TEST CHARGING SYSTEM AND GENERATOR IS OK Charging System Test ...

Page 377: ...o refer to the operating instructions supplied with test equipment 11 Connect the inductive clamp ammeter probe Refer to the operating instructions supplied with test equipment 12 If volt amp tester is not equipped with an engine tachometer connect a separate tachometer to the engine TEST 1 1 Perform the previous test Preparation 2 Fully engage the parking brake 3 Start engine 4 Bring engine speed...

Page 378: ... Powertrain Diag nostic Procedures manual To test the sensor only refer to the following BR 1 The sensor is located under the battery and is attached snapped into the battery tray Fig 1 A two wire pigtail harness is attached directly to the sensor The opposite end of this harness connects the sensor to the engine wiring harness 2 Disconnect the two wire pigtail harness from the engine harness 3 At...

Page 379: ...tion indicator Check Engine lamp will display a DTC by flashing on and off There is a short pause between flashes and a longer pause between digits AH DTCs displayed are two digit numbers with a four second pause between codes An example of a DTC is as follows 1 Lamp on for 2 seconds then turns off 2 Lamp flashes 4 times pauses and then flashes 1 time 3 Lamp pauses for 4 seconds flashes 4 times pa...

Page 380: ...ics in Group 7 Cooling System BATTERY TEMPERATURE SENSOR The battery temperature sensor is located under the vehicle battery Fig 6 and is attached snapped into a mounting hole on battery tray On models equipped with a diesel engine dual batteries only one sensor is used The sensor is located under the battery on drivers side of vehicle BATTERY 8056d9f6 Fig 6 Battery Temperature Sensor Location REM...

Page 381: ... 9L 5 2L 5 9L 90 DENSO 53008651 136 3 9L 5 2L 5 9L 120 DENSO 56027221 136 DIESEL 120 TORQUE SPECiFiCATiOIS DESCEIPTION TOEQUE Generator Mounting Bolt All Engines 41 N m 30 ft lbs Generator Pivot Bolt All Engines 41 N m 30 ft lbs Battery Terminal N u t 8 5 N m 75 in lbs Ground Terminal N u t 8 5 N m 75 in lbs Harness Hold down Nut 8 5 N m 75 in lbs Field Terminal Nuts 2 8 N m 25 in lbs ...

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Page 383: ...T 8 0L V 10 ENGINE 13 CAMSHAFT POSITION SENSOR 3 9L 5 2L 5 9L ENGINES 12 CRANKSHAFT POSITION SENSOR T E S T 8 0L V 10 ENGINE 12 page CRANKSHAFT POSITION SENSOR 3 9L 5 2L 5 9L ENGINE 11 DISTRIBUTOR CAP 3 9L 5 2L 5 9L ENGINES 11 DISTRIBUTOR ROTOR 3 9L 5 2L 5 9L ENGINES 11 ENGINE COOLANT TEMPERATURE SENSOR 14 FAILURE TO START TEST 3 9L 5 2L 5 9L ENGINES 9 IGNITION COIL PACK TESTS 8 0L V 10 ENGINE 8 I...

Page 384: ...identical Similar ities and differences between the systems will be dis cussed The ignition system is controlled by the powertrain control module PCM on all engines The ignition system consists of Spark Plugs Ignition Coil Secondary Ignition Cables Distributor contains rotor and camshaft position sensor Powertrain Control Module PCM Also to be considered part of the ignition system are certain inp...

Page 385: ... the spark plugs and examine them for burned elec trodes and fouled cracked or broken porcelain insu lators Keep plugs arranged in the order in which they were removed from the engine A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder Replace spark plugs at the intervals recommended in Group O Lubrication and Maintenance Spark plugs that ha...

Page 386: ...of its functions the ASD relay will supply bat tery voltage to the ignition coil The ground circuit for the ASD relay is controlled by the Powertrain Control Module PCM The PCM regulates ASD relay operation by switching the ground circuit on and off AUTOMATIC SHUTDOWN ASi RELAY 8 0L V 10 ENGINE As one of its functions the ASD relay will supply battery voltage to each of the 5 independent ignition ...

Page 387: ... located on the right lower side of the cylinder block forward of the right engine mount just above the oil pan rail Fig 6 Fig 6 Crankshaft Position Sensor 8 0L V 10 Engine The crankshaft position sensor detects notches machined into the middle of the crankshaft Fig 7 Fig 7 Sensor Operation 8 0L V 10 Engine There are five sets of notches Each set contains two notches Basic ignition timing is deter...

Page 388: ...t front side of the engine Fig 8 CAMSHAFT POSITION SENSOR Fig 8 Camshaft Position Sensor Location 8 0L V 10 Engine The camshaft position sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events It is also used to synchronize the fuel injectors with their respective cylinders The sensor generates electrical pulses These pulses signal...

Page 389: ...iagnostic Procedures service manual To test the relay only refer to ASD and Fuel Pump Relays in Group 14 Fuel System Fig 10 Power Distribution Center TESTING FOR SPARK AT COIL 3 9L 5 2L 5 9L ENGINES CAUTION When disconnecting a high voltage cable from a spark plug or from the distributor cap twist the rubber boot slightly 1 2 turn to break it loose Fig 11 Grasp the boot not the cable and pull it o...

Page 390: ...t B R If the ignition coil is being replaced the secondary spark plug cable must also be checked Replace cable if it has been burned or damaged Arcing at the tower will carbonize the cable boot which if it is connected to a new ignition coil will cause the coil to fail If the secondary coil cable shows any signs of dam age it should be replaced with a new cable and new terminal Carbon tracking on ...

Page 391: ...cking Coil Secondary Resistance Front Coils 8 0L V 10 Engine FAILURE TO START TEST 3 9L 5 2L 5 9L ENGINES To prevent unnecessary diagnostic time and wrong test results the Testing For Spark At Coil test should be performed prior to this test WARNING SET PARKING BRAKE OR BLOCK THE DRIVE WHEELS BEFORE PROCEEDING WITH THIS TEST 1 Unplug the ignition coil harness connector at the coil Fig 13 OHMMETER ...

Page 392: ...k the pow ertrain control module circuit Refer to On Board Diagnostics in Group 14 Fuel Systems If voltage remains at or near battery voltage during the entire 5 seconds turn the key off Remove the three 32 way connectors Fig 20 from the PCM Check 32 way connectors for any spread terminals or corrosion POWERTRAI CONTROL MODULE Fig 20 PCM and Three 32 Way Connectors 6 Remove test lead from the coil...

Page 393: ... charred com pound Test the spring for insufficient tension Replace a rotor that displays any of these adverse conditions INSUFFICIENT SPRING TENSION CORRODED EVIDENCE OF PHYSICAL CONTACT WITH CAP J908D 48 Fig 24 Rotor inspection Typical IGNITION TIMING NOTE Base initial ignition timing is NOT adjust able on any engine On 3 9L75 2L 5 9L engines do not attempt to adjust ignition timing by rotating ...

Page 394: ...f the right engine mount just above the oil pan rail Fig 27 BR Fig 27 Crankshaft Position Sensor 8 01 10 Engine Typical To perform a complete test of this sensor and its circuitry refer to the DRB scan tool Also refer to the appropriate Powertrain Diagnostics Procedures man ual To test the sensor only refer to the following 1 Raise and support the vehicle 2 Disconnect the sensor pigtail harness fr...

Page 395: ...9 If voltage is still not present perform vehicle test using the DRB scan tool 10 If voltage is present at cavity A 17 but not at the supply wire a Check continuity between the supply wire This is checked between the distributor connector and cavity A 17 at the PCM If continuity Is not present repair the harness as necessary b Check for continuity between the camshaft position sensor output wire a...

Page 396: ...ondition the engine rpm should drop and the engine will run poorly If engine rpm does not drop the cable and or spark plug may not be operat ing properly and should be replaced Also check engine cylinder compression With the engine not running connect one end of a test probe to a good ground Start the engine and run the other end of the test probe along the entire length of all spark plug cables I...

Page 397: ...si cally carbon Fig 32 A dry black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables Cold carbon fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operat ing times short trips WET FOULING OR GAS FOULING A spark plug coated with excessive wet fuel or oil is wet fouled In older engines worn pis...

Page 398: ...adjusting the spark plug electrode gap Under certain conditions severe detonation can also separate the insulator from the center electrode Fig 36 Spark plugs with this condition must be replaced rs ro GROUND ELECTRODE J908D 13 Fig 36 Chipped Electrode Insulator PREMONITION DAMAGE Preignition damage is usually caused by excessive combustion chamber temperature The center elec trode dissolves first...

Page 399: ...urn to break it loose Fig 39 Grasp the boot not the cable and pull it off with a steady even force SPARK PLUG BOOT PULLER SPARK PLUG CABLE AND BOOT TWIST AND PULL Install cables into the proper engine cylinder firing order Fig 40 Fig 41 or Fig 42 o FRONT OF ENGINE CLOCKWISE ROTATION 1 6 5 4 3 2 J9314 80 Fig 40 Engine Firing Order 3 9 L V 6 Engine o FRONT OF ENGINE CLOCKWISE ROTATION 1 8 4 3 6 5 7 ...

Page 400: ...irectly on the cable Internal damage to cable will result 2 Prior to removing the spark plug spray com pressed air around the spark plug hole and the area around the spark plug This will help prevent foreign material from entering the combustion chamber 3 Remove the spark plug using a quality socket with a rubber or foam insert 4 Inspect the spark plug condition Refer to Spark Plug Condition in th...

Page 401: ...with the same type REMOVAL 3 9L V 6 or 5 2 5 9L V 8 LDC Gas Engines The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head Fig 45 This bracket is mounted on top of the automatic belt tensioner bracket using common bolts 5 9L V 8 HDC Gas Engine The coil is mounted to a bracket that is bolted to the air injection pump AIR pump mounting bracket Fig 46 1 Disconn...

Page 402: ...tors face downward 2 Install coil pack mounting bolts Tighten bolts to 10 N m 90 in lbs torque 3 Install coil pack to engine mounting bracket if necessary 4 Connect primary wiring connectors to coil packs four wire connector to front coil pack and three wire connector to rear coil pack 5 Connect secondary spark plug cables to coil packs Refer to Fig 48 for correct cable order AUTOMATIC SHUTDOWN AS...

Page 403: ...m The sensor is bolted to the top of the cylinder block near the rear of right cylinder head Fig 51 1 Remove the air cleaner assembly and its plastic air intake tube 2 Remove the spark plug cable loom and spark plug cables from valve cover mounting stud at rear of right valve cover Fig 51 Position spark plug cables to top of valve cover 3 Disconnect 2 hoses at Exhaust Gas Recircula tion EGR valve ...

Page 404: ...o engine and tighten to 14 N m 130 in lbs torque install electrical connector to sending unit 6 Clean the intake manifold and EGR valve of any old gasket material 7 Install a new EGR valve gasket at intake man ifold 8 Install EGR valve to intake manifold Tighten 2 bolts to 23 N m 200 in lbs torque 9 Position EGR valve control and install its elec trical connector Connect hoses between EGR valve an...

Page 405: ...shaft position sensor wiring harness from main engine wiring harness 5 Remove distributor rotor from distributor shaft 6 Lift the camshaft position sensor assembly from the distributor housing Fig 56 INSTALLATION 1 Install camshaft position sensor to distributor Align sensor into notch on distributor housing 2 Connect wiring harness 8 Install rotor 4 install distributor cap Tighten mounting screws...

Page 406: ...rs are of a certain thickness and are to be used as a tool to set sensor depth 3 Clean the face of sensor and apply paper spacer Fig 58 4 Apply a small amount of engine oil to the sen sor o ring Fig 59 A low and high area are machined into the cam shaft drive gear Fig 60 The sensor is positioned in the timing gear cover so that a small air gap Fig 60 exists between the face of sensor and the high ...

Page 407: ... opening on the timing gear cover Do not install sensor with gear positioned at low area Fig 61 or Fig 60 When the engine is started the sensor will be broken 2 Using a 1 2 in wide metal ruler measure the distance from the cam gear to the face of the sensor mounting hole opening on the timing gear cover Fig 61 3 If the dimension is approximately 1 818 inches it is OK to install sensor Proceed to s...

Page 408: ...over Alignment Marks Typical 8 The distributor rotor should now be aligned to the CYL NO 1 alignment mark stamped into the camshaft position sensor Fig 63 i f not rotate the crankshaft through another complete 360 degree turn Note the position of the number one cylinder spark plug cable on the cap in relation to rotor Rotor should now be aligned to this position 9 Disconnect camshaft position sens...

Page 409: ...ections on the DRB screen and start the engine With the engine running the words IN RANGE should appear on the screen along with 0 This indicates correct distributor position If a plus or a minus is displayed next to the degree number and or the degree displayed is not zero loosen but do not remove the distributor hold down clamp bolt Rotate the distributor until IN RANGE appears on the screen Con...

Page 410: ...tion switch Fig 68 7 To remove key cylinder from ignition switch KEY IN SWITCH MULTI FUNCTION Fig 68 Key ln Switch and Halo Lamp Connector a Insert key in ignition switch Turn key to LOCK position Using a TTXR20A2 or equivalent torx bit remove key cylinder retaining screw and bracket Fig 69 or Fig 70 b Rotate key clockwise to the OFF position Key cylinder will unseat from ignition switch Fig 71 Wh...

Page 411: ...ated In wiring connectors 2 Before attaching ignition switch to a tilt steer ing column the transmission shifter must be In Park position The park lock dowel pin and column lock flag must also be properly indexed before installing switch Fig 73 908D 18 Fig 73 Ignition Switch View From Column a Place transmission shifter in PARK position b Place ignition switch in lock position The switch is in the...

Page 412: ...cable to battery 12 Check for proper operation of halo light shift lock if applicable and column lock Also check for proper operation of ignition switch accessory lock off run and start positions COLUMN SHIFT INTERLOCK The column shift interlock is used to lock the transmission shifter in the Park position when the key is in the Off position The interlock device is located within the steering colu...

Page 413: ... used 5 N m 50 in lbs Ignition Coil Mounting 3 9L 5 2L 5 9L Engines if nuts bolts are used 11 N m 100 in lbs Ignition Coil Mounting 8 0L Engine 10 N m 90 in lbs Powertrain Control Module PCM Mounting Screws 1 N m 9 in lbs Spark Plugs all engines 41 N m 30 ft lbs SPA1I PLUGS Engine Spark Plug Application Gap lightening Torque Size Engine Original Equipment Replacement Application Gap lightening Tor...

Page 414: ...MANUFACTURER PRSMARY RESISTANCE 21 27 C 7 0 8 0 F SECONDARY RESISTANCE 21 27 C 70 80 F Diamond 0 97 1 18 Ohms 11 300 15 300 Ohms Toyodenso 0 95 1 20 Ohms 11 300 13 300 Ohms IGNITION COIL RESISTANCE 8 0L 4 0 ENGINE JVS8D 2 Primary Resistance 0 53 to 0 65 ohms Secondary Resistance 10 9 to 14 7 K ohms Test across the primary connector Refer to text for test procedures Test across the individual coil ...

Page 415: ...MP 5 WARNING LAMP 16 HAZARD WARNING INDICATOR LAMP 5 TRIP ODOMETER 10 HEADLAMP HIGH BEAM INDICATOR LAMP 5 TURN SIGNAL INDICATOR LAMPS 16 LOW FUEL WARNING LAMP 5 UPSHIFT INDICATOR LAMP 17 LOW OIL PRESSURE WARNING LAMP 6 VOLTMETER 10 LOW WASHER FLUID WARNING LAMP 6 WAIT TO START LAMP 17 MAINTENANCE REQUIRED INDICATOR LAMP 6 WATER IN FUEL LAMP 17 MALFUNCTION INDICATOR LAMP 6 REMOVAL AND INSTALLATION ...

Page 416: ...e group refer to the Component and System Index at the back of this manual Refer to Group 8W Wir ing Diagrams for complete circuit descriptions and diagrams INSTRUMENT PANEL Modular instrument panel construction allows all of the gauges and controls to be serviced from the front of the panel In addition most of the instru ment panel wiring or heating and air conditioning components can be accessed...

Page 417: ...tachometer The gauge needle moves as the movable permanent magnet aligns itself to the changing magnetic fields created around It by the electromagnets INDICATOR LAMPS Indicator lamps are located in several areas of the instrument cluster and the instrument panel Those lamps within the gauge area of the cluster are served by the cluster printed circuit s and cluster connec tors Those lamps located...

Page 418: ...rmation TACHOMETER The tachometer gives an indication of the engine speed in revolutions per minute rpm With the engine running the tachometer receives an engine speed pulse signal from the powertrain control mod ule An electronic integrated circuit contained within the tachometer unit reads and analyzes this pulse signal It then adjusts the ground path resistance for one of the electromagnets in ...

Page 419: ...battery voltage is supplied to one side of the indicator lamp bulb A normally open plunger type four wheel drive switch is threaded into the front axle disconnect housing The switch is connected in series between the other side of the indicator lamp bulb and ground When the vacuum actuated front axle disconnect is engaged providing four wheel drive the plunger of the four wheel drive switch is mov...

Page 420: ...on MALFUNCTION INDICATOR LAMP The Check Engine or Malfunction Indicator Lamp MIL lights each time the ignition switch is turned to the On position and stays on for three seconds as a bulb test If the Powertrain Control Module PCM receives an incorrect signal or no signal from certain fuel or emission system related circuits or compo nents the lamp is turned on This indicates that the PCM has recor...

Page 421: ... heading for that gauge or lamp For circuit descriptions and diagrams refer to 8W 40 Instrument Cluster in Group 8W Wiring Diagrams If more than one gauge or lamp is inoperative perform the following 1 Check the fuse in the fuseblock module If OK go to Step 2 If not OK replace the faulty fuse 2 Check for battery voltage at the fuse with the ignition switch in the On position If OK go to Step 3 If ...

Page 422: ... to Step 2 If not OK go to Step 3 Fig 1 Cooiant Temperature Sending Unit V 6 V 8 Engine 2 Install a jumper wire from the sending unit connector to a good ground The gauge needle should move to the high end of the gauge scale If OK replace the faulty sending unit If not OK remove the jumper wire and go to Step 3 3 Turn the ignition switch to the Off position Disconnect and isolate the battery negat...

Page 423: ... sor signal circuit cavities of the right cluster connec tor and the fuel pump module connector There should be continuity If OK replace the faulty gauge If not OK repair the open circuit as required OIL PRESSURE OAUIE The diagnosis found here addresses an inoperative gauge condition If the problem being diagnosed is related to gauge accuracy be certain to confirm that the problem is with the gaug...

Page 424: ...cir cuit as required TACHOMETER For circuit descriptions and diagrams refer to 8W 40 Instrument Cluster in Group 8W Wiring Diagrams 1 With the engine running check for a tachome ter signal at the tachometer signal circuit cavity of the PCM connector C gray See the Tachometer Cal ibration chart in Specifications at the back of this group for the frequency ranges If OK go to Step 2 If not OK refer t...

Page 425: ...zel and the cluster assembly 2 Connect the battery negative cable Check for battery voltage between the fused ignition switch output circuit and the ABS warning lamp driver cir cuit cavities of the right cluster connector within five seconds of turning the ignition switch to the On posi tion If OK replace the faulty bulb If not OK go to Step 3 3 Disconnect and isolate the battery negative cable Di...

Page 426: ...e fuseblock module Rotate the headlamp switch knob clockwise while observing the test voltmeter The reading should go from battery voltage to zero volts If OK go to Step 3 If not OK repair the open circuit to the headlamp switch or refer to Group 8L Lamps to diagnose the headlamp switch 3 Disconnect and Isolate the battery negative cable Remove the instrument cluster bezel and the cluster assembly...

Page 427: ...ht If OK go to Step 3 If not OK replace the faulty bulb 3 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable The PCM connector C is still unplugged Unplug the right cluster connector Probe the generator lamp driver circuit cavity of the right cluster connector and check for continuity to a good ground There should be no continuity If OK go to Step 4 If n...

Page 428: ...he jumper wire and the lamp should go off If OK replace the faulty sending unit If not OK go to Step 2 Fig 7 Oii Pressure Switch Sending Unit V 6 V 8 Engine 2 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Remove the instrument cluster bezel and the cluster assembly Disconnect the right cluster connector 3 Probe the oil pressure switch sense circuit ...

Page 429: ...light If OK remove the jumper wire and go to Step 3 If not OK replace the faulty bulb 3 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Unplug the message center connector Check for con tinuity between the service reminder indicator lamp driver circuit cavity of the message center connector and a good ground There should be no continuity I f OK go to ...

Page 430: ...cable Turn the ignition switch to the On position Check for bat tery voltage at the fused ignition switch output cir cuit cavity of the message center connector I f OK go to Step 2 If not OK repair the open circuit as required 2 Turn the ignition switch to the Off position Install a jumper wire between the transmission tem perature lamp driver circuit cavity of the message center connector and a g...

Page 431: ...short or open in the lamp circuit For circuit descriptions and dia grams refer to 8W 46 Message Center in Group 8W Wiring Diagrams 1 Disconnect and isolate the battery negative cable Remove the instrument cluster bezel and the message center Unplug the message center connec tor 2 Connect the battery negative cable Turn the Ignition switch to the ON position Check for battery voltage at the fused i...

Page 432: ...emove lnstaii 3 Remove the ash receiver bracket assembly from the instrument panel 4 Reverse the removal procedures to install CUP HOLDER 1 Open the cup holder and remove the two screws securing the assembly to the instrument panel Fig 11 2 Remove the cup holder assembly from the instrument panel 3 Reverse the removal procedures to install KNEE BLOCKER 1 Remove the five screws securing the knee bl...

Page 433: ... Remove the cluster bezel as described in this group 2 Unscrew the cigar lighter and or power outlet housing from the rear of the cluster bezel Fig 15 ELECTRICAL CONNECTOR CLIPS J948E 10 Fig 15 Cigar Lighter Remove Install 3 Remove the cigar lighter and or power outlet from the front of the cluster bezel 4 Reverse the removal procedures to install INSTRUMENT CLUSTER 1 Remove the cluster bezel as d...

Page 434: ... the lens and mask to the cluster housing Fig 19 3 Remove the cluster lens and the gauge mask Fig 20 NOTE Do not touch the face of a gauge or the back of the lens with your finger It will leave a per manent finger print REMOVE SCREWS REMOVE SCREWS J948E 13 Fig 19 Cluster Lens Remove Install LENS GAUGE BEZEL MOUNTING BEZEL AND GAUGES PRND21 CABLE RETAINER J948E 14 Fig 20 Instrument Cluster Assembly...

Page 435: ...f TURN SIGNAL INDICATORS HIGH BEAM INDICATOR LOW FUEL Fig 21 Gauge Mounting SPEEDOMETER SCREWS High Line Cluster FUEL GAUGE SCREWS J948E 22 OIL PRESSURE GAUGE SCREWS 1 ILLUMINATION 2 TURN SIGNAL INDICATORS 3 HIGH BEAM INDICATOR 4 ABS 5 MAINTENANCE INDICATOR 6 BRAKE 7 UPSHIFT INDICATOR 8 SEAT BELT WARNING LAMP 9 MALFUNCTION INDICATOR CHECK ENGINE 10 LOW OIL INDICATOR 11 AIRBAG 12 4WD INDICATOR J948...

Page 436: ...ve the left turn signal bulb and cluster illumination bulb O FUEL CIRCUIT CONNECTOR J 9 4 8 E 5 9 Fig 24 Low Fuel Warning Circuit Connector 4 Pull the flexible printed circuit back away from the rear of the cluster housing 5 Remove the low fuel warning circuit 6 Reverse the removal procedures to install PRINTED CIRCUIT 1 Remove the instrument cluster as described in this group 2 Remove all of the ...

Page 437: ...ve instali 3 Reverse the removal procedures to install Tighten coupling nut to 17 N m 150 in lbs MESSAGE CENTER 1 Remove the cluster bezel as described in this group 2 Remove the four message center heater A C control attaching screws Fig 27 3 Pull the message center and heater A C control assembly rearward J948E 7 Fig 28 Message Center and Heater A C Controi Connectors 5 Push in on the red temper...

Page 438: ...stem assembly out to its stop Depress the release button on the bottom of the switch housing and remove the knob and stem from the switch 6 Remove the two screws and the switch bezel from the housing 7 Reverse the removal procedures to install OVERDRIVE LOCKOUT FOG LAMP SWITCH 1 Remove the cluster bezel as described in this group 2 Remove the three screws from the switch bezel and remove the switc...

Page 439: ...snap fit 4 To remove the latch striker remove the two mounting screws Fig 34 5 Disconnect the wires to the switch and lamp Fig 35 6 Remove the bulb from the lamp socket 7 Reverse the removal procedures to install NOTE Tuck any wiring that was exposed by the lamp removal procedure back into the recess behind the lamp Do not leave wires exposed in the glove box latch area REMOVE SCREWS GLOVE BOX LAM...

Page 440: ...Support Remove Install 7 Unplug the airbag wiring connector at the lower left corner of the instrument panel 8 Pull the gearshift selector PRND21 indicator cable and twist to remove it from the position arm on the steering column Fig 37 9 Push tab on bottom of cable retainer up then squeeze sides to remove retainer from column 10 Remove the tilt steering column lever if equipped 11 Remove the uppe...

Page 441: ...1 Fig 41 Steering Column Toe Plate 18 Remove the two nuts and washers attaching the steering column bracket to the Instrument panel steering column support bracket Fig 42 19 Lower the steering column and allow It to rest on the seat 20 Remove the two screws from the bottom of the Airbag Control Module ACM cover Fig 43 21 Remove the four screws holding the ACM to the transmission tunnel on the floo...

Page 442: ... instrument panel down 30 Using a screwdriver or pointed tool push through the plastic flashing to release the locking tab on heater A C temperature control cable Fig 45 LOCKING Fig 45 Heat A C Temperature Controi Cable Remove 31 Pull the temperature control cable from the top of the heater A C housing 32 Remove the instrument panel from the vehi cle 33 Reverse the removal procedures to install Be...

Page 443: ...tion Resistance Low Normal 65 ohms 3 65 ohms High Normal 4 24 5 ohms Speedometer Calibration Pointer Position Frequency 20 mph 3 0 41 1 Hz 55 mph 2 5 118 8 Hz 75 mph 2 5 163 2 Hz Tachometer Calibration Engines Pointer Position Frequency l 6 V 6 V 8 3000 rpm 200 100 Hz V 10 3000 rpm 200 125 Hz Temperature Gauge Calibration Engine Pointer Position Resistance Gas Low Normal 3 361 7 ohms Gas High Norm...

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Page 445: ...vent battery discharge during vehicle storage When removing or installing the IOD fuse it is important that the ignition switch be in the Off posi tion Failure to place the ignition switch in the Off position can cause the radio display to become scram bled when the IOD fuse is removed and replaced Removing and replacing the IOD fuse again with the ignition switch in the Off position will correct ...

Page 446: ...ed in the case of RFI or EMI noise complaints include the following Radio antenna base ground Radio chassis ground wire strap or bracket Engine to body ground strap if equipped Cab to bed ground strap if equipped Heater core ground strap if equipped Resistor type spark plugs Radio suppression type secondary ignition wir ing In addition if the source of RFI or EMI noise is identified as a component...

Page 447: ...orroded radio connector Repair if required 3 Check for battery voltage at radio connector Repair wiring if required 4 Check for continuity between radio chassis and a known good ground There should be continuity Repair ground if required 5 Exchange or replace radio if required NO MEMORY 1 Fuse faulty 2 Radio connector faulty 3 Wiring faulty 4 Ground faulty 5 Radio faulty 1 Check ignition off draw ...

Page 448: ... negative cable Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output circuit cavity of the left gray radio connector If OK go to Step 6 If not OK repair the open circuit as required 6 Turn the ignition switch to the Off position Check for battery voltage at the fused B circuit cavity of the left gray radio connector If OK replace the faulty radi...

Page 449: ...pair the open circuit as required 3 Unplug the choke relay harness connector Check for battery voltage at the fused B circuit cavity of the choke relay connector If OK go to Step 4 If not OK repair the open circuit as required 4 Probe the ground circuit cavity of the choke re lay connector Check for continuity to a good ground There should be continuity I f OK go to Step 5 If not OK repair the ope...

Page 450: ...pair the ground strap connection if required TEST 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows 1 Connect one ohmmeter test lead to the fender and the other lead to the crimp on the coaxial antenna cable shield 2 The resistance should be less then one ohm 3 If the resistance is more then one ohm clean and or tighten antenna base to fender moun...

Page 451: ...om the instrument panel far enough to disconnect the wiring and the antenna coaxial cable Fig 7 9 Remove the screw from the radio ground strap and remove the radio 10 Reverse the removal procedures to install SPEAKERS FRONT DOOR 1 Disconnect and isolate the battery negative cable ANTENNA J948F 6 Fig 7 Radio Connectors 2 Remove the two screws in the door pull cup and remove the cup Fig 8 REMOVE 2 S...

Page 452: ...ower mirrors pull the power mirror switch control knob rearward to remove it from the switch stem Fig 12 Fig 12 Power Mirror Switch Knob Remove Install 8 Remove the mirror switch retaining nut from the switch Fig 13 Fig 13 Power Mirror Switch Nut 9 Using a wide flat bladed tool such as a trim stick pry the trim panel away from the door around the perimeter and remove the trim panel NOTE To aid in ...

Page 453: ...tery negative cable 2 Remove the five screws securing the knee blocker to the lower instrument panel and remove the knee blocker Fig 15 3 If equipped remove the two screws holding the bottom of the RWAL module bracket to the instru ment panel brace Fig 16 4 If equipped remove the screw holding the top of the RWAL module bracket to the instrument panel and remove the module Fig 17 5 Remove the two ...

Page 454: ...Fig 20 5 Lower the antenna assembly through the fender far enough to gain access to the antenna body Fig 21 6 Remove the antenna body and cable by pulling the coaxial cable and grommet out through the Fig 21 Antenna Mounting Typical engine compartment side of the dash panel outboard of the powertrain control module then through the opening in the cowl side reinforcement 7 To install the antenna bo...

Page 455: ...H Two horn switches are installed in the steering wheel one on each side of the center mounted driv er s airbag module When either switch is depressed it completes a circuit to ground for the coil side of the page HORN SWITCH 2 HORN 2 REMOVAL AND INSTALLATION HORN RELAY 3 HORN SWITCH 3 HORN 4 horn relay The steering wheel and steering column must be properly grounded for the horn switches to funct...

Page 456: ...scriptions and diagrams refer to 8W 41 Horns Cigar Lighter in Group 8W Wiring Diagrams WARNING ON EHICLES EQUIPPED WITH AN AIR BAG REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative c...

Page 457: ...H AN AIRBAG REFER TO GROUP 8 1 PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL OR STEERING COLUMN COMPONENT DIAGNOSIS OR SERVICE FAIL URE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Wait two minutes for the airbag system capac itor to discharge before further service 2 From t...

Page 458: ...wire connectors and remove the horn switch assembly Fig 7 Fig 7 Horn Switch Connectors 8 Reverse the removal procedures to install Tighten the airbag module mounting nuts to 1 5 N m 15 in lbs HORN 1 Disconnect and Isolate the battery negative cable 2 Raise and support the vehicle 3 Disconnect the horn s wiring connector s Fig 8 Fig 8 Horn Remove install 4 Remove the bolt holding the horn bracket t...

Page 459: ... steering wheel below the driver s airbag module Three momentary contact switches sup page SPEED CONTROL SERVO 8 SPEED CONTROL SWITCH 7 STOP LAMP SWITCH 8 VACUUM SUPPLY TEST 8 VEHICLE SPEED SENSOR 7 REMOVAL AND INSTALLATION POWERTRAIN CONTROL MODULE 11 SERVO CABLE 11 SPEED CONTROL SERVO 9 SPEED CONTROL SWITCH 11 STOP LAMP SWITCH 11 VACUUM RESERVOIR 13 VEHICLE SPEED SENSOR 13 SPECIFICATIONS TORQUE ...

Page 460: ...a problem which might cause surging in the speed control sys tem The cause of any speedometer problems should be corrected before proceeding Refer to Group 8E Instrument Panel and Gauges for speedometer diag nosis If a road test verifies a system problem and the speedometer operates properly check for A misadjusted brake stop lamp switch This could also cause an intermittent problem Loose or corro...

Page 461: ...SSED AND RELEASED FUSE BLOWN NO VACUUM AT SERVO SPEED CONTRQt THROTTLE CABLE DISCONNECTED IMPROPER STOP LAMP SWITCH ADJUSTMENT FAULTY ELECTRICAL CIRCUIT DEFECTIVE SERVO DEFECTIVE VACUUM RESERVOIR HIJIIflfiG StJiGE O R V A R I A T I O N S A T L O W SPIIDS REMOVE FOOT FROM ACCELERATOR SPEED SHOULD BE CONTROLLED TORQUE CONVERTER CLUTCH ROUGHNESS AMPLIFICATION OF ENGINE SURGE _ t DEFECTIVE SERVO DEFEC...

Page 462: ...LD RESUME PREVIOUSLY MEMORIZED SPEED VEHICLE RESUMES SPEED I DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE SPEED CONTROL DISENGAGES DEFECTIVE SWITCH I FAULTY ELECTRICAL CIRCUIT NO SYSTEM DISENGAGEMENT WHEN SHAKE PEDAL IS DEPRESSED I DEFECTIVE OR IMPROPERLY ADJUSTED STOP LAMP AND SPEED CONTROL SWITCH I SPEED CONTROL THROTTLE CABLE KINKED OR DAMAGED I FAULTY ELECTRICAL CIRCUIT I DEFECTIVE SERVO...

Page 463: ...ULD BE CONTROLLED N O SPEED CONTROL WMm SB MSB BUTTON IS PRESSED AND REUA5ED FUSE BLOWN INSUFFICIENT VACUUM AT SERVO SPEED CONTROL THROTTLE CABLE DISCONNECTED IMPROPER STOP LAMP SWITCH ADJUSTMENT FAULTY ELECTRICAL CIRCUIT HUNTING SURGE OR SKID VARIATION AflOW TORQUE CONVERTER CLUTCH ROUGHNESS AMPLIFICATION OF ENGINE SURGE T DEFECTIVE SERVO t DEFECTIVE CABLE DEFECTIVE POWERTRAIN CONTROL MODULE EXCE...

Page 464: ...GAGES PUSH RESUME ACCEL SWITCH VEHICLE SHOULD RESUME PREVIOUSLY MEMORIZED SPEED VEHICLE RESUMES SPEED DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE DEFECTIVE OR IMPROPERLY ADJUSTED STOP LAMP SWITCH SPEED CONTROL THROTTLE CABLE KINKED OR DAMAGED FAULTY ELECTRICAL CIRCUIT DEFECTIVE SERVO SPEED CONTROL DISENGAGES DEFECTIVE SWITCH NO SYSTEM DISENGAGE WHEN BRAKE PEDAL IS DEPRESSED FAULTY ELECTRICA...

Page 465: ...cation CAUTION When test probing for voltage or conti nuity at electrical connectors care must be taken not to damage connector terminals or seals If these components are damaged intermittent or complete system failure may occur When electrical connections are removed corrosion should be removed from electrical terminals and a light coating of Mopar Multi Purpose Grease or equivalent should be app...

Page 466: ...gauge should read at least ten inches of mer cury 4 If vacuum does not meet this requirement check for vacuum leaks or poor engine performance On diesel powered engines refer to Group 5 Brakes for vacuum pump diagnosis SPEED CONTROL SERVO For complete speed control system diagnosis refer to the appropriate Powertrain Diagnostic Procedures manual To test the speed control servo only refer to the fo...

Page 467: ...e 2 nuts from cable sleeve 4 Pull speed control cable away from servo to expose cable hairpin clip 5 Remove hairpin clip attaching cable to servo 6 Pull servo away from mounting bracket INSTALLATION 1 Insert servo studs through holes in servo mounting bracket 2 With throttle blocked to full open position align hole in cable sleeve with hole in servo pin and install hairpin clip 3 Insert servo stud...

Page 468: ...attery tray to vehicle Fig 8 7 Lift battery tray up far enough for access to speed control servo electrical connector Fig 9 8 Unplug electrical connector 9 Remove 2 nuts from cable sleeve Fig 8 Battery Tray Mounting Fig 9 Servo Mounting 10 Pull speed control cable away from servo to expose cable hairpin clip Fig 10 11 Remove hairpin clip attaching cable to servo 12 Pull servo away from mounting br...

Page 469: ...R TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POS SIBLE PERSONAL INJURY REMOVAL 1 Disconnect and isolate negative battery cable from battery 2 From underside of steering wheel remove 2 speed control switch mounting screws Fig 11 CLOCKSPRING SWITCH 908M 1 Fig 11 Speed Control Switch Remove Install 3 Pull switch module assembly from wheel and...

Page 470: ...8H 12 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION Continued B R Fig 13 Servo Cable V 10 Engine ...

Page 471: ...ig 15 Removing Wiper Arms 2 Remove weather strip along front edge of cowl screen Fig 16 3 Release plastic anchor screws Fig 17 4 Move cowl screen aside far enough to access reservoir in right cowl plenum area 5 Remove 2 push nuts and slide vacuum reser voir off studs Fig 18 J948K 3 Fig 16 Cowl Screen Weatherstrip 6 Disconnect all hoses 7 Reverse removal procedures to install Refer to Group 8K Wipe...

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Page 473: ...L SYSTEM 1 iiAONOSIS AND TESTING HAZARD WARNING SYSTEM 3 INTRODUCTION 2 MULTI FUNCTION SWITCH 3 TURN SIGNAL SYSTEM 2 REiOWAL A N i INSTALLATION HAZARD WARNING TURN SIGNAL FLASHER 4 MULTI FUNCTION SWITCH 5 cators front park turn signal lamps and rear tail stop turn signal lamps will flash TURN SliNAL FLASHER The turn signal flasher contains one fixed contact point and one contact point attached to ...

Page 474: ... N D T E S T I N G INTRODUCTION When diagnosing the turn signal or hazard warn ing circuits remember that high generator output can burn out bulbs rapidly and repeatedly If this is a problem on the vehicle being diagnosed refer to Group 80 Charging System for further diagnosis WARNING ON VEHICLES EQUIPPED WITH AN AIR BAG REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL ...

Page 475: ...t of the same rating With the hazard warning switch in the On position the lamps should flash If OK discard the faulty flasher If not OK re install the original flasher and go to Step 4 WARNING ON VEHICLES EQUIPPED WITH AN AIR BAG REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL OR STEERING COLUMN COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COU...

Page 476: ... remove the snap in fuseblock module cover on the left end of the instru ment panel Fig 3 3 Unplug the flasher from the fuseblock module 4 To install the flasher align the terminals with the cavities in the fuseblock module and push the flasher firmly into place 5 Reverse the remaining removal procedures to complete the installation BUZZER MODULE Fig 3 Fuseblock Module VIEW FROM TERMINAL CASE SWIT...

Page 477: ... 4 Remove the lower fixed column shroud 5 Move the upper fixed column shroud to gain access to the rear of the multi function switch Fig 5 6 Remove the multi function switch tamper proof mounting screws a Snap On tamper proof torx bit TTXR20B2 or equivalent is required 7 Gently pull the switch away from the column Loosen the connector screw The screw will remain in the connector 8 Remove the wirin...

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Page 479: ...cally operated windshield washer system is standard equipment A reservoir in the engine com partment holds the washer fluid which is pressur ized by a pump when the washer multi function switch is actuated The washer pump feeds the pres surized washer fluid through the washer system plumbing to the washer nozzles An optional low washer fluid warning lamp on the instrument panel will warn the drive...

Page 480: ...s mounted to the wiper linkage and pivot module bracket with three screws The motor output shaft passes through a hole in the module bracket where a nut secures the wiper motor crank arm to the motor output shaft Wiper speed is controlled by current flow to the appropriate set of brashes The wiper motor com pletes its wipe cycle when the wiper washer multi function switch is turned to the Off posi...

Page 481: ...g are routed to the two nozzles which are snap fit into openings in the cowl plenum cover grille panel The hoses are clipped to the underside of the cowl plenum cover grille panel The two fluidic washer nozzles are not adjustable The nozzles cannot be repaired and if faulty must be replaced D I A G N O S I S A N D T E S T I N G WIPER AND WASHER SYSTEMS WARNING ON VEHICLES EQUIPPED WITH AN AIR BAG ...

Page 482: ...leaking plumbing 4 Wiring faulty 5 Switch faulty 6 Pump faulty 1 Fill reservoir if required 2 Drain and flush system if required 3 Re route pinched or kinked hoses Replace leaking hoses or fittings 4 Refer to Group 8W Wiring Diagrams Check continuity between switch and pump Repair wiring if required 5 See Multi Function Switch tests in this group Replace switch if required 6 See Washer Pump tests ...

Page 483: ... Disconnect the drive links from the motor If the motor now runs and draws less than 3 amps repair the linkage system If the motor contin ues to draw more than 3 amps replace the faulty motor assembly TERMINAL AMMETER Fig 3 Ammeter Between Terminal L and Battery 3 Check the motor wiring harness for a short between the high and low speed circuits Connect a voltmeter or test lamp to the motor ground...

Page 484: ...d P2 Fig 6 I f there is con tinuity between these terminals the problem is a faulty motor I f there is no continuity the problem is an open in the wiring or a faulty multi function switch OHMMETER TERMINALS Fig 6 Ohmmeter Between Terminal L and P2 MULTI FUNCTION SWITCH Perform the diagnosis for the wiper and or washer systems as described in this group before testing the multi function switch For ...

Page 485: ...tent wipe module WASHER PUMP For circuit descriptions and diagrams refer to 8W 53 Wipers in Group 8W Wiring Diagrams 1 Check for continuity between the ground cir cuit cavity of the pump connector and a good ground There should be continuity If OK go to Step 2 If not OK repair the open circuit as required 2 Turn the ignition switch to the On position Check for battery voltage at the washer pump co...

Page 486: ...nt the arms on the pivot shafts so that the distance of the wiper blade tip from the upper edge of the lower windshield blackout area is 22 mm 0 86 in BLACK OUT AREA Fig 9 Wiper Element Remove 4 Install the wiper blade on the wiper arm or the wiper element in the wiper blade as follows a To install the wiper blade on the wiper arm slide the blade retainer into the U shaped forma tion on the tip of...

Page 487: ...side 7 Remove the wiper linkage and pivots module mounting bolts Fig 15 8 Turn the wiper linkage module over and unplug the wiring harness and ground tab connectors from the wiper motor Fig 16 Fig 15 Linkage and Pivots Module Mounting Bolts Fig 16 Wiper Motor Connectors 9 Remove the drive links from the wiper motor crank arm by prying the retainer bushing from the crank arm ball stud with a suitab...

Page 488: ...e knee blocker as described in Group 8E Instrument Panel Systems 3 Unplug the harness connector from the inter mittent wipe module Fig 18 4 Disengage the intermittent wipe module snap fit mounting slot from the blade of the mounting bracket 5 Reverse the removal procedures to install MULTI FUNCTION SWITCH WARNING ON VEHICLES EQUIPPED WITH AN AIR BAG REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFO...

Page 489: ... screws 1 9 N m 17 in lbs WASHER PUMP AND RESERWOIR 1 Disconnect and isolate the battery negative cable 2 Drain the engine coolant and remove the upper radiator hose from the radiator Refer to Group 7 Cooling System for the procedures 3 Remove the hose from the washer pump and drain the washer fluid from the reservoir into a clean container for reuse 4 Unplug the connectors from the washer pump an...

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Page 491: ...higher candle power than indicated in the Bulb Application table at the end of this group Damage to lamp can result Do not use fuses circuit breakers or relays hav ing greater amperage value than indicated on the fuse panel or in the Owners Manual When it is necessary to remove components to ser vice another it should not be necessary to apply excessive force or bend a component to remove it Befor...

Page 492: ...circuit informa tion HEADLAMP DIAGNOSIS Always begin any diagnosis by testing all of the fuses and circuit breakers in the system Refer to Group 8W Wiring Diagrams Conventional and halogen headlamps are inter changeable It is recommended that they not be intermixed on a given vehicle ...

Page 493: ...r to Group 8W HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 2 Poor headlamp circuit ground 3 High resistance in headlamp circuit 4 Both headlamp bulbs defective 1 Test and repair charging system refer to Group 8A 2 Test voltage drop across Z1 ground refer to Group 8W 3 Test amperage draw of headlamp circuit 4 Replace both headlamp bulbs HEADLAMPS FLASH RANDOMLY ...

Page 494: ... to Group 8A 2 Inspect and repair all connectors and splices refer to Group 8W FOG LAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 2 Poor fog lamp circuit ground 3 High resistance in fog lamp circuit 4 Both fog lamp bulbs defective 1 Test and repair charging system refer to Group 8A 2 Test voltage drop across Z1 ground refer to Group 8W 3 Test amperage draw of fog lam...

Page 495: ...ALIGNMENT PREPARATION 1 Verify headlamp dimmer switch and high beam indicator operation 2 Correct defective components that could hinder proper headlamp alignment 3 Verify proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is not heavily loaded 6 Fuel tank should be FULL Add 2 94 kg 6 5 lbs of weight over the fuel tank for each estimated gallon of missing fuel ALIGNMENT SCREE...

Page 496: ...will project top edge of high intensity pattern on screen from 50 mm 2 in above to 50 mm 2 in below headlamp centerline The side to side outboard edge of high intensity pattern should be from 50 mm 2 in left to 50 mm 2 in right of head lamp centerline Fig 1 The preferred headlamp align ment is 1 down for the up down adjustment and CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS LEFT AND RIGHT ADJUSTM...

Page 497: ...B R LAMPS 8L 7 SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C 4466 A ...

Page 498: ...p bulb 4 Remove retaining ring holding bulb to head lamp Fig 1 5 Pull bulb from headlamp INSTALLATION CAUTION Do not touch the bulb glass with fin gers or other oily surfaces Reduced bulb life will result 1 Position bulb in headlamp 2 Install retaining ring holding bulb to headlamp Fig 1 3 Connect wire connector to headlamp bulb F 0 i LAMP BULB SOCKET REMOVAL 1 Disengage fog lamp harness connector...

Page 499: ...all the CHMSL CARGO LAMP BULB The cargo lamp bulb is incorporated in the CHMSL assembly refer to the CHMSL bulb removal and installation procedure for bulb replacement SIDE IDENTIFICATION ID LAMP BULBS The bulbs in the side ID lamps can not be replaced If a bulb should fail the entire lamp would require replacement Refer to the Side Identification Lamp Removal Installation procedure in this group ...

Page 500: ...rom the lamp socket fffSTALLATIOM 1 Insert the replacement bulb in the lamp base socket Rotate it clockwise 2 Connect the wire harness connector to the lamp DOME LAMP BULB _ _ _ _ r a s mm INSTALLATION 1 Install bulb in lamp 2 Position lens on lamp and snap into place OVERHEAD CONSOLE READING LAMP BULB REMOVAL 1 Insert a flat blade screwdriver in slot at front of lens Fig 4 2 Rotate the screwdrive...

Page 501: ...adlamp module from vehicle INSTALLATION 1 If removed install headlamp bulb 2 Connect headlamp bulb wire connector 3 Position headlamp in radiator closure panel 4 From behind front bumper install the screws holding bottom of headlamp module to radiator clo sure panel 5 Install the screws holding top of headlamp module to radiator closure panel Fig 1 6 Install park and turn signal lamp 7 Close hood ...

Page 502: ...GH MOUNTED STOP LAMP CHMSL REMOVAL 1 Remove screws holding CHMSL to roof panel Fig 4 2 Separate CHMSL from roof 3 Disengage wire connector from body wire har i e s s 4 Separate CHMSL from vehicle NSTALLATION 1 Position lamp at cab roof and connect wire con ector 2 Install screws holding CHMSL to roof panel ighten securely BR Fig 3 Roof Clearance Lamps SCREW J948L 4X Fig 4 Center High Mounted Stop ...

Page 503: ...p in cargo box engage retain ing studs and install screws 3 Close tailgate TAIL STOP TURN SIGNAL AND BACK UP LAMPS CHASSIS CAB REMOVAL 1 Remove nuts holding tail lamp to mounting bracket Fig 7 2 Disengage tail lamp wire connector from body wire harness 3 Separate tail lamp from vehicle LICENCE PLATE BRACKET BRACKET J948L 9 Fig 7 Tail Stop Turn Signal and Back up Lamps Cab Chassis INSTALLATION Reve...

Page 504: ...rom dome lamp 2 Remove screws holding dome lamp to roof rein forcement Fig 10 3 Separate dome lamp from roof 4 Disengage dome lamp wire connector from body wire harness 5 Separate dome lamp from vehicle INSTALLATION 1 Position dome lamp at headliner 2 Connect dome lamp wire connector to body wire harness 3 Install screws holding dome lamp to roof rein forcement Fig 10 LAMP PANEL SCREW BUMPER LICEN...

Page 505: ...D I N S T A L L A T I O N DAYTIME RUNNING LAMP MODULE REMOVAL 1 Release hood latch an open hood 2 Disconnect wire connector from DRLM Fig 1 3 Remove screw holding DRLR to engine com partment dash panel 4 Separate DRLM from dash panel INSTALLATION Reverse the removal procedure Fig 1 Daytime Running Lamp Module DRLM ...

Page 506: ...y be serviced by a Authorized Service Center ASC after the component is removed from the vehicle Contact local dealer for location of nearest ASC When illumination goes out in the Electronic Instru ment Cluster EIC the complete button module must page INTERIOR LAMPS 16 be replaced The Mechanical Instrument Cluster MIC uses PC194 bulbs for illumination LAMP BULB A C Heater Control 158 Ash Receiver ...

Page 507: ...G COLUMN COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BAT TERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG SYSTEM DEPLOYMENT AND POSSIBLE PERSONAL INJURY THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND ...

Page 508: ... an impact that is severe enough to require airbag system protection The impact sensors are available for service replacement The safing sensor is only serviced as part of the ACM CL0CISPRIN6 The clockspring is mounted on the steering column behind the steering wheel It is used to maintain a continuous electrical circuit between the wiring har ness and the driver s side airbag module This assem bl...

Page 509: ...armed whenever the steering wheel or steering column requires service or removal Failure to observe this warning could result in accidental airbag deployment and possible personal injury Refer to Group 19 Steering for additional service procedures on the steering wheel and steering column DEPLOYED Any vehicle which is to be returned to use after an airbag system deployment must have the airbag mod...

Page 510: ...TOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG SYSTEM DEPLOYMENT AND POSSIBLE PERSONAL INJURY WHEN REMOVING A DEPLOYED AIRBAG MOD ULE RUBBER GLOVES EYE PROTECTION AND A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES IN LARGE DOSES THE...

Page 511: ...E 8 AND 8 ENGINE 1 Disconnect and isolate the battery negative cable I f the airbag module is undeployed wait two minutes for the system capacitor to discharge before further service 2 Remove the plastic retainers holding the rub ber air dam to the radiator support on the driver s side 3 Working through the air dam opening remove the three screws holding the sensor to the front wheelhouse extensio...

Page 512: ...e airbag module is undeployed wait two minutes for the system capacitor to discharge before further service 2 Remove the two battery holddown bolts Fig 10 J948B 2 Fig 10 Battery Holddown 3 I f equipped pull up on the battery heat shield to remove it Fig 11 4 Remove the battery from the vehicle 5 From under the left front wheel opening remove the two forward battery tray nuts Fig 12 UNDERSIDE OF LE...

Page 513: ...rrow pointed forward using the three screws provided with the new sensor Tighten the screws to 4 5 5 6 N m 40 50 in lbs 14 Plug the harness connector into the speed con trol servo 15 Install the battery tray Tighten all battery tray mounting hardware to 16 N m 140 in lbs 16 Install the battery in the vehicle making sure that the battery is properly positioned in the battery tray 17 If equipped ins...

Page 514: ...m the harness to the connector on the body of the sen sor 5 Mount the sensor arrow pointed forward using the three screws provided with new sensor Tighten screws to 4 5 5 6 N m 40 50 in lbs 6 Do not connect the battery negative cable at this time See Airbag System in Diagnosis and test ing for the proper procedures AIRBAG CONTROL MODULE WARNING THE ACM CONTAINS ONE OF THE IMPACT SENSORS WHICH ENAB...

Page 515: ...th a steering wheel puller Special Tool C 3428B 5 Unplug the wiring for the horn switches 6 Remove the lower steering column shroud to gain access to the clockspring wiring Fig 21 7 Remove the lower fixed column shroud 8 Remove the knee blocker Fig 22 9 Disconnect the two way connector between the clockspring and the instrument panel wiring harness at the lower left corner of the instrument panel ...

Page 516: ...ng the centering procedure 2 Disconnect and isolate the battery negative cable If the airbag system is undeployed wait two minutes for the system capacitor to discharge before further service 3 Remove the airbag module as described in this group 4 Remove the steering wheel with a steering wheel puller Special Tool C 3428B 5 Unplug the wiring for the horn switches 6 Depress the two plastic auto loc...

Page 517: ...aired If faulty the entire switch must be replaced POWER LOCK MOTOR In the power lock system the locks are actuated by a reversible motor mounted within each door The motor direction is controlled by the battery and ground feeds from the power lock switches The power lock motor cannot be repaired If faulty the entire motor must be replaced D I A G N O S I S A N D T E S T I N G POWER LOCI SWITCH Fo...

Page 518: ...r ative go to Step 3 2 If all lock motors are inoperative the problem may be caused by one shorted motor Disconnecting a shorted motor will allow the good motors to operate Disconnect each motor connector one at a time and re check both the lock and unlock functions while operating the power lock switch If both motors are still inoperative after the above test repair the short or open circuit betw...

Page 519: ...g 5 Power Mirror Switch Knob Remove Install 5 Remove the mirror switch retaining nut from the switch Fig 6 6 Using a wide flat bladed tool such as a trim stick pry the trim panel away from the door around the perimeter and remove the trim panel NOTE To aid in the removal of the trim panel start at the bottom of the panel 7 Roll the door watershield away from the bot tom of the inner door panel to ...

Page 520: ......

Page 521: ...r ent motors They can be raised or lowered indepen dently of each other When the center seat switch is pushed to the Up or Down position both the front and rear motors operate in unison moving the entire seat up or down The forward rearward motor is operated by pushing the center seat switch to the Forward or Rearward position When a switch is actuated battery feed and a ground path are applied th...

Page 522: ...en circuit from the power distribution center as required POWER SEAT ADJUSTER MOTORS For circuit descriptions and diagrams refer to 8W 63 Power Seat in Group 8W Wiring Diagrams Operate the power seat switch to move all three seat motors The seat should move in all directions If one or more of the motors operate see the diagno sis for the Power Seat Switch in this group If no motors operate proceed...

Page 523: ...block Carefully release the locking tabs and separate the multiple terminal block on the wiring harness from the switch body Fig 3 5 Reverse the removal procedures to install J948R 3 Fig 8 Seat Switch Remove POWER SEAT ADJUSTER MOTORS 1 Disconnect and isolate the battery negative cable 2 Remove the three bolts attaching the seat frame to the floor pan 3 Remove the one nut from the stud locating th...

Page 524: ... the four screws attaching the seat adjuster to the seat cushion frame Fig 6 8 Reverse the removal procedures to install Tighten the seat mounting hardware as follows Seat cushion frame to adjuster bolts 25 N m 18 ft lbs Seat adjuster to floor pan bolts 29 N m 20 ft lbs Seat adjuster to floor pan nut 41 N m 80 ft lbs Center seat section bolts 25 N m 18 ft lbs Fig 6 Power Seat Adjuster Remove ...

Page 525: ...osite direction In addition each power window motor is equipped with an integral self resetting circuit breaker to protect the motor from overloads The power window motor and gear box assembly cannot be repaired If faulty the entire motor assembly must be replaced CIRCUIT BREAKER An automatic resetting circuit breaker in the fuseblock module is used to protect the power window system circuit The c...

Page 526: ... 60 Power Windows in Group 8W Wiring Diagrams 1 Locate the correct circuit breaker in the fuseblock module Pull out the circuit breaker slightly but be sure that the terminals still contact the terminals in the fuse block module 2 Connect the negative lead of a 12 volt DC volt meter to a good ground 3 With the voltmeter positive lead check both terminals of the circuit breaker for battery voltage ...

Page 527: ... tracks and regulator for sticking binding or improper adjustment R E M O V A L AND INSTALLATION POWER WINDOW SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the two screws in the door pull cup and remove the cup Fig 3 REMOVE 2 SCREWS J948S 2 Fig 3 Door Pull Cup Remove Install Typical 3 Remove power window and lock switches by reaching through the door pull cup opening and depr...

Page 528: ...Nut Fig 10 Glass Channel Rear Attaching Nut 7 Slide the glass rearward to disengage the chan nel nuts from the slotted holes in the regulator arm 8 Pull the glass to its full up position and tape it to the upper door frame 9 Unplug the wiring connector from the power window motor 10 Remove the two window track screws and the two rear regulator screws Fig 8 11 Loosen the two front regulator screws ...

Page 529: ...egulator arm POWER WINDOW SYSTEMS 8S a Fig 9 and Fig 10 Tighten the door glass channel nuts to 12 N m 105 in lbs 18 Connect the wire harness connector to the power regulator motor 19 Using an adhesive sealant 3M 08041 or 08044 is recommended install the plastic water shield to the door inner panel 20 Reverse the remaining removal procedures to complete the installation ...

Page 530: ......

Page 531: ...ction switch The switch knob is rotated clockwise right mirror con trol or counterclockwise left mirror control to select the mirror to be adjusted The switch knob is then page DIAGNOSIS AND TESTING POWER MIRROR SYSTEM 1 REMO AL AND INSTALLATION POWER MIRROR SWITCH 2 POWER MIRROR 4 moved in a joystick fashion to control movement of the selected mirror up down right or left The power mirror switch ...

Page 532: ...ndicated in the chart remove the mirror and check those circuits between the mirror and the switch for a short or open If not OK repair the circuits as required If the circuits are OK replace the faulty mirror assembly 12 Volts Ground 12 Volts Ground light Y L B K WT U P Y L YL PK UP WT Y L B K D O W N YL PK Y L D O W N WT D B R I G H T YL PK D B W T R I G H T D B W T L E F T D B W T YL PK L E F T...

Page 533: ...ob Remove install 8 Remove the mirror switch retaining nut from the switch Fig 8 9 Using a wide flat bladed tool such as a trim stick pry the trim panel away from the door around the perimeter and remove the trim panel NOTE To aid in the removal of the trim panel start at the bottom of the panel SWITCH RETAINING NUT DOOR TRIM PANEL POWER MIRROR SWITCH J948T 5 Fig 8 Power Mirror Switch Nut 10 Unplu...

Page 534: ... as described in Power Mirror Switch in this group 2 Unplug the power mirror motor wiring connec tor Fig 10 3 Remove the three nuts holding the mirror to the door 4 Pull the mirror wiring and grommet from the outside of the door 5 Reverse the removal procedures to install Fig 10 Power Mirror Remove instail ...

Page 535: ...de LED The automatic dimming feature will only operate when the ignition switch is in the On position The mirror also senses the back up lamp circuit and dis ables the self dimming feature whenever the trans mission manual or automatic gear selector is in the Reverse position The automatic day night mirror cannot be repaired If faulty the entire assembly must be replaced page DIAGNOSIS AND TESTING...

Page 536: ...r should darken If OK go to Step 8 If not OK replace the faulty mirror unit 8 With the mirror darkened place the transmis sion gear selector lever in the Reverse position The mirror should return to its normal condition If not OK replace the faulty mirror unit R E M O V A L A N D I N S T A L L A T I O N AUTOMATIC DAY NIGHT MIRROR 1 Disconnect and isolate the battery negative cable 2 If so equipped...

Page 537: ... seat belt switch the ignition key in switch and the headlamp switch The only output of the module is a timed four to eight second feed to the seat belt reminder lamp on the instrument panel The timer function begins after the ignition switch is turned to the On position The buzzer module cannot be repaired If faulty it must be replaced DRIVER S POOR JAMB SWITCH The driver s door jamb switch is mo...

Page 538: ...ck module as required 7 Turn the ignition switch to the Off position Check for continuity between the ground circuit cav ity of the buzzer module connector and a good ground There should be continuity If OK go to the diagnosis for the switch that is related to the buzzer malfunction If not OK repair the circuit to ground as required DRIVERS DOOR JAMB SWITCH For circuit descriptions and diagrams re...

Page 539: ...e should be no continuity with the switch in the Off position and there should be conti nuity with the switch in the park or head lamps On position If not OK replace the faulty headlamp switch DRIVER S SEAT BELT SWITCH For circuit descriptions and diagrams refer to 8W 44 Interior Lighting in Group 8W Wiring Dia grams 1 Unplug the seat belt switch connector on the floor under the driver s seat near...

Page 540: ...e various switches used in the chime buzzer warning system can be found in the appropriate group as follows Driver s door jamb switch refer to Group 8L Lamps Ignition key in switch refer to Group 8D Igni tion Systems Headlamp switch refer to Group 8E Instru ment Panel Systems Driver s seat belt switch refer to Group 23 Body Components ...

Page 541: ...anything magnetic directly on the roof of the vehicle Magnetic mounts for an antenna a repair order hat or a funeral pro cession flag can exceed the compensating ability of the compass unit if placed on the roof panel Mag netic bit drivers used on the fasteners that hold the assembly to the roof header can also affect compass operation If the vehicle roof should become magne tized the demagnetizin...

Page 542: ... as the dimmer switch is rotated If OK replace the faulty compass display module If not OK repair the open circuit to the fuseblock module as required SELF DIAGNOSTICS A self diagnostic test is used to determine that the compass and all of the display module segments are operating properly electrically Initiate the self diag nostic test as follows 1 With the ignition switch in the Off position sim...

Page 543: ...r if the sensor circuit is shorted An OC open circuit will appear in place of the temperature when the sensor is exposed too temperatures below 40 C 40 F or if the sensor circuit is open The temperature sensor circuit can also be diag nosed using the following Sensor Test and Sensor Circuit Test If the temperature sensor and circuit are confirmed to be OK but the temperature display is inoperative...

Page 544: ...mory 7 Confirm that the correct directions are now indicated COMPASS CALIBRATION CAUTION Do not place any external magnets such as magnetic roof mount antennas in the vicinity of the compass Do not use magnetic tools when ser vicing the overhead console The electronic compass unit features a self cali brating design which simplifies the calibration pro cedure This feature automatically updates the...

Page 545: ...he area to be demagnetized PULL TIP OF DEGAUSSING TOOL AWAY C AT LEAST TWO FEET AND DISCONNECT c C C 3 1 2 c c 3 WINDSHIELD EDGE START 4 Slowly approach the center line of the roof panel at the windshield header with the degaussing tool plugged in 5 Contact the roof panel with the tip of the tool Be sure the template is in place to avoid scratching the roof panel Using a slow back and forth sweepi...

Page 546: ...ometer display module to the overhead console housing Fig 5 J948C3 Fig 5 Compass Thermometer Display Module Remove Install 3 Unplug the lighting harness connector from the compass thermometer display module Fig 6 Fig 6 Lighting Harness Connector 4 Remove the module from the overhead console housing 5 Reverse the removal procedures to install TEMPERATURE SENSOR 1 Disconnect and isolate the battery ...

Page 547: ...om the housing and pivot the lens down It may be necessary to move the tool along the edge of the lens to free the lens from the console housing 2 Remove the bulb by pulling it straight down 3 Install a new bulb by pushing it firmly into the socket 4 Pivot the lens up into position and press upwards until it snaps into place 5 Test the lamp by depressing the lens to check for proper switching and ...

Page 548: ......

Page 549: ...EEL ANTI LOCK BRAKES 8W 35 1 8W 40 INSTRUMENT CLUSTER 8W 40 1 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 8W 42 AIR CONDITIONING HEATER 8W 42 1 8W 43 AIRBAG SYSTEM 8W 43 1 page 8W 44 INTERIOR LIGHTING 8W 44 1 8W 46 MESSAGE CENTER 8W 46 1 8W 47 AUDIO SYSTEM 8W 47 1 8W 49 OVERHEAD CONSOLE 8W 49 1 8W 50 FRONT LIGHTING 8W 50 1 8W 51 REAR LIGHTING 8W 51 1 8W 52 TURN SIGNALS 8W 52 1 8W 53 WIPERS 8W 53...

Page 550: ......

Page 551: ... the same as a long one In addition switches and other components are shown as simply as possible with regard to function only SECTION IDENTIFICATION Sections in Group 8W are organized by sub sys tems The sections contain circuit operation descrip page TROUBLESHOOTING TESTS 6 TROUBLESHOOTING TOOLS 5 TROUBLESHOOTING WIRING PROBLEMS 6 SERVICE PROCEDURES CONNECTOR AND TERMINAL REPLACEMENT 9 CONNECTOR...

Page 552: ...NT IN AND AROUND THE BATTERY WARNING ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOTH ING WIRE CODE IDENTIFICATION Each wire shown in the diagrams contains a code Fig 1 which identifies the main circuit part of the main circuit gauge of wire and color The color is shown as a two letter code which can be identified by referring to the Wire Color Code Chart Fig 2 A 2 18 LB YL COLOR ...

Page 553: ...tor number Fig 4 For viewing connector pin outs with two terminals or greater refer to section 8W 80 This section iden FEMALE TERMINAL C O N N E C T O R IDENTIFICATION NUMBER 948W 191 Fig 4 Connector identification titles the connector by number and provides terminal numbering circuit identification wire colors and functions All connectors are viewed from the terminal end unless otherwise specifie...

Page 554: ...S TO ONE OF TWO CIRCUITS A A A RESISTOR SPLICE VARIABLE RESISTOR S100 SPLICE IDENTIFICATION SERIES RESISTOR sffcP THERMAL ELEMENT COIL 1 rrTl TIMER STEP UP COIL Y Y Y 1 MULTIPLE CONNECTOR OPEN CONTACT OPTIONAL WIRING WITH WIRING WITHOUT CLOSED CONTACT Y Y WINDINGS CLOSED SWITCH BB BB DIGITAL READOUT OPEN SWITCH SINGLE FILAMENT LAMP CLOSED GANGED SWITCH DUAL FILAMENT LAMP OPEN GANGED SWITCH L E D L...

Page 555: ...nnect the black lead to a known good ground and the red lead to the positive side of the circuit CAUTION Most of the electrical components used in today s vehicle are solid state When checking voltages in these circuits use a meter with a 10 me gohm or greater impedance Ohmmeter Used to check the resistance between two points of a circuit Low or no resistance in a circuit means good continuity CAU...

Page 556: ...the test lamp glows there is a short to ground in that gen eral area of the wiring harness FUSE REMOVED FROM CIRCUIT X 948W 195 Fig 9 Testing for Continuity TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer to the wiring diagrams and disconnect or isolate all items on the fused circuit 2 Replace the blown fuse 3 Supply power to the fuse by turning ON the ignition switch or re c...

Page 557: ...one side of the wire Make sure the tubing will be long enough to cover and seal the entire repair area 4 Spread the strands of the wire apart on each part of the exposed wire example 1 Fig 11 5 Push the two ends of wire together until the strands of wire are close to the insulation example 2 Fig 11 6 Twist the wires together example 3 Fig 11 7 Solder the connection together using rosin core type s...

Page 558: ...nector 6 Repair or replace the terminal 7 Install the wire and terminal in the connector Fully seat the terminal in the connector 803f588c Fig 16 Single Lock Tab CONNECTOR REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Remove the connector locking wedge if required Fig 17 4 Position the connector locking finger away from the term...

Page 559: ... the repair Allow extra length for soldered connections Check that the overall length is the same as the original Fig 20 REPAIR SIDE WIRES STAGER CUTS HARNESS WIRES 928W 145 Fig 20 Stagger Cutting Wires 7 Remove 1 inch of insulation from each wire 8 Place a piece of heat shrink tubing over one side of the wire Be sure the tubing will be long enough to cover and seal the entire repair area 9 Spread...

Page 560: ...apart on each part of the exposed wires 11 Spread the strands of the wire apart on each part of the exposed wires 12 Push the two ends of wire together until the strands of wire are close to the insulation 13 Twist the wires together 14 Solder the connection together using rosin core type solder only Do not use acid core solder 15 Center the heat shrink tubing over the joint and heat using a heat ...

Page 561: ... 948W 197 Fig 24 Diode Identification 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the elements 8 Re connect the battery and test affected sys tems 0I1AT10N 8W 01 11 SPECIAL TOOLS WIRING TERMINAL Terminal Removing Tool 6934 Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 ...

Page 562: ......

Page 563: ...PONENT INDEX G E N E R A L I N F O R M A T I O N on system operation refer to the appropriate section of the wiring diagrams INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W For information ...

Page 564: ... 2 8W 11 50 Fog Lamp Switch 8W 50 Fog Lamps 8W 50 Forward Backward Seat M o t o r 8W 63 Forward Fender Lamps 8W 51 Four Wheel Drive 4WD Switch 8W 31 34 35 40 Front Up Down Seat Motor 8W 63 Component Section Front Wheel Speed Sensors 8W 35 Fuel Heater 8W 30 Fuel Heater Relay 8W 30 Fuel Pump Module 8W 30 Fuel Pump Relay 8W 11 30 Fuel Shut Down Relay 8W 30 Fuel Shut Down Solenoid 8W 30 Fuse Block 8W ...

Page 565: ... Tweeter 8W 47 Right Power Door Lock M o t o r 8W 47 Right Power Door Lock Switch 8W 61 8W 02 3 Section Right Power Mirror Motors 8W 62 Right Power Window Motor 8W 60 Right Power Window Switch 8W 60 Right Rear Premium Speaker 8W 47 Right Rear Speaker 8W 47 RWAL Valve 8W 34 35 Seat Belt Switch 8W 44 Stop Lamp Switch 8W 33 34 35 51 52 Tail Stop and Turn Signal Lamps 8W 51 52 Tailgate Lamps 8W 51 Thr...

Page 566: ......

Page 567: ...E F U S E BLOCK D E S C R I P T I O N A N D O P E R A T I O N INTRODUCTION This section covers the Fuse Block and all circuits involved with it For additional information on sys tem operation refer to the appropriate section of the wiring diagrams ...

Page 568: ...W 10 5 Fuse 9 8W 10 6 Fuse 11 8W 10 7 Fuse 12 8W 10 7 Fuse 13 8W 10 11 Fuse 14 8W 10 8 Fuse 15 8W 10 9 Component Page Fuse 16 8W 10 9 Fuse 17 8W 10 10 Fuse 18 8W 10 11 Fuse 19 8W 10 12 Fuse 20 8W 10 12 Fuse Block 8W 10 3 Fuse C h a r t 8W 10 4 F2 8W 10 9 Headlamp Switch 8W 10 11 Ignition Switch 8W 10 5 6 7 8 9 Instrument Cluster 8W 10 7 Joint Connector A 8W 10 11 Joint Connector B 8W 10 10 12 Join...

Page 569: ...B R 8W 10 FUSE FUSE BLOCK 8 W 1 0 3 F U S E BLOCK C241 8040bfee J968W 9 ...

Page 570: ... 10 11 19 20 YELLOW 8W 10 12 20 15 LIGHT BLUE 8W 10 12 F1 F2 30 GRPFN 8W 10 9 CIRCUIT BREAKER 8W 10 9 X B 2 W CIRCUIT 4S EAKER 8W 10 5 TURN CAV CIRCUIT FUNCTION SECTION PAGE SIGNAL 1 L6 20RD GY TURN SIGNAL FLASHER OUTPUT 8W 52 3 FLASHER 2 L5 20BK FUSED IGNITION SWITCH OUTPUT ACC RUN 8W 52 3 HAZARD CAV CIRCUIT FUNCTION SECTION PAGE WARNING 3 L19 18PK WT HAZARD FLASHER OUTPUT 8W 52 3 FLASHER 4 L9 18...

Page 571: ...L 8W 20 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8W 20 4 C303 P O W E R OUTLET 8W 41 3 P O W E R SEAT SWITCH 8W 53 4 8W 63 3 INTERMITTENT INTERMITTENT WIPER SWITCH 8W 53 3 WIPER CONTROL MODULE CAVITY 3 8W 53 3 4 WITH GAS ENG WITH DIESEL ENG 8040bff0 J968W 9 ...

Page 572: ...L SHUT DOWN SOLENOID 8 W 3 0 4 7 HEATED I N T A K E A I R S Y S T E M R E L A Y NO I 8 W 3 0 4 8 HEATED I N T A K E A I R S Y S T E M R E L A Y NO 2 8 W 3 0 4 8 A C COMPRESSOR CLUTCH R E L A Y 8 W 4 2 8 C8W 11 8 WITH DIESEL ENG F U E L H E A T E R R E L A Y 8 W 3 0 4 7 WITH 5 2L AND 5 9L ENG TRANSMISSION R E L A Y 8W 31 4 8 W 1 1 9 AUTOMATIC SHUT DOWN R E L A Y 8W 30 12 8W 11 10 C 1 3 5 A2 FUSED I...

Page 573: ...m 8W 10 FUSE FUSE BLOCK 8 W 1 0 7 AO 6RD BATTERY POSITIVE TERMINAL 8 4 20 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8W 20 4 MESSAGE CENTER 8W 46 3 WITH WITH 8040bff2 GAS ENG DIESEL ENG J968W 9 ...

Page 574: ...OUTPUT RUN 1 1 6 7 12 17 21 1 CONTROLLER ANTI LOCK BRAKE ABS A20 18RD DB C121 A20 18RD DB A20 A20 18RD 18RD DB DB A20 A20 18RD 18RD DB DB A20 18RD DB WITH RWAL A20 18RD DB C133 A20 18RD DB I A20 18RD DB A20 18RD DB A20 18RD DB SllO C133 8W 70 6 A20 18RD DB f A20 18RD DB ABS WARNING LAMP RELAY 8W 35 6 8W 11 16 ABS PUMP MOTOR RELAY 8W 35 6 8W 11 16 VACUUM SENSOR WITH DIESEL ENG 8W 34 4 8W 35 5 C228 ...

Page 575: ...W 70 26 A22 12BK 0R FUSE BLOCK A22 12BK OR 2 3 A22 12BK 0R K F U S E S F U S E C 15 C 16 10A 2 7 15A 2 8 1 1 1 2 7 Y F21 14TN f 3 0 A J 8 241 CB1 30A 241 F21 14TN F21 14TN C345 L10 22BR LG F23 18DB YL 2 8 2 FUSED IGNITION SWITCH OUTPUT RUN 232 AIRBAG CONTROL MODULE CI 12DG BLOWER MOTOR 8W 42 4 5 F21 14TN F21 14TN S214 8W 70 32 F21 14TN C239 F21 14TN r F21 14TN 207 OPTIONAL C209 FUSED IGNITION SWIT...

Page 576: ...ARTER MOTOR 8W 21 3 4 S204 AO 20BK i AO 14PK SPLICE S148 C8W 70 21 FUSE 1 50A C 1 8 0 n POWER DISTRIBUTION CENTER 1 A7 S147 10RD BK 8W 70 21 WITH POWER SEAT C 3 5 3 CARGO LAMP NO 1 CARGO LAMP NO 2 C8W 44 5 8W 44 5 8040bff5 DOME LAiP 8W 44 5 Ml 2 0 P K POWER MIRROR SWITCH C8W 62 3 RIGHT VISOR VANITY LAMP C8W 44 4 WITH OVERHEAD CONSOLE WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 577: ...K SPLICE S148 C8W 70 21 I FUSE I 50A FUSE xsm i S147 A7 10RD BK 8W 70 21 POWER DISTRIBUTION CENTER 8W 70 28 I A7 12RD BK A7 12RD BK A7 12RD BK WITH P O W E R SEAT A7 12RD BK C133 A7 12RD BK 1 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL JOINT CONNECTOR C 5 C209 REF TO OVERDRIVE SWITCH ILLUMINATION LAMP 8W 31 7 JOINT CONNECTOR A FOG LAMP SWITCH 8W 50 10 WITH F O G LAMPS WITH G A S E N G WITH DIESEL E N G...

Page 578: ...R D O O R LOCK SWITCH 8W 61 4 F35 16RD i SPLICE S148 C8W 70 21 F35 14RD T F35 16RD F35 14RD C348 F35 C346 16RD F35 F35 14RD 0 P A L 1 6 R D F35 14RD F35 16RD C207 S216 8W 70 33 F35 16RD _ F35 16RD C239 1 JOINT CONNECTOR i B FUSED B 4 k C231 F35 16RD F32 18PK DB A3 12RD LG 19 20 4 14 FUSE 19 20A 16 C241 N FUSE C 2 0 s 15A C241 FUSE BLOCK C133 A3 12RD LG A7 12RD BK S203 A3 12RD LG 8W 70 27 WITH GAS ...

Page 579: ...BUTION D E S C R I P T I O N A N D O P E R A T I O N INTRODUCTION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate section of the wiring diagrams ...

Page 580: ...6 Fuse6 8W 11 19 Fuse 6 PDC 8W 11 14 Fuse 7 8W 11 19 Fuse 7 PDC 8W 11 6 Fuse 8 8W 11 19 Fuse 8 PDC 8W 11 9 11 Fuse 9 8W 11 8 9 10 11 19 20 B R Page Fuse 11 8W 11 19 Fuse 12 8W 11 19 Fuse 14 8W 11 15 18 Fuse 15 8W 11 18 Fuse 16 8W 11 18 Fuse 17 8W 11 18 Fuse 18 8W 11 13 18 Fuse 19 8W 11 18 Fuse 20 8W 11 14 Fuse A PDC 8W 11 12 Fuse B PDC 8W 11 7 8 Fuse C PDC 8W 11 18 Fuse Gen PDC 8W 11 19 F2 8W 11 1...

Page 581: ...B 8W 11 I0 5 A10 12RD DG 40 FUSED B 8W 11 16 6 A3 12RD LG 40 FUSED B 8W 11 14 7 A6 12RD TN 40 FUSED B 8W 11 6 7 A6 12RD TN 40 FUSED B 8W 11 6 8 A14 16RD WT 20 FUSED B 8 W l l 9 i l 8 A14 16RD WT 20 FUSED B 8W ll 9 il FUSE GEN 8040bff9 CAV CIRCUIT AMPS FUNCTION SECTION PAGE FUSE A Al A7 12RD BK 15 FUSED B 8W 11 12 A2 L38 20LB BK 15 FUSED B 8W 11 12 CAV CIRCUIT AMPS FUNCTION SECTION PAGE FUSE B Bl A...

Page 582: ... K31 20BR WT FUEL PUMP RELAY CONTROL 8W 11 11 86 F18 20LG BK FUSED IGNITION SWITCH OUTPUT START RUN 8W 11 11 87 A61 16DG BK FUEL PUMP RELAY OUTPUT 8W 11 11 AUTOMATIC SHUT DOWN RELAY CAV CIRCUIT FUNCTION SECTION PAGE 30 A16 14GY WT FUSED 3 8W 11 10 85 K51 22DB YL AUTO SHUT DOWN RELAY CONTROL 8W 11 10 86 F18 20LG BK FUSED IGNITION SWITCH OUTPUT START RUN 8W 11 10 86 F18 20LG BK FUSED IGNITION SWITCH...

Page 583: ...GE 30 L7 20BK YL PARK LAMP SWITCH OUTPUT 8W 11 13 14 85 Zl 18BK GROUND 8W 11 13 14 86 G34 18RD GY HIGH BEAM INDICATOR LAMP DRIVER 8W 11 13 14 86 L3 16RD 0R DIMMER SWITCH HIGH BEAM OUTPUT 8W 11 13 14 A87 L139 20LB WT FOG LAMP RELAY OUTPUT 8W 11 13 14 FOG LAMP RELAY NO 2 CAV CIRCUIT FUNCTION SECTION PAGE 30 L39 20LB FRONT FOG LAMP SWITCH OUTPUT 8W 11 12 85 L35 22BR WT FOG LAMP RELAY CONTROL 8W 11 12...

Page 584: ... LAMP SWITCH OUTPUT 4 C 2 1 7 17 18BK YL C 1 3 3 86 17 18BK YL L7 20BK YL 85 S 1 0 6 8W 70 4 87 E L E C T R I C B R A K E P R O V I S I O N BOTTOM LEFT OF I P TRAILER TOW RELAY POWER D I S T R I B U T I O N C E N T E R A6 12RD TN C1SO L76 12BK 0R 11 20BK 108 8W 70 5 C 1 2 9 C 3 3 2 Zl I2BK n i l 8W 15 3 1 L76 12BK OR L76 12BK OR TRAILER TOW 8W 54 4 C332 o C 1 2 9 A6 12RD TN A6 12RD TN TRAILER TOW ...

Page 585: ... 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8W 20 4 ENGINE STARTER MOTOR 8W 21 3 4 SPLICE S148 8W 70 21 X3 POWER W I N D O W S 22BK AND POWER LOCKS RD VEHICLE SPEED CONTROL HORN SWITCH C8W 41 4 LOW NOTE HORN 8W 41 4 WITH GAS ENG WITH DIESEL ENG 8040bffe J968W 9 ...

Page 586: ... POSITIVE TERMINAL 8W 20 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG C 8 W 2 0 4 ENGINE STARTER MOTOR C8W 21 3 4 SPLICE S148 8W 70 21 POWER DISTRIBUTION CENTER A C COMPRESSOR CLUTCH C8W 42 8 8040cc00 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 587: ...BR 8W 11 POWER DISTRIBUTION 8W 11 9 BATTERY POSITIVE TERMINAL 8W 2 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8W 20 4 8040cc01 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 588: ... F18 22LG BK C133 F18 20LG BK 1 F 1 8 2 0 L G B K 1 S114 A21 12DB r mm C212 START ACC f f 2 J RUN OFF IGNITION SWITCH 8W 70 7 F18 20LG BK 8 3 0 8 5 8 7 TRANSMISSION RELAY 8W 11 9 8W 31 4 K51 22DB YL A16 14GY WT cieo AUTOMATIC POWER DISTRIBUTION CENTER SHUT D O W N RELAY A142 14DG OR A142 14DG OR A142 14DG OR C180 C127 A142 14DG 0R S138 WITH DIESEL ENG S143 8W 70 17 8W 70 19 A142 16DG OR A142 16DG ...

Page 589: ...LG BK S132 8W 70 13 F18 20LG BK 2 DUTY CYCLE EVAP PURGE SOLENOID WITH GAS ENG C153 F18 20LG BK 2 1 F18 20LG BK I F18 18LG BK C146 C153 K52 20PK AC137 1 POWER DISTRIBUTION CENTER EXHAUST GAS TRANSMISSION RELAY C8W 11 9 8H 31 4 RECIRCULATION C135 C20 EVAP SOL CONTROL A2 FUSED IGN SW OUTPUT START RUN V K35 20GY YL B32 EGR SOL CONTROL C146 SOLENOID WITH 5 2L AND 5 9L ENG A14 16RD WT NOT USED ON DIESEL...

Page 590: ...RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8W 20 4 ENGINE STARTER MOTOR 8W 21 3 4 SPLICE S148 8W 70 21 FOG LAMP RELAY NO 1 8W 11 13 X4 8W 50 8 RIGHT FOG LAMP 8W S0 10 LEFT FOG LAMP C8W 50 10 FOG LAMP SWITCH 8W 50 10 WITH GAS ENG WITH DIESEL ENG 8040cc04 J968W 9 ...

Page 591: ... SPLICE S148 8W 70 21 12RD BK S204 A7 12RD BK A7 12RD BK C133 A7 12RD BK l WITH POWER SEAT 8W 11 14 8W 70 10 8W 70 23 L3 16RD OR G34 18RD GY DAYTIME RUNNING LAMP MODULE CAVITY 4 8W 50 12 8W 11 14 WITH DRL FOG LAMP RELAY POWER DISTRIBUTION CENTER PARK LAMP SWITCH OUTPUT PARK LAMP SWITCH OUTPUT JOINT CONNECTOR A S103 FOG LAMP RELAY NO 2 C8W 11 12 C8W 50 9 8W 70 3 Z l 18BK G102 8W 15 4 WITH GAS ENG W...

Page 592: ...23 HIGH FUSED BEAM 4 INDICATOR LAMP DRIVER DIMMER SWITCH i HIGH BEAM OUTPUT WITHOUT DRL SPLICE S106 8W 11 13 8W 70 4 L7 20BK YL G34 18RD GY 3 0 A87 8 6 C180 8 5 L139 20LB WT FOG LAMP RELAY NO 2 8W 11 12 8W 50 9 NO 1 CIS POWER DISTRIBUTION CENTER L3 16RD 0R Z l 18BK DIMMER SWITCH HIGH BEAM OUTPUT HEADLAMP SWITCH OUTPUT FUSED B SWITCH PART OF MULTI FUNCTION SWITCH A3 12RD LG S103 8W 70 3 Z l 18BK G1...

Page 593: ...TION CENTER FUSED IGNITION SWITCH OUTPUT RUN CONTROLLER ANTI LOCK BRAKE ABS T T A20 A20 18RD 18RD DB DB 12 f A20 18RD DB 17 A20 18RD DB 21 r C121 A20 A20 18RD DB A20 18RD DB A20 18RD DB L ABS WARNING LAMP RELAY 8W 11 16 8W 35 6 ABS PUMP MOTOR RELAY 8W 11 16 8W 35 6 A20 18RD DB S110 3 FUSED IGNITION SWITCH OUTPUT RUN A20 18RD DB CONTROLLER ANTI LOCK BRAKE RWAL C133 8W 70 6 A20 18RD DB WITH RWAL VAC...

Page 594: ...D 1 4 C21S ABS WARNING LAMP DRIVER Z l 12BK G1Q1 8W 15 3 HYDRAULIC CONTROL UNIT C 8 M 3 5 9 B120 12BR WT B120 12BR WT B120 12BR WT S112 8W 70 7 G19 20LG RD INSTRUMENT C L U S T E R C 1 2 1 24 13 J ABS ABS i WARNING WARNING LAMP LAMP i i DRIVER RELAY J CONTROL CONTROLLER ANTI LOCK B R A K E B120 12BR WT RWAL V A L V E 8W 35 10 B120 14BR WT 34 ABS PUMP MOTOR RELAY OUTPUT C 1 2 1 CONTROLLER A N T I L...

Page 595: ...ER WITH GAS ENG WITH FUEL SHUT m RELAY C8W 30 47 C119 T40 12BR T 4 0 12BR t ENGINE STARTER MOTOR 8W 21 3 4 WITH AUTO Z12 20BK TN I MAN TRANS 151 T41 20BK WT TRANS S141 Z12 20BK TN 1 8W 70 22 8W 70 I9 Z12 10BK T41 18BK Z12 14BK WITH D I E S E L ENG WITH MAN TRANS S152 8W 70 22 FUSE BLOCK 8W 10 5 TN S142 3W 70 19 Z12 14BK TN Clif PARK NEUTRAL POSITION SWITCH CASE GROUND G119 8W 15 12 A41 18DB YL 804...

Page 596: ...3 WITH I POWER A7 A7 SEAT 12RD 12RD BK BK S204 A7 12RD BK 8W 70 28 12BK OR S201 8W 70 26 A7 12RD BK A7 12RD BK A22 A22 12BK 12BK OR OR 1 4 C241 I CB2 1 30A 1 4 _ C241 I CB2 1 30A i FUSE J FUSE 17 C 18 C 15A 15A FUSE 19 20A C241 I CB2 1 30A A22 12BK OR FUSE BLOCK 7 11 23 C24I 1 FUSE BLOCK CB1 S F2 S J 30A C 30A C S FUSE S FUSE J C 14 C 15 C FUSE 16 20A 10A 15A 4 0 c c c l WITH GAS ENG WITH DIESEL E...

Page 597: ...E TERMINAL 8 W 2 0 3 4 AO 6RD A O OQERD SPLICE S148 8 W 7 0 2 1 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8 W 2 0 4 FUSE BLOCK 8 W 1 0 5 ENGINE STARTER MOTOR 8W 21 3 4 GENERATOR 8W 20 3 4 FUSE BLOCK WITH GAS ENG WITH DIESEL ENG 8040ccc2 J968W 9 ...

Page 598: ... CLUTCH R E L A Y 8 W 1 1 8 81 42 8 F U E L SHUT DOWN SOLENOID 8 W 3 0 4 7 H E A T E D I N T A K E A I R S Y S T E M R E L A Y NO 1 8 W 3 0 4 8 POWERTRAIN CONTROL MODULE C A V I T Y A 2 8 W 3 0 2 0 4 1 iiTY C Y C L E E V A P PURGE SOLENOID 8 W 3 Q 2 0 EXHAUST GAS R E C I R C U L A T I O N SOLENOID 8 W 3 0 2 0 F U E L H E A T E R R E L A Y HEATED I N T A K E A I R S Y S T E M 8 W 3 0 4 7 R E L A Y ...

Page 599: ... 2 L AND 5 9 L ENG DOWNSTREAM HEATED OXYGEN SENSOR 8 1 3 0 2 9 3 2 3 3 L E F T UPSTREAM HEATED OXYGEN SENSOR 8 1 3 0 3 7 WITH 8 0 L ENG RIGHT UPSTREAM HEATED OXYGEN SENSOR 8 1 3 0 3 7 I N J E C T O R 810 2 8 1 3 0 3 1 3 5 4 0 I N J E C T O R N O 4 8 1 3 0 3 1 3 5 4 0 I N J E C T O R 10 8 1 3 0 3 1 3 5 4 0 I N J E C T O R N O 8 8 1 3 0 3 5 4 0 2 L 5 9 L AND 8 0 L ENG I N J E C T O R N O l 8 1 3 0 3...

Page 600: ... 1 0 8 W 3 0 1 2 C 1 2 7 A142 14DG 0R A142 14DG OR EXHAUST OAS R E C I R C U L A T I O N SOLENOID 8 W 3 0 4 9 EGR CONTROL MODULE C A V I T Y 1 8 W 3 0 4 9 S 1 4 3 A142 18DG 0R WITH EGR A142 20DG 0R A142 14DB GENERATOR C 8 W 2 0 4 A142 16DG OR C 1 3 7 POWERTRAIN CONTROL MODULE 8040ccc5 J968W 9 ...

Page 601: ...oint connectors For additional information on sys tem operation refer to the appropriate section of the wiring diagrams WIRING DIAGRAM INDEX The following index covers all components found in this section of the wiring diagrams If the component you are looking for is not found here refer to section 8W 02 for a complete list of all components shown in the wiring diagrams ...

Page 602: ...W 12 5 Fuse 11 8W 12 7 Fuse 13 8W 12 3 6 Fuse 15 8W 12 9 Fuse 17 8W 12 5 Fuse 18 8W 12 3 6 Component Page Fuse 20 8W 12 5 Headlamp Switch 8W 12 3 4 6 8 Ignition Switch 8W 12 7 9 10 Instrument Cluster 8W 12 6 7 10 Joint Connector A 8W 12 3 4 6 Joint Connector B 8W 12 5 Joint Connector C 8W 12 3 6 7 8 9 10 Overhead Console 8W 12 3 4 6 7 Park Brake Switch 8W 12 7 Powertrain Control Module 8W 12 6 8 8...

Page 603: ...K WITH FOG LAMPS E2 220R E2 200R E2 200R 5 C209 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL JOINT CONNECTOR C FOG LAMP SWITCH 8W 50 10 REF TO OVERDRIVE SWITCH ILLUMINATION LAMP 8W 31 7 SPLICE S106 RADIO 8W 70 4 8W 47 4 6 L7 18BK YL C133 L7 20BK YL L7 18BK YL 4 5 9 C217 1 0 JOINT CONNECTOR A WITH OVERHEAD CONSOLE ONLY C208 L L7 2 0 B K Y L L7 20BK YL C338 2 PARK LAMP SWITCH 1 OUTPUT J i J OVERHEAD CONSO...

Page 604: ...IGH LINE CLUSTER 6 k C338 M2 22YL M2 22YL M2 18YL JAMB SWITCH 8 W 4 9 4 M2 18YL M2 22YL 1 js C208 M2 22YL C201 M2 22YL 7 3 8 M2 22YL HEADLAMP SWITCH DOME C240 M2 22YL 2 TIME DELAY RELAY C8W 44 4 5 M2 20YL DOME LAMP NO 8 W 4 4 5 CONNECTION ciaa M2 20YL C202 M2 20YL M2 18YL M2 20YL C133 S218 8W 70 34 M2 20YL 6 1 C217 JOINT CONNECTOR A _ J C217 8040ccc9 J968W 9 ...

Page 605: ... DRL 12RD 12RD LG LG A3 12RD LG X C 1 3 3 A3 12RD LG A3 12RD LG S 1 1 8 8W 70 9 C 2 3 1 S 2 0 3 8W 70 27 4 A3 12RD LG FUSE BLOCK C 2 4 1 FUSE 20 2 4 1 1 6 15A 2 0 8W 70 28 8 7 6 2 1 5 Ml 18PK HOT A T A L L T I M E S FUSE BLOCK Ml 18PK Ml 20PK Ml 18PK Ml 20PK Ml 20PK F32 18PK DB C 2 2 8 1 7 FUSE 17 15A C 2 4 1 DATA L I N K CONNECTOR 8 W 3 0 1 3 RADIO CHOKE 8 W 4 7 7 GLOVE BOX L A M P SWITCH 8W 44 8...

Page 606: ...8W 50 10 C209 C209 JOIWT CONNECTOR E2 220R l i I OVERDRIVE SWITCH ILLUMINATION LAMP 8W 31 7 RADIO CSW 47 4 6 INSTRUMENT CLUSTER C21S E2 220R 2 FUSED PANEL f LAMPS DIMMER SWITCH SIGNAL 1 E2 T 220R 3 HEATER CONTROL SWITCH C8W 42 4 A C HEATER CONTROL SWITCH C8W 42 6 OR C208 C338 FUSED PANEL E2 220R f E2 2 2 0 R f LAMPS DIMMER 4 i 1 i OVERHEAD CONSOLE WITH HIGH LINE J CLUSTER 17 j V32 20YL RD V32 22YL...

Page 607: ...4 4 7 F12 20DB W T 14 13 11 10 G i l 22WT BK C133 G i l 20WT BK C131 G i l 22WT BK 5 3 PARK BRAKE SWITCH SENSE DAYTIME RUNNING LAMP A l 12RD S124 C133 8W 70 12 C212 A l 12RD f 7 A C C OFF RUN j START IGNITION SWITCH C338 f 7 F12 22DB W T FUSED IGNITION SWITCH OUTPUT START RUN OVERHEAD CONSOLE WITH HIGH LINE CLUSTER C208 F12 22DB W T 15 9 G i l 22WT BK MODULE PARK BRAKE SWITCH SENSE C216 1 INSTRUME...

Page 608: ...NECTORS B R POWERTRAIN CONTROL MODULE CONTROLLER A N T I L O C K BRAKE KEY IN S W I T C H HALO LAMP C8W 44 7 LEFT POOR JAMB SWITCH 8 W 4 9 4 8040ccd0 B i H E R MODULE C8W 44 7 K E Y I N S W I T C H HALO LAMP C 8 W 4 4 7 J968W 9 ...

Page 609: ...CENTER A2 12PK BK 1 WITH HIGH LINE CLUSTER f L10 22BR LG L10 22BR LG C208 DAY NIGHT MIRROR 8W 44 9 3 0 C209 29 C209 28 L10 18BR LG C126 L10 18BR LG 120 8W 70 10 C126 L10 20BR LG L 1 0 1 8 B R L G L10 18BR LG L10 18BR LG 1 WITH DRL L10 18BR LG DAYTIME RUNNING LAMP MODULE CAVITY 5 8W 50 12 L10 18BR LG 1 1 WITH h MAN L10 TRANS 18BR LG i PARK NEUTRAL BACK UP POSITION LAMP SWITCH SWITCH 8W 51 6 C8W 51 ...

Page 610: ...BRAKE WARNING LAMP DRIVER 4 B R A K E SWITCH C 8 W 3 4 4 BLACK VACUUM SENSOR 8 W 3 4 4 8 W 3 5 5 G9 20GY BK G9 18GY BK WITH RWAL WITHOUT DIESEL C 1 3 3 C 2 1 6 RED BRAKE WARNING LAMP DRIVER 6 CONTROLLER AiSTI LOCK B R A K E RWAL C 2 2 8 C 2 1 2 G9 22GY BK G9 22GY BK 3 CASE GROUND START ACC RUN OFF i I G N I T I O N SWITCH G9 22GY BK 26 23 2 4 G9 22GY BK 25 C 2 0 9 J O I N T CONNECTOR C 8040ccd4 J9...

Page 611: ...RODUCTION This section identifies the grounds splices that connect to those grounds and the components that connect those grounds For additional information on system operation refer to the appropriate section of the wiring diagrams For an illustration of the phys ical location of each ground refer to group 8W 90 ...

Page 612: ... 8W 15 10 G103 8W 15 5 G116 8W 15 10 G104 8W 15 6 7 8 G117 8W 15 10 G105 8W 15 6 7 8 G118 8W 15 10 G106 8W 15 6 7 8 G119 8W 15 11 12 G107 8W 15 9 G201 8W 15 13 G108 8W 15 9 G202 8W 15 13 G109 8W 15 9 G301 8W 15 14 G110 8W 15 9 G302 8W 15 14 G111 8W 15 9 G303 8W 15 15 G112 8W 15 10 G304 8W 15 15 G113 8W 15 10 8040ccd6 J968W 9 ...

Page 613: ...TCH 8W 53 4 x WITH SPEED CONTROL HIGH LINE CLUSTER VEHICLE SPEED CONTROL SERVO 8W 33 4 VACUUM SENSOR 8W 34 4 8W 35 5 WITH DIESEL ENG Z l 12BK WITH LOW LINE CLUSTER HIGH NOTE HORN 8W 41 4 Z l 12BK I G1Q1 A L O W NOTE HORN 8W 41 4 WITH HIGH LINE CLUSTER SPLICE S103 8W 15 4 C8W 70 3 Z l 14BK SPLICE S115 8W 15 6 7 8 8W 70 8 LEFT PARK TURN SIGNAL LAMP C8W 52 6 8W 50 5 8040ccd8 WITH MEDIUM LINE AND HIGH...

Page 614: ...3 1 8 C8W 34 6 C 8 W 3 5 7 8 W 4 0 9 Zl 20BK S 4 0 9 8W 70 43 Zl 20BK Zl 20BK L E F T FOG LAMP 8 W 5 0 1 0 L E F T P A R K TURN S I G N A L LAMP 8 W 5 2 6 C 8 W 5 0 5 Zl 18BK Zl 18BK Z l 20BK RIGHT P A R K TURN S I G N A L LAMP 8 W 5 2 6 csw si si RIGHT HEADLAMP 8 W 5 0 5 WINDSHIELD WASHER PUMP MOTOR C 8 W 5 3 4 8040ccda J968W 9 ...

Page 615: ...18BK LG Z2 18BK LG Z2 18BK LG Z2 18BK LG Z2 18BK LG fP 12 J 18BK 1 LG C 2 0 2 Z2 18BK LG Z2 18BK LG Z2 18BK LG WITH STANDARD SPEAKERS S 3 0 1 8W 70 34 Z2 18BK LG L E F T R E A R P R E M I U M S P E A K E R 8 W 4 7 7 8040ccdc Z2 18BK LG R I G H T R E A R P R E M I U M S P E A K E R C 8 W 4 7 7 R A D I O 8 W 4 7 5 7 8 9 Z8 10BK PK S 1 2 2 8W 70 11 WITH RWAL A B S 2 W A Y POWER F E E D C 8 W 3 5 9 WI...

Page 616: ...5 3 4 C 3 4 2 BLACK Z13 16BK UNDERHOOD LAMP 8 W 4 4 8 S P L I C E _ S 4 0 2 8 W 1 5 7 8 W 7 0 4 1 S 3 1 1 S P L I C E S 4 0 1 8 W 1 5 7 8 W 7 0 4 1 8W 70 37 Z13 16BK F U E L _ PUMP MODULE 8 W 3 0 2 1 4 2 Z13 12BK Z13 C 1 2 8 Z13 16BK t Z13 12BK I WITH TRAILER TOW C 1 2 8 RIGHT L I C E N S E LAMP 8 W 5 1 4 1 0 Z l 18BK L E F T HEADLAMP 8 W 5 0 5 Z l 20BK G 1 0 4 NO CONNECTION WITH HIGH LINE CLUSTER...

Page 617: ... S E LAMP 8 W 5 1 4 1 0 Z13 18BK I WITH T_ DUAL REAR Z13 WHEELS 18BK C 3 4 3 C 3 4 1 Z13 18BK Z13 18BK i i L E F T S P L I C E L I C E N S E S 4 0 5 L A M P C 8 W 1 5 8 8 W 5 1 4 8 W 7 0 4 2 Zl 18BK L E F T HEADLAMP 8 W 5 0 5 Zl 20BK G 1 0 4 L RIGHT B A C K U P LAMP 8 W 5 1 7 R I G H T T A I L S T O P A N D T U R N S I G N A L LAMP 8 W 5 1 5 8 W 5 2 6 S 1 1 5 8W 70 8 T V Z l 12BK Zl 14BK WITH DIES...

Page 618: ...2 Z13 18BK S 4 0 8 Z13 18BK Z13 18BK 8W 70 42 Z13 18BK RIGHT L E F T T A I L G A T E T A I L G A T E LAMP LAMP C 8 W 5 1 1 1 8 W 5 1 1 1 C4Q4 C 4 0 5 Z13 18BK L E F T R E A R FENDER LAMP 8 W 5 1 1 2 CI Z13 18BK RIGHT R E A R FENDER LAMP W 5 1 1 2 3 Z13 18BK Z13 18BK C 4 0 2 L E F T L I C E N S E LAMP 8 W 5 1 1 0 Z13 18BK L E F T FORWARD FENDER LAMP Z13 18BK C 4 0 3 Z13 18BK RIGHT FORWARD FENDER LA...

Page 619: ... 5 9 SPLICE 122 8 W 1 5 5 8 W 7 0 1 1 C133 16 18BK 0R 16 18BK 0R 232 11 GND i A I R B A G CONTROL M O D U L E mm ZO 10BK ZO 6BK B A T T E R Y N E G A T I V E TERMINAL WITH GAS ENG 8 W 2 0 3 iioi GllO ZO 8BK I I 1 G i l l 8040cce5 J968W 9 ...

Page 620: ...U T DOWN SOLENOID 8 W 3 0 4 7 WITH DIESEL ENG Zl 6BK G E N E R A T O R C 8 W 2 0 3 4 G 1 1 3 LEFT B A T T E R Y N E G A T I V E T E R M I N A L WITH DIESEL ENG 8 M 2 0 4 1118 R I G H T B A T T E R Y N E G A T I V E T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 8040cce7 J968W 9 ...

Page 621: ...ENSOR 81 30 38 f 8 W 3 0 3 8 f 8 W 3 0 3 7 f I Z l l I Z l l 1 Z l l 18BK 18BK 18BK WT WT WT RIGHT UPSTREAM HEATED OXYGEN SENSOR 8 W 3 0 3 7 DOWNSTREAM HEATED OXYGEN SENSOR 8 W 3 0 2 9 3 2 3 3 UPSTREAM HEATED OXYGEN SENSOR P A R K N E U T R A L P O S I T I O N SWITCH 8 W 2 1 3 BLACK ENGINE COOLANT SENDING UNIT 8 W 4 0 6 ENGINE S T A R T E R MOTOR R E L A Y 8 W 2 1 3 81 11 17 A C COMPRESSOR CLUTCH ...

Page 622: ...UT DOWN RELAY 8W 30 47 FUEL FUEL HEATER P U M P RELAY NODULE 8W 30 47 8W 30 42 Z12 111 20BK 20BK TN WT X V in 20BK WT SPLICE S208 8H 15 13 8W 70 30 Z l l 18BK WT f Z l l 18BK WT A C COMPRESSOR CLUTCH 8W 42 8 FUEL HEATER 8W 30 47 G119 WITH DIESEL ENG 8040ccee WITH AUTO TRANS J968W 9 ...

Page 623: ...USTER Z3 20BK 0R Z3 20BK 0R Z3 20BK 0R GND j 1 0 C216 K EY IN SWITCH HALO LAMP C 8 W 4 4 5 Z3 16BK 0R WITH RWAL BLACK OVERHEAD CONSOLE GLOVE BOX LAMP SWITCH 8W 44 8 WITH FOG LAMPS FOG LAMP SWITCH 8W 50 10 INSTRUMENT CLUSTER 9 C215 6 C216 Z l l 20BK WT Z l l 20BK WT Z l l 20BK WT C208 WITH OVERHEAD CONSOLE OVERDRIVE SWITCH ILLUMINATION LAMP 8W 31 7 STOP LAMP SWITCH 8W 33 4 8W 34 5 8W 35 7 Z l l 20B...

Page 624: ...STOP LAMP NO 1 8W 51 9 CENTER HIGH MOUNTED STOP LAMP NO 2 8W 51 9 Z3 14BK 0R C303 Z3 14BK 0R WITH POWER SEAT Z3 14BK 0R Z3 18BK 0R POWER SEAT SWITCH 8W 63 3 L E F T POWER WINDOW SWITCH 8W 60 3 POWER MIRROR SWITCH 8W 62 3 Z3 18BK 0R WITHOUT POWER WINDOWS AND POWER LOCKS G302 WIHOUT OPTIONAL Z3 14BK 0R S306 8W 70 36 Z3 18BK 0R Z3 14BK OR LEFT POWER WINDOW SWITCH 8W 60 3 POWER MIRROR SWITCH 8 W 6 2 3...

Page 625: ... P 8 W 4 4 4 LEFT V I S O R V A N I T Y LAMP C8W 44 4 Z4 18BK L E F T O U T B O A R D C L E A R A N C E L A M P 8 W 5 0 6 Z4 18BK Z4 18BK Z4 18BK S 3 1 8 8W 70 40 R I G H T O U T B O A R D C L E A R A N C E L A M P 8 W 5 0 6 D A Y N I G H T M I R R O R 8 W 4 4 9 Z4 20BK Z4 20BK WITH HIGH LINE CLUSTER C 3 S 3 C 3 5 2 WITH LOW LINE CLUSTER G 3 Q 4 O V E R H E A D M A P C O U R T E S Y LAMP 8 W 4 9 5...

Page 626: ......

Page 627: ...and is connected to battery voltage A 40 amp fuse in cavity 3 of the PDC protects the A l circuit When the ASD relay energizes it connects circuit A16 from the PDC to circuit A142 Circuit A142 splices to connect to the generator connector supply ing battery voltage to the generator field The Powertrain Control Module PCM has an internal voltage regulator that controls generator output Circuit K20 ...

Page 628: ... 20 CHARGING SYSTEM BR DIAGRAM INDEX Component Page Component1 Page Battery 8W 20 3 4 Powertrain Control Module 8W 20 3 4 Fuse Gen PDC 8W 20 3 4 Right Battery 8 W 2 0 4 Generator 8W 20 3 4 8 0 4 0 c c f 7 J968W 9 ...

Page 629: ... 10BK AUTOMATIC SHUT DOWN RELAY 8 W 3 G 1 2 8 W 1 1 1 0 G110 G i l l G109 8W 15 9 i 1 8W 15 9 i1 8W 15 9 C 1 3 7 A142 16DG OR C 1 2 7 f A142 14DG 0R S 1 3 8 8W 70 17 ASD C12 RELAY SENSE GENERATOR FIELD DRIVER BIO POWERTRAIN CONTROL MODULE A142 14DG OR C 1 3 6 K20 18DG S 1 3 5 A142 14DB 8W 70 15 S 1 3 4 8W 70 14 K20 18DG J968W 9 ...

Page 630: ...W 21 4 A U T O M A T I C S P L I C E SHUT DOWN S14S RELAY 8W 70 21 8W 30 12 C8W 11 CIS1 I 4 I J GENERATOR C137 C151 2 ASD C12 RELAY SENSE GENERATOR FIELD DRIVER BIO POWERTRAIN CONTROL MODULE A142 14DB T K20 18DG C136 S134 8W 70 14 K20 18DG Y zi 6BK C151 1113 1 8W 15 10 J968W 9 ...

Page 631: ...NUAL TRANSMISSION The Power Distribution Center PDC supplies bat tery voltage to the engine starter motor solenoid on circuit T40 when the coil side of the engine starter motor relay energizes Circuit AO from the battery is triple crimped at the positive battery post One branch of circuit AO bat tery positive cable connects to the engine starter motor Another branch of circuit AO supplies voltage ...

Page 632: ... Jumper 8W 21 3 4 Clutch Pedal Position Switch 8W 21 3 4 Engine Starter Motor 8W 21 3 4 Engine Starter Motor Relay 8W 21 3 4 Component Page Fuse 2 PDC 8W 21 3 4 Fuse 3 PDC 8W 21 3 4 Ignition Switch 8W 21 3 4 Park Neutral Position Switch 8W 21 3 4 8 0 4 0 c c f c J968W 9 ...

Page 633: ... 8 0 Al 12RD i A2 1 2 P K BK S 1 4 6 30 j 8 6 A2 ENGINE S T A R T E R MOTOR R E L A Y C 1 8 0 W I T H MAN T R A N S Z12 20BK TN S 1 5 1 T 4 1 20BK WT S 1 4 1 8W 70 22 8W 70 19 T141 12PK 14YL 8W 7Q 201 BK RD C 1 3 3 Z12 10BK TN S 1 5 0 T41 18BK WT 8W 70 22 Z12 14BK TN G i l t I I I 8 W 1 5 1 1 WITH MAN TRANS 2 C169 I 4 i T141 14YL RD T141 14YL RD P A R K N E U T R A L P O S I T I O N SWITCH CASE GR...

Page 634: ...40 12BR POWER T40 12BR C12S T41 2 2 B K W T TRANS 8W 70 22 Z12 14BK TN S142 I 8W 70 19 Z12 14BK TN l i l t ENGINE STARTER MOTOR r 9 1 L ON Q FUEL SHUT D O W N RELAY 8W 30 47 Z12 20BK T41 WITH TN 20BK M A N I S152 WT S141 8W 70 19 T41 18BK WT 8W 15 12 2 WITH M A N TRANS C169 PARK NEUTRAL POSITION SWITCH CLUTCH PEDAL POSITION SWITCH CASE GROUND C132 1 C132 A41 18DB YL 2 BYPASS JUMPER C132 T 1 4 1 20...

Page 635: ...tch pedal position sensor or the clutch pedal position switch bypass jumper Also in the START position the ignition switch connects circuit G9 to ground In the ACCESSORY or RUN position the ignition switch connects circuit Al to circuit A31 Circuit A31 page HEATED OXYGEN SENSORS 3 IDLE AIR CONTROL MOTOR 6 IGNITION COIL V 10 ENGINES 6 IGNITION COIL V 6 AND V 8 ENGINES 6 IGNITION SWITCH 1 INTAKE AIR...

Page 636: ...mp relay contacts close circuit A61 feeds the fuel pump motor Circuit Z13 provides ground for the fuel pump motor FUEL LEVEL SENSOR The fuel level sensor is a variable resistor Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster Circuit F14 from fuse 12 in the fuse block supplies voltage to the fuel gauge The fuel level sensor draws voltage from circuit F14 throug...

Page 637: ...ty A4 of the PCM connector Circuit Z l l provides a ground for the heater circuit in the sensors V fO ENGINES Vehicles with the V 10 engine built for sale in the State of California use four heated oxygen sensors All other V 10 equipped vehicles use two heated oxy gen sensors Circuit K141 delivers the signal from the left heated oxygen sensor to the Powertrain Control Mod ule PCM Circuit K141 conn...

Page 638: ...anifold absolute pressure sensor Vehicle speed sensor THROTTLE POSITION SENSOR From the Powertrain Control Module PCM cir cuit K6 supplies 5 volts to the Throttle Position Sen sor TPS Circuit K6 connects to cavity A17 of the PCM Circuit K22 delivers the TPS signal to the PCM Circuit K22 connects to cavity A23 of the PCM The PCM provides a ground for the TPS signal circuit K22 through circuit K4 Ci...

Page 639: ...3 of the PDC protects circuits A l and A41 The Park Neutral position switch and back up lamp switch are molded together FUEL INJECTORS When the Automatic Shut Down ASD relay con tacts close they connect circuits A16 and A142 Cir cuit A142 supplies voltage to the fuel injectors Each injector has a separate ground circuit controlled by the Powertrain Control Module PCM Circuit K l l provides ground ...

Page 640: ... the PCM The PCM controls the ground path for the coil that supplies spark to cylinders 4 and 7 on circuit K32 Circuit K32 connects to cavity A l of the PCM The PCM controls the ground path for the coil that supplies spark to cylinders 5 and 10 on circuit K17 Circuit K17 connects to cavity A9 of the PCM IDLE AIR CONTROL MOTOR The Powertrain Control Module PCM operates the Idle Air Control motor th...

Page 641: ...from the PCM The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw The PCM provides a ground for the intake air tem perature sensor signal circuit K21 through circuit K4 Circuit K4 connects to cavity A4 of the PCM HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following Water in fu...

Page 642: ...connects to the intake air heater When the second intake manifold air heater relay energizes its contacts close and connect circuit A8 from the left battery positive terminal to circuit A122 Circuit A122 connects to the intake air heater The intake manifold air heaters are case grounded Refer to Group 14 Fuel Systems for intake manifold heater Pre Heat and Post Heat Cycles EGR SOLENOID DIESEL ENGI...

Page 643: ... 9 8W 30 11 12 20 Fuse 11 8W 30 11 Fuse 12 8W 30 11 Fuse 14 8W 30 11 8W 30 9 Page Fuse 15 8W 31M7 Fuse 16 8W 30 11 F2 8W 30 11 Generator 8W 30 28 Heated Oxygen Sensors 8W 30 29 32 33 37 38 Idle Air Control Motor 8W 30 26 Ignition Coil 8W 30 28 Ignition Coil 4 Pack 8 0L ENG 8W 30 36 Ignition Coil 6 Pack 8 0L ENG 8W 30 36 Ignition Switch 8W 30 11 12 20 Injectors 3 9L ENG 8W 30 30 31 Injectors 5 2L 5...

Page 644: ... PDC 8W 30 11 12 41 Fuse 4 PDC 8W 30 12 Fuse 5 8W 30 11 Fuse 6 8W 30 11 Fuse 7 8W 30 11 Fuse 8 8W 30 11 Fuse 8 PDC 8W 30 41 43 B R Page Fuse 9 8W 30 11 12 41 Fuse 11 8W 30 11 Fuse 12 8W 30 11 Fuse 14 8W 30 11 Fuse 15 8W 30 11 Fuse 16 8W 30 11 F2 8W 30 11 Generator 8W 30 45 Heated Intake Air System 8W 30 48 Heated Intake Air System Relay 1 8W 30 48 Heated Intake Air System Relay 2 8W 30 48 Ignition...

Page 645: ...WITH DIESEL ENG 8 W 2 0 4 8W 30 FUEL IGNITION SYSTEMS AO 6RD 8W 30 11 RED BRAKE WARNING LAMP DRIVER A41 A41 18Db 18DB YL I YL f B Y P A S S f CLUTCH JUMPER P E D A L 8 W 2 1 3 4 P O S I T I O N SWITCH 8 M 2 1 3 4 3 9 C 2 4 1 FUSE S FUSE S FUSE 15A 15A 1 20A F U S E BLOCK WITH GAS ENG WITH DIESEL ENG 8040d007 J968W 9 ...

Page 646: ...Ol SYSTEMS BR POWER B A T T E R Y P O S I T I V E T E R M I N A L 8W 20 3 4 RIGHT BATTERY POSITIVE T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 TRANSMISSION R E L A Y C8W 31 4 8 W 1 1 9 8040d009 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 647: ...B R 8W 30 FUEL IGNITION SYSTEMS 8W 30 1 3 WITH GAS ENG WITH D I E S E L ENG 8040d00c J968W 9 ...

Page 648: ... SENSOR WITH D I E S E L ENG G7 20WT OR C 1 2 7 G7 22WT OR C 1 3 3 G7 20WT OR S 2 1 0 8W 70 31 G7 20WT OR INSTRUMENT C L U S T E R 8 W 4 0 5 A4 SENSOR GND B31 5 VOLT SUPPLY B29 GOV PRESS SIG B27 VEHICLE SPEED SENSOR SIGNAL POWERTRAIN CONTROL MODULE 8040d00f J968W 9 ...

Page 649: ... I T C H A C H E A T E R C O N T R O L S W I T C H 8 W 4 2 6 C90 22LG C 1 3 3 C90 18LG C20 18BR C 1 2 S S 1 6 0 C90 18LG 8W 70 26 A C C O M P R E S S O R C L U T C H R E L A Y 8 W 4 2 8 8 W 1 1 8 C13 22DB OR C 1 2 S C90 18LG C13 20DB OR C 1 3 7 C22 A C REQUEST C23 A C SELECT INPUT CI A C CMP CLUTCH RLY CTRL J P O W E R T R A I N C O N T R O L M O D U L E 8040d010 J968W 9 ...

Page 650: ...RAKE S W SENSE 9 C 1 2 1 1 I N S T R U M E N T C L U S T E R UPSHIFT LAMP DRIVER 3 C 2 1 6 G54 220R BK NOT USED C 2 2 S C 1 3 3 T18 22LG OR C 1 2 S G54 200R BK C 1 3 6 B l l UPSHIFT LAMP DRIVER P O W E R T R A I N C O N T R O L N O D U L E WITH MAN TRANS EXCEPT HEAVY DUTY EXCEPT DIESEL ENG AND 8 0 L ENG 8040d012 J968W 9 ...

Page 651: ... 22TN YL G3 22BK PK G21 22GY LB C 1 3 3 C 1 3 3 G86 18TN OR G24 20GY PK G14 18PK BK G12 20TN YL G3 22BK PK G21 22GY LB C 1 2 5 C 1 2 6 CI 25 C 1 2 5 C 1 2 6 C 1 2 7 G86 18TN OR G24 20GY PK G14 18PK BK G12 20TN YL G3 20BK PK G21 20GY LB s C 1 3 7 2 K C 1 3 7 S C 1 3 7 s C 1 3 7 2 K C 1 3 7 r S C 1 3 7 i C18 C18 C7 C16 C17 C31 WATER SRI TRANS GEN MIL TACH I N LAMP TEMP LAMP DRIVER SIGNAL j FUEL DRIV...

Page 652: ... 8 W 3 1 4 8 W 1 1 9 S 1 2 9 8W 70 25 8W 70 12 C 1 3 3 K4 20BK LB K4 20BK LB V37 20RD LG OUTPUT SHAFT SPD SENSOR GND OUTPUT SHAFT SPD SENSOR SIGNAL 2 C 1 2 6 1 T R A N S M I S S I O N O U T P U T S H A F T S P E E D S E N S O R WITH AUTO TRANS K30 20PK C 1 8 7 K4 20BK LB 37 20RD LG T13 18DB BK T 1 4 18LG BK C 1 2 S K30 20PK C 1 3 S C 1 3 7 C 1 3 6 C13e A4 SENSOR GND C32 B25 B28 SC OUTPUT OUTPUT SW...

Page 653: ...E OVERDRIVE SWITCH NOT FUNCTIONAL WITH AUTO TRANS G54 220R BK 1 f C133 T18 22LG OR 3 C225 C216 T6 220R WT UPSHIFT LAMP DRIVER INSTRUMENT CLUSTER C133 T6 220R WT K88 20VT WT T60 20BR K54 200R BK T54 18VT C125 T18 20LG OR C136 C125 16 200R WT C137 B8 VARIABLE FORCE SOL CONTROL B21 OD SOL CONTROL B l l TCC SOL CONTROL B l TRANS TEMP SENSOR SIG C6 OD LAMP DRIVER C13 TRANS OD SW SENSE POWERTRAIN CONTRO...

Page 654: ...L E E V A P PURGE SOLENOID F18 20LG BK K52 20PK F18 20LG BK I Y K35 20GY YL EXHAUST GAS R E C I R CULATION SOLENOID WITH 5 2 L AND C 1 4 6 5 9 L ENG 86 T R A N S M I S S I O N R E L A Y 8W 31 4 C 8 W 1 1 9 A14 16RD WT 3 0 85 8 7 C 1 3 7 C135 C138 C 1 3 7 K31 20BR WT C 1 2 7 K31 20BR WT 4 C 1 2 7 A14 16RD WT POWER D I S T R I B U T I O N C E N T E R C 1 8 0 F U E L PUMP R E L A Y C 1 8 0 A61 16DG B...

Page 655: ...tot 8W 30 FUEL IGNITION SYSTEMS WITH GAS E1G 8W 30 21 F U E L PUMP RELAY 8 W 3 0 2 0 8 W 1 1 1 1 INSTRUMENT CLUSTER WITH TRAILER TOW 8040d01b J968W 9 ...

Page 656: ...0VT WT C A M S H A F T POSITION SENSOR IN DISTRIBUTOR WITH 3 9 L 5 2 L AND 5 9 L ENG C171 K4 20BK LB S 1 3 6 8W 70 16 K4 18BK LB S 1 5 4 8W 70 23 K4 18BK LB S 1 2 9 8W 70 12 K4 20BK LB C135 A17 A18 A4 5 VOLT CMP SENSOR SUPPLY SENSOR GND SIGNAL P O W E R T R A I N C O N T R O L M O D U L E ...

Page 657: ...ENG K4 18BK LG K4 18BK LG S136 K21 18BK RD S129 I8W 70 12I 8W 70 16 K4 18BK LB S154 8W 70 23 K4 18BK LB K4 20BK LB S129 8W 70 12 K4 20BK LB A15 I AT SIGNAL K4 20BK LB C13S A4 SENSOR GND POWERTRAIN CONTROL MODULE A17 5 VOLT SUPPLY A27 MAP SENSOR SIGNAL A4 SENSOR GND POWERTRAIN CONTROL MODULE WITH 8 0L ENG WITH 3 9L 5 2L AND 5 9L ENG J968W 9 ...

Page 658: ...8W 30 24 8W 30 FUEL IGNITION SYSTEMS WITH GAS EIG THROTTLE C15 BATTERY TEMP SENSOR SIGNAL A4 S E N S O R G N D A17 A23 5 VOLT TP SUPPLY SENSOR SIGNAL POWERTRAIN CONTROL MODULE 8040d021 J968W 9 ...

Page 659: ...RD WT F U E L PUMP R E L A Y C8W 30 20 8W 11 11 G 1 1 9 8W 15 11 SC VACUUM SOL CONTROL SC VENT SOL CONTROL V E H I C L E S P E E D CONTROL SERVO WITH SPEED CONTROL HIGH LINE CLUSTER 1 2 C 1 0 9 J O I N T V36 20TN RD V35 20LG RD C 1 2 6 WITH SPEED CONTROL HIGH LINE CLUSTER C 1 3 3 V32 20YL RD V36 20TN RD V35 20LG RD C 1 2 6 V32 20YL RD C 1 3 7 C4 sc VACUUM SOL CONTROL C5 SC VENT SOL CONTROL C l l S...

Page 660: ... 0 K39 18GY RD K60 18YL BK K40 18BR WT K59 18VT BK K4 18BK LB C 1 5 2 E N G I N E C O O L A N T T E M P E R A T U R E S E N S O R S 1 2 9 1 8W 70 12 C 1 5 2 K4 20BK LB K2 18TN BK C 1 3 S A19 I AC MOTOR NO 1 DRIVER AlO I AC MOTOR NO 2 DRIVER A l l I AC MOTOR NO 3 DRIVER A20 I AC MOTOR NO 4 DRIVER A4 SENSOR GND A16 ECT SENSOR SIGNAL 1 P O W E R T R A I N C O N T R O L M O D U L E J968W 9 ...

Page 661: ... 23 K4 18BK LB S 1 2 9 O 8W 70 12 K4 20BK LB ENGINE S T A R T E R MOTOR R E L A Y 8 W 2 1 3 8 W 1 1 1 7 T41 22BK WT C 1 2 5 T41 20BK WT WITH i MAN Z12 TRANS 20BK TN I S 1 5 1 8W 70 22 S 1 4 1 I T41 18BK WT f P A R K N E U T R A L P O S I T I O N SWITCH 8 W 2 1 3 y 8W 70 19 Z12 10BK TN S 1 5 0 8W 70 22 T41 20BK WT Z12 14BK TN G 1 1 9 8W 15 11 C 1 3 5 A17 A8 5 VOLT CKP SUPPLY SENSOR SIGNAL A4 SENSOR...

Page 662: ... N I T I O N C O I L WITH 3 9L 5 2L AND 5 9L ENG A142 14DG 0R C 1 7 0 C 1 7 0 A142 14DG OR S 1 3 5 8W 70 15 A142 14DB 2 C 1 5 1 ASD RELAY OUTPUT GENERATOR FIELD DRIVER 1 C 1 5 1 K20 18DG G E N E R A T O R S 1 3 4 8W 70 14 C 1 3 5 K20 18DG A7 IGN COIL NO 1 DRIVER C 1 3 6 BIO GENERATOR FIELD DRIVER P O W E R T R A I N C O N T R O L M O D U L E J 8040d027 J968W 9 ...

Page 663: ...TOMATIC SHUT DOWN RELAY 8W 30 12 8 W X 1 1 0 C 1 2 7 A142 14DG 0R UPSTREAM HEATED OXYGEN i A25 A4 DOWNSTREAM SENSOR i HEATED GND OXYGEN i SENSOR SIGNAL CONTROL MODULE A24 UPSTREAM HEATED OXYGEN SENSOR SIGNAL A4 SENSOR GND CONTROL MODULE 8040d029 J968W 9 ...

Page 664: ...8W 30 30 8W 30 FUEL IGNITION SYSTEMS 3 9L ENGINE AUTOMATIC SHUT DOWN IELAY i 8 W 3 0 1 2 C S W 1 1 1 0 A142 14DG 0R 8040d02b J968W 9 ...

Page 665: ...YSTEMS 3Ml ENGINE 8W 30 31 AUTONATIC SHUT DOWN RELAY i 8 W 3 0 1 2 8 W 1 I 1 0 C 1 2 7 A142 14DG 0R C 1 4 2 INJECTOR NOo B15 INJ NO 2 DRIVER B16 INJ NO 4 DRIVER B12 INJ NO 6 DRIVER POWERTRAIN CONTROL MODULE 8040d02e J968W 9 ...

Page 666: ...TOMATIC SHUT DOWN RELAY 8 W 3 0 1 2 8 W 1 1 1 0 C 1 2 7 C 1 6 2 A142 16DG OR f 1 Z l l 18BK WT UPSTREAM i A25 A4 DOWNSTREAM SENSOR i HEATED GND J OXYGEN i SENSOR i SIGNAL CONTROL MODULE A24 UPSTREAM HEATED OXYGEN SENSOR SIGNAL A4 SENSOR GND POWERTRAIN CONTROL MODULE 8040d02f J968W 9 ...

Page 667: ...S 5 9L ENGINE HEAVY DUTY TRANS ONLY 8W 3 0 3 3 AUTOMATIC SHUT DOMN R E L A Y 8 W 3 0 1 2 C 8 W 1 1 I 0 C 1 2 7 A142 14DG 0R A142 16DG OR Z l l 18BK WT C 1 3 5 A4 A24 SENSOR UPSTREAM GND HEATED OXYGEN SENSOR SIGNAL 8040d032 J968W 9 ...

Page 668: ...1 C 1 5 9 I N J E C T O R NO 1 C 1 5 9 K l l 18WT DB A142 14DG OR S 1 3 3 8W 70 14 A142 16DG OR A142 16DG OR 2 C 1 5 8 2 I N J E C T O R C 1 5 6 1 I N J E C T O R NO 5 C 1 5 8 1 C 1 5 6 K13 18YL WT K38 18GY B4 INJ NO 1 DRIVER B5 INJ NO 3 DRIVER B6 INJ NO 5 DRIVER A142 16DG OR C 1 5 5 I N J E C T O R NO 7 C 1 5 5 C 1 3 6 B2 INJ NO 7 DRIVER POWERTRAIN CONTROL MODULE 8040d034 J968W 9 ...

Page 669: ...L 5 9L ENGINES 8W 30 35 A U T O M A T I C SHUT DOWN RELAY 8W 30 12 8W 11 10 A142 14DG 0R C127 A142 14DG OR _ S3L38 8W 7G 17 B15 INJ NO 2 DRIVER B16 INJ NO 4 DRIVER B12 INJ NO 6 DRIVER B13 INJ NO 8 DRIVER CONTROL MODULE 8040d036 J968W 9 ...

Page 670: ...IL j NO 2 NO 3 DRIVER DRIVER i _ k _ 3_ jJ C141 IGNITION COIL 4 PACK IGN COIL NO 1 DRIVER 1 K17 18DB WT K18 18RD BK K19 18BK GY A142 14DG OR 3 C144 ASD RLY OUTPUT IGN COIL NO 4 DRIVER IGN COIL NO 5 DRIVER IGNITION COIL 6 PACK 2 4 C144 K32 18YL GY K43 18DG GY C135 A9 IGN COIL NO 2 DRIVER A3 IGN COIL NO 3 DRIVER A7 IGN COIL NO 1 DRIVER Al IGN COIL NO 4 DRIVER A5 IGN COIL NO 5 DRIVER POWERTRAIN CONTR...

Page 671: ...BR 8W 30 FUEL IGNITION SYSTEMS 8 0L ENGINE 8W 30 37 A U T O M A T I C SHUT DOWN RELAY 8W 30 12 8W I1 10 C12 A142 14DG 0R 8040d03c J968W 9 ...

Page 672: ... 38 FUEL IGNITION SYSTEMS 8 0L ENGINE CALIFORNIA ONLY BR AUTOMATIC SHUT DOWN RELAY 8 W 3 0 I 2 8W 11 IO C 1 2 7 A142 14DG 0R A29 A4 PRE CATALYST S E N S O R HEATED G N D O X Y G E N SENSOR SIGNAL 8040d03e J968W 9 ...

Page 673: ...BR 8W 30 FUEL IGNITION SYSTEMS 8JL ENGINE 8W 30 31 A U T O M A T I C SHUT DOWN RELAY i 8 W 3 0 1 2 8 W 1 1 1 0 A142 14DG 0R 127 f A142 14DG OR 138 8W 70 17 8040d040 J968W 9 ...

Page 674: ...8 W 1 1 1 0 A142 14DG 0R C 1 2 7 A142 14DG OR S 1 3 8 8W 70 17 A142 14DG OR S135 8W 70 15 A142 16DG OR A142 16DG OR A142 16DG OR A142 16DG OR A142 16DG OR B15 INJ NO 2 DRIVER B16 INJ NO 4 DRIVER B12 INJ NO 6 DRIVER B13 INJ NO 8 DRIVER B14 INJ NO 10 DRIVER POWERTRAIN CONTROL MODULE 8040d042 J968W 9 ...

Page 675: ... A N S M I S S I O N R E L A Y 8 W 3 1 4 8 W 1 1 9 A14 16RD WT F18 18LG BK 8 6 3 0 C 1 2 7 A14 16RD WT POWER D I S T R I B U T I O N C E N T E R C 1 8 0 C 1 2 6 F18 18LG BK NOT FUNCTIONAL ON DIESEL NOT FUNCTIONAL ON DIESEL NOT FUNCTIONAL ON DIESEL NOT FUNCTIONAL ON DIESEL NOT USED ON DIESEL F U E L PUMP R E L A Y NOT USED ON DIESEL ClfO S 1 3 2 8W 70 13 F18 18LG BK C 1 2 7 C 1 3 5 K31 20BR WT K31 ...

Page 676: ...4 20DB C133 INSTRUMENT G4 22DB C128 G4 20DB OR 3 4 FUEL LEVEL SENSOR Z l l 20BK WT C128 Z l l 20BK WT S116 8W 70 8 Z l l 16BK WT C127 Z l l 16BK WT S140 8W 70 18 Z l l 16BK WT G119 8W 15 12 C128 K4 20BK LB K4 20BK LB S156 i8W 70 24 5 C328 NOT FUNCTIONAL ON DIESEL NOT FUNCTIONAL ON DIESEL K4 20BK FUEL LB PUMP MODULE 2 C328 C125 K104 20DB WT K4 20BK LB C128 S157 8W 70 25 K226 20DB WT C126 K4 20BK LB...

Page 677: ...EL PUMP RELAY C8W 30 41 C8W 11 11 A14 16RD WT G119 8W 15 12 SC SC VACUUM VENT SOL SOL CONTROL CONTROL VEHICLE SPEED CONTROL SERVO WITH SPEED CONTROL HIGH LINE CLUSTER 111 14BK TN 1 2 V36 20TN RD V35 20LG RD C109 JOINT CONNECTOR C C126 S142 WITH SPEED CONTROL HIGH LINE CLUSTER 8W 70 19 C127 V32 20YL RD V36 20TN RD V35 20LG RD C126 V32 20YL RD C137 C4 SC VACUUM SOL CONTROL C5 SC VENT SOL CONTROL C l...

Page 678: ... C8W 30 49 I N T A K E A I R TEMPERATURE SENSOR C157 K4 20BK LB THROTTLE POSITION SENSOR WITH EGR OR AUTO TRANS k A15 INTAKE AIR TEMP SENSOR SIGNAL A4 SENSOR GROUND A27 WATER I N FUEL SENSOR SIGNAL C135 A23 TP SENSOR SIGNAL A17 5 VOLT SUPPLY POWERTRAIN CONTROL MODULE 8040d049 J968W 9 ...

Page 679: ...A142 14DB 2 C 1 5 1 ASD RELAY OUTPUT GENERATOR FIELD DRIVER GENERATOR WAIT TO START WARNING LAMP DRIVER MESSAGE C E N T E R 1 C 1 5 1 4 C 2 2 4 K20 18DG G85 200R BK C 1 3 3 S 1 3 4 8W 70 14 G85 180R BK K20 18DG C 1 2 S G85 180R BK C 1 3 6 C 1 3 6 C15 BATTERY TEMP SENSOR SIGNAL A4 SENSOR GND BIO GENERATOR FIELD DRIVER B20 WAIT TO START WARNING LAMP DRIVER POWERTRAIN CONTROL MODULE 8040d04b J968W 9 ...

Page 680: ... MAN TRANS WITHOUT EGR C 1 2 5 8W 70 17 K4 20BK LB K6 20VT WT T41 20BK WT WITH MAN Z12 TRANS 20BK TN I S 1 5 2 K6 20VT WT 8W 70 22 S 1 4 1 y 8W 70 19 K6 20VT WT 4 T41 18BK WT P A R K N E U T R A L P O S I T I O N SWITCH 8 W 2 1 4 Z12 14BK TN S 1 4 2 8W 70 19 T41 20BK W T Z12 14BK TN G 1 1 9 8W 15 12 C 1 3 5 A4 A8 SENSOR ENGINE GND SPEED SENSOR SIGNAL A17 5 VOLT SUPPLY A6 PNP SWITCH SENSE POWERTRAI...

Page 681: ...45 8W 70 20 Qg A18 16DB A12 Z12 14RD 20BK TN TN A18 Z12 10RD 18BK BK TN 172 FUEL HEATER RELAY 173 FUEL SHUT D O W N 172 1 r 177 FUEL HEATER 2 177 Z12 16BK TN 132 8W 70 13 SPLICE 114 8W 30 12 8W 70 7 i F18 18LG BK C126 F18 18LG BK F18 20LG BK RELAY ENGINE STARTER MOTOR 8W 21 4 T40 12BR C119 T40 12BR ENGINE STARTER M O T O R RELAY 8W 21 4 8W 11 17 FUEL SHUT D O W N SOLENOID 8040d04f J968W 9 ...

Page 682: ...ICE S114 8W 30 12 8W 70 7 BATTERY CASE CASE GROUND GROUND A7 AIR INTAKE HEATER RELAY NO 1 A9 AIR INTAKE HEATER RELAY NO 2 A2 FUSED IGN SW INPUT START RUN C16 C17 GEN MIL LAMP DRIVER DRIVER C31 TACH SIGNAL CONTROL CONTROL POWERTRAIN CONTROL MODULE 8040d050 J968W 9 ...

Page 683: ...EGR AUTOMATIC SHUT D O W N RELAY 8W 30 I2 C8W 11 10 l i t ENGINE C O O L A N T 8W 30 49 Z12 14BK TN G 1 1 9 8W 15 12 C9 A12 A17 A23 i EGR EGR 5 VOLT TP DIAG FAULT SUPPLY SENSOR i TEST MONITOR SIGNAL 1 REQUEST POWERTRAIN CONTROL MODULE 8040d052 J968W 9 ...

Page 684: ......

Page 685: ... All three solenoids are molded together When the ignition switch is in the START or RUN positions it connects circuit A l from fuse 3 in the Power Distribution Center PDC to circuit A21 Cir cuit A21 powers circuit F18 through fuse 9 in the fuse block Circuit F18 powers the coil side of the electronic transmission relay The Powertrain Control Module PCM provides ground for the relay on cir cuit K3...

Page 686: ...he PCM The transmission temperature warning lamp is located in the message center HELPFUL INFORMATION Circuit K7 also supplies 5 volts to the vehicle speed sensor Circuit K4 also provides ground for the signals from the following Heated oxygen sensors Crankshaft position sensor Camshaft position sensor Engine coolant temperature sensor Intake air temperature sensor Throttle position sensor Manifol...

Page 687: ...se 9 8W 31 4 Fuse 11 8W 31 6 Fuse 13 8W 31 6 Fuse 18 8W 31 6 Headlamp Switch 8W 31 6 Component Page Ignition Switch 8W 31 4 6 Instrument Cluster 8W 31 7 8 Joint Connector A 8W 31 6 Joint Connector C 8W 31 6 Overdrive Switch 8W 31 7 Powertrain Control Module 8W 31 4 5 7 Transmission Output Shaft Speed Sensor 8W 31 7 Transmission Relay 8W 31 4 Transmission Solenoid Assembly 8W 31 4 5 8040d054 J968W ...

Page 688: ...1 4 8W 31 TRANSMISSION CONTROL BR B A T T E R Y P O S I T I V E T E R M I N A L 8W 2Q 3 4 RIGHT BATTERY P O S I T I V E TERMINAL WITH DIESEL ENG 8W 20 4 AO 6RD WITH GAS ENG WITH DIESEL ENG 8040 1055 J968W 9 ...

Page 689: ...AL 8 TRANSMISSION SOLENOID ASSEMBLY T K7 180R S130 8W 70 12 T K4 18BK LB I WITH DIESEL ENG K7 180R K4 18BK LB S154 8W 70 23 167 T25 20LG WT K88 20VT WT T60 20BR K4 18BK LB K4 18BK LB S129 S157 8W 70 12 8W 70 25 K4 20BK LB K4 20BK LB C136 K4 20BK LB C135 K54 200R BK T54 18VT C136 B31 5 VOLT SUPPLY A4 SENSOR GROUND B29 GOVERNOR PRESSURE SIGNAL B8 B21 VARIABLE OVERDRIVE FORCE SOLENOID SOLENOID CONTRO...

Page 690: ...12RD C133 IGNITION SWITCH 31 A7 12RD BK C241 1 4 3 5 1 2 1 4 F12 22DB WT FUSE 11 10A C241 1 8 C241 A7 m 12RD BK FUSE BLOCK A7 12RD BK S204 8W 70 28 A7 12RD BK A7 12RD BK 133 A7 12RD BK J FUSE 18 15A C241 WITH POWER SEAT HEADLAMP SWITCH PARK LAMP SWITCH OUTPUT JOINT CONNECTOR A 1 0 C217 C209 L F 3 3 20PK RD JOINT CONNECTOR C C209 F12 22DB WT FUSE 13 C241 G Xs 5A 2 1 OVERDRIVE SWITCH 8W 31 7 8040d05...

Page 691: ...R WITH AUTO TRANS OUTPUT OUTPUT i SHAFT SHAFT SPEED SPEED i i SENSOR SENSOR J j GROUND SIGNAL FOG LAMP SWITCH 8 W 5 0 1 0 C133 INSTRUMENT CLUSTER 2 1 T6 220R WT WITH AUTO TRANS C187 T18 20LG OR 654 200R BK WITH MAN TRANS EXCEPT HEAVY DUTY EXCEPT 8 0 L AND DIESEL ENG USED FOR UPSHIFT INDICATOR LAMP C125 T13 18DB BK T14 18LG BK T6 200R WT C136 C137 B25 OUTPUT SHAFT SPEED SENSOR GROUND B28 OUTPUT SHA...

Page 692: ...USTER 13 C215 WITH ABS 6107 22BK GY C133 C133 ABS CONTROLLER 6107 20BK GY 6107 20BK 6Y 6107 20BK GY 6107 20BK GY 6107 20BK 6Y WITH ABS S103 8W 70 3 Zl 18BK 0102 18W 15 41 C106 6107 18BK 6Y 1 jS C407 411 SWITCH 2 C407 Zl 18BK C106 Zl 20BK 8040d05e J968W 9 ...

Page 693: ...SET COAST switch closes the voltage level on circuit V37 at PCM cavity C32 has nominal value of 3 8 volts with a range from 3 6 to 3 9 volts When the RESUME ACCEL switch closes the voltage level on circuit V37 at PCM cavity C32 has nominal value of 4 4 volts with a range from 4 2 to 4 5 volts The PCM controls the vent and vacuum functions of the vehicle speed control servo on circuits V35 and V36 ...

Page 694: ...DEX Component Page Controller Anti Lock Brake 8W 33 4 Joint Connector C 8W 33 3 4 Powertrain Control Module 8W 33 3 4 Component Page Stop Lamp Switch 8W 33 4 Vehicle Speed Control Servo 8W 33 4 Vehicle Speed Control Horn Switch 8W 33 3 8040d060 J968W 9 ...

Page 695: ...RD LG K4 20BK LB K4 20BK LB SIS4 8W 70 23 K4 18BK LB C125 C133 K4 20BK LB K4 20BK LB C133 V37 20RD LG S156 8W 70 24 S I S S129 8W 70 12 8W 70 25 C126 WITH DIESEL ENG V37 20RD LG K4 20BK LB K4 20BK LB JOINT CONNECTOR C STOP LAMP SWITCH 8W 33 4 C126 V32 20YL RD C135 K4 20BK LB C137 A4 SENSOR GROUND C32 SPEED CONTROL SWITCH SIGNAL C l l SPEED CONTROL FEED POWERTRAIN CONTROL MODULE 8040d063 J968W 9 ...

Page 696: ...NTROL SERVO 4 1 2 2 V C109 32 33 19 C209 JOINT CONNECTOR C V32 22YL RD VEHICLE SPEED CONTROL HORN SWITCH C8W 33 3 J31 sfe C209 V40 22WT PK C133 1 V40 20WT PK WITH ABS Zl 20BK V36 20TN RD V35 20LG RD V32 22YL RD V40 22WT PK S108 8W 70 5 Zl 12BK C126 C133 S i l l 8W 70 6 V40 20WT PK V32 20YL RD V36 20TN RD V35 20LG RD C126 G101 8W 15 3 V32 20YL RD V40 20WT PK C121 9 BRAKE SWITCH SENSE CONTROLLER ANT...

Page 697: ...rcuit B113 connects to cavity 14 of the CAB Cir cuit B114 connects to cavity 13 of the CAB RWAL WALWE The rear wheel anti lock RWAL valve contains an isolation solenoid a dump solenoid and a reset switch Each is powered by the Controller Anti Lock Brake CAB on separate circuits page RWAL VALVE 1 STOP LAMP SWITCH INPUT 1 VACUUM SENSOR 2 WARNING LAMP 1 SCHEMATICS AND DIAGRAMS WIRING DIAGRAM INDEX 2 ...

Page 698: ... This circuit is HOT in the RUN position only and protected by a 20 amp fuse located in cavity 14 of the fuse block Ground for the switch is supplied on cir cuit Z l Circuit Z l connects to the vacuum sensor and sup plies a ground path for circuit G 9 If there is a prob lem in the system the sensor grounds circuit G9 and the red brake warning lamp in the instrument clus ter is illuminated S C H E ...

Page 699: ...Drive 4WD Switch 8W 34 6 Fuse 2 PDC 8W 34 4 Fuse 6 PDC 8W 34 5 Fuse 14 8W 34 4 Fuse 20 8W 34 5 Ground Joint 8W 34 4 Component Page Ignition Switch 8W 34 4 Instrument Cluster 8W 34 4 6 Joint Connector B 8W 34 5 Joint Connector C 8W 34 4 5 6 Park Brake Switch 8W 34 6 Powertrain Control Module 8W 34 5 Rear Wheel Speed Sensor 8W 34 7 RWAL Valve 8W 34 7 Stop Lamp Switch 8W 34 5 Vacuum Sensor 8W 34 4 80...

Page 700: ... 20GY BK 2 C123 4 GND r Z l 18BK J C133 5 A20 18RD DB Zl 12BK WITH HIGH LINE AND MEDIUM LINE CLUSTER G9 22GY BK WITH DIESEL ENG G9 20GY BK G9 16GY BK G9 18GY BK BLACK Zl 14BK S108 JOINT CONNECTOR C 26 8W 70 5 C209 Zl 12BK 24 23 G101 8W 15 3 G9 22GY BK 25 G9 22GY BK C209 C209 BRAKE SWITCH G9 22GY BK C228 4 3 FUSED IGN SW OUTPUT RUN 6 RED BRAKE WARNING LAMP DRIVER CONTROLLER ANTI LOCK BRAKE 3 C216 R...

Page 701: ...ANTI LOCK BRAKES 8W 34 5 B A T T E R Y P O S I T I V E T E R M I N A L C 8 W 2 0 3 4 RIGHT BATTERY POSITIVE T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 SPLICE S148 8W 70 21 WITH G A S E N G WITH DIESEL E N G 8040d06c J968W 9 ...

Page 702: ...l l SWITCH 18BK C407 C106 G107 18BK GY Z l 20BK S103 8W 70 3 C106 Z l 18BK G107 20BK GY ABS i WARNING LAMP 4WD DRIVER LAMP INSTRUMENT CLUSTER 1 4 1 3 C215 0102 8W 15 4 C133 G i l 22WT BK 5 PARK BRAKE SWITCH SENSE PARK BRAKE SWITCH G19 G107 22LG 20BK RD GY CASE GROUND 2 ABS WARNING LAMP DRIVER 4 4WD SENSE CONTROLLER ANTI LOCK BRAKE 8040d06e J968W 9 ...

Page 703: ... B113 20RD VT TWISTED PAIR C128 DATA LINK CONNECTOR B113 20RD VT C133 RIGHT REAR WHEEL SPEED SENSOR RWAL SERVICE DIAG SIGNAL TWISTED PAIR 9 13 C223 C133 TWISTED PAIR B113 20 R D VT B112 20BK B i l l 22LB BK B108 18WT C228 B101 18LG WT C228 14 RIGHT REAR WHEEL SPEED SENSOR 12 RWAL SERVICE DIAG SIGNAL 11 8 1 RWAL RWAL RWAL RESET DUMP ISOLATION SWITCH SOLENOID SOLENOID CONTROLLER ANTI LOCK BRAKE 8040...

Page 704: ......

Page 705: ... to cavity 2 of the CAB and provides the HIGH signal Circuits B8 and B9 provide signals to CAB from left front wheel speed sensor Circuit B8 which pro vides the LOW signal connects to cavity 16 of the page INTRODUCTION 1 REAR WHEEL ANTILOCK RWAL VALVE 2 STOP LAMP SWITCH SENSE 2 VACUUM SENSOR 2 WHEEL SPEED SENSORS 1 SCHEMATICS AND DIAGRAMS WIRING DIAGRAM INDEX 2 CAB Circuit B9 connects to cavity 3 ...

Page 706: ...n circuit B47 When the relay energizes its contacts open and dis connect circuits G19 and Zl Circuit A20 from fuse 14 in the fuse block supplies power to the coil side of the relay Circuit G19 from the ABS warning splices to the ABS warning lamp and the CAB BRAKE WARNING LA1P SWITCH INPUT Circuit G9 provides an input to the Controller Anti Lock Brake CAB The CAB receives the input when either the ...

Page 707: ...l Drive 4WD Switch 8W 35 7 Front Wheel Speed Sensors 8W 35 8 Fuse 2 PDC 8W 35 4 5 Fuse 5 8W 35 6 LOCK BRAKES 8W 35 3 Component Page Fuse 14 8W 35 4 5 Ground Joint 8W 35 5 Hydraulic Control Unit 8W 35 9 Ignition Switch 8W 35 4 5 Instrument Cluster 8W 35 5 6 7 Joint Connector C 8W 35 5 7 Powertrain Control Module 8W 35 7 Rear Wheel Speed Sensor 8W 35 8 RWAL Valve 8W 35 10 Stop Lamp Switch 8W 35 7 Va...

Page 708: ...OERD t ENGINE S T A R T E R MOTOR 8W 21 3 4 S P L I C E S 1 4 8 8 W 7 0 2 1 F U S E VACUUM SENSOR 8W 35 5 FUSED IGNITION SWITCH OUTPUT RUN GND 20 C 1 2 1 17 18BK RD G 1 0 7 C O N T R O L L E R A N T I L O C K B R A K E A20 18RD DB 8W 15 9 A B S PUMP MOTOR R E L A Y C8W 35 6 8W 11 16 A B S WARNING LAMP R E L A Y 8 W 3 5 6 8 W 1 1 1 6 WITH GAS ENG WITH DIESEL ENG 8040d073 J968W 9 ...

Page 709: ... 35 5 BATTERY POSITIVE TERMINAL 8W 20 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8 4 20 4 SPLICE S148 8W 70 21 WITH LOW LINE CLUSTER CASE G R O U N D CASE G R O U N D WITH G A S E N G WITH DIESEL E N G 8040d075 J968W 9 ...

Page 710: ...R Y POSITIVE T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 AO 20BK AO 14PK S P L I C E S 1 4 8 8 W 7 0 2 1 ENGINE S T A R T E R MOTOR 8 W 2 1 3 4 C L U S T E R RWAL V A L V E 8 W 3 5 1 0 34 4 J ABS ABS i PUMP PUMP MOTOR MOTOR i RELAY RELAY 1 OUTPUT CONTROL B R A K E WITH GAS ENG WITH DIESEL ENG 8040d077 J968W 9 ...

Page 711: ...TA i SCI SCI i LINK i 1 TRANSMIT RECEIVE i CONNECTOR i i 15 JJ31 C223 D12 220R D l l 22WT RD V40 20WT PK C133 C133 D12 200R D l l 20WT RD 10 SCI TRANSMIT 11 SCI RECEIVE 9 BRAKE SWITCH SENSE 103 8W 70 3 Zl 18BK G102 8W 15 4 C106 INSTRUMENT CLUSTER 4WD LAMP 13 C215 4WD SWITCH G107 22BK GY C133 C106 G107 20BK GY S105 8W 70 4 G107 20BK GY C121 8 4WD SENSE CONTROLLER ANTI LOCK BRAKE 8040d078 J968W 9 ...

Page 712: ...114 20WT VT TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR C121 1 RIGHT REAR WHEEL SPEED SENSOR 14 RIGHT REAR WHEEL SPEED SENSOR 2 RIGHT FRONT WHEEL SPEED SENSOR 15 RIGHT FRONT WHEEL SPEED SENSOR 3 LEFT FRONT WHEEL SPEED SENSOR 16 LEFT FRONT WHEEL SPEED SENSOR CONTROLLER ANTI LOCK BRAKE 8040d07a J968W 9 ...

Page 713: ...20VT LG BK LG B249 B248 18WT 16DG TN WT B60 12LB BK B C 1 2 0 PUMP MOTOR CONTROL GND A C 1 2 0 18 10BK PK ABS 2 WAY POWER F E E D i G 1 0 3 8W 15 5 34 ABS PUMP MOTOR RELAY OUTPUT 5 LEFT FRONT 37 LEFT FRONT RESET ISOLATION 35 LEFT FRONT DUMP 18 RIGHT FRONT 33 RIGHT FRONT C 1 2 1 3 0 C O N T R O L L E R RIGHT FRONT RESET ISOLATION DUMP SWITCH SENSE VALVE VALVE SWITCH VALVE VALVE CONTROL CONTROL SENS...

Page 714: ...LIC CONTROL UNIT I 8M 35 9 t t i B120 B120 B120 12BR 12BR 12BR W T W T W T CASE GROUND B120 12BR WT B252 B254 18BR 16DG TN OR C121 34 ABS PUMP MOTOR RELAY OUTPUT 19 REAR VALVE RESET SWITCH SENSE 28 26 REAR REAR ISOLATION DUMP VALVE VALVE CONTROL CONTROL CONTROLLER ANTI LOCK BRAKE O40d07d J968W 9 ...

Page 715: ...SION UP SHIFT LAMP 3 OIL PRESSURE GAUGE 2 OIL PRESSURE WARNING LAMP 2 PARKING BRAKE LAMP 3 SEAT BELT INDICATOR WARNING LAMP 2 SERVICE REMINDER INDICATOR SRI LAMP 3 SPEEDOMETER 1 TACHOMETER 2 TURN SIGNAL INDICATOR LAMPS 2 VOLTMETER 2 SCHEMATICS AND DIAGRAMS WIRING DIAGRAM INDEX 3 gauge The fuel level sensor draws voltage from cir cuit F14 through the fuel gauge on circuit G4 The fuel level sensor i...

Page 716: ...he MIL displays the message CHECK ENGINE For information regarding diagnostic trouble code access using the MIL refer to Group 14 Fuel Systems IOWWASHER FLUID LAMP Circuit G29 connects the low washer fluid switch to the warning lamp in the instrument cluster Cir cuit F14 supplies battery voltage to the lamp When the low washer fluid switch CLOSES it con nects circuits G29 and Z l Circuit Z l provi...

Page 717: ...hen the Powertrain Control Module PCM provides ground for the lamp on circuit G54 Circuit G54 con nects to cavity B l l of the PCM AIRBAG WARNING LAMP Circuit F14 supplies power for the airbag warning lamp The lamp illuminates when the Airbag Control Module ACM provides ground for the lamp on cir cuit R41 FOUR WHEEL DRffE INDICATOR Power for the four wheel drive indicator lamp is supplied on circu...

Page 718: ...W 40 6 Engine Oil Pressure Sensor 8W 40 6 Four Wheel Drive 4WD Switch 8W 40 9 Fuel Pump Module 8W 40 6 Fuse 1 PDC 8W 40 10 Fuse 3 PDC 8W 40 5 7 8 9 12 Component Page Fuse 12 8W 40 5 7 8 9 Fuse 13 8W 40 10 Fuse 18 8W 40 10 Headlamp Switch 8W 40 10 Ignition Switch 8W 40 5 7 8 9 12 Instrument Cluster 8W 40 5 thru 11 Joint Connector C 8W 40 7 8 10 Low Washer Fluid Switch 8W 40 12 Park Brake Switch 8W ...

Page 719: ...A l 12RD 1 C133 VEHICLE SPEED SENSOR 8W 30 14 POWERTRAIN CONTROL MODULE S209 G7 18WT OR TACHOMETER SIGNAL C31 S131 F14 18LG YL 8W 70 30 8W 70 13 S208 8W 70 30 F14 20LG YL Z l l 18BK WT Z l l 20BK WT Z l l 20BK WT 9 G202 C215 6 C216 8 I G7 20WT OR C127 G7 22WT OR C133 G7 20WT OR S210 C137 G21 20GY LB sjs C127 G21 22GY LB C133 G21 22GY LB 8W 70 31 C215 1 1 i G7 20WT OR X C216 3 VOLT C215 0 _ 1 INSTR...

Page 720: ...G UNIT BLACK BLACK F U E L L E V E L SENSOR FUEL PUMP MODULE CASE GROUND G20 18VT YL C 3 2 8 C 1 2 8 Z l l 2 0 B K W T f 4 C 1 2 7 G20 22VT YL C 1 2 8 G4 20DB C 1 3 3 G20 22VT YL C 1 3 3 G4 22DB INSTRUMENT C L U S T E R S 1 1 6 8W 70 8 C 1 2 7 S 1 4 0 8W 70 18 G 1 1 9 8 W 1 5 1 1 1 2 Z3 20BK 0R C 2 1 6 S 2 0 6 8W 70 29 Z3 12BK OR G201 I8W 15 13I WITH GAS ENG WITH DIESEL ENG 8040CI082 J968W 9 ...

Page 721: ...ENT CLUSTER 8W 40 7 B A T T E R Y P O S I T I V E T E R M I N A L 8W 20 3 4 RIGHT BATTERY P O S I T I V E T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 AO 6RD BLACK CASE GROUND WITH GAS ENG WITH DIESEL ENG 8040d088 J968W 9 ...

Page 722: ...OR C C8W 40 7 8W 12 10 G9 22GY BK 8 6 MIL CHECK ENGINE C 2 1 5 4 BRAKE C 2 1 6 3 FUSE 3 40A C 1 8 0 POWER D I S T R I B U T I O N C E N T E R I G N I T I O N SWITCH A l 12RD S 1 2 4 C2I2 8W 70 12 7 A l 12RD 4 A l 1 2 R D J CI33 C O N T R O L L E R A N T I L O C K B R A K E RWAL C 1 3 1 G i l 20WT BK PARK BRAKE SWITCH SENSE DAYTIME RUNNING LAMP MODULE PARK BRAKE SWITCH SENSE 5 C 1 3 3 C 2 2 8 1 1 G...

Page 723: ...BR1 8W 4Q INSTRUMENT CLUSTER 8W 40 9 BATTERY POSITIVE TERMINAL 8 W 2 0 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG C8W 20 4 AO 6RD WITH GAS ENG WITH DIESEL ENG 8040d08c J968W 9 ...

Page 724: ... 21 AO OOERD ENGINE S T A R T E R MOTOR 8W 21 3P 4 A7 12RD BK A7 12RD BK S 2 0 4 A7 12RD BK C 1 3 3 R E F TO O V E R D R I V E SWITCH ILLUMINATION 8W 31 7 WITH FOG LAMPS E2 2 2 0 R E2 200R E2 220R SEAT BELT J I LAMP DRIVER l _ J B U Z Z E R MODULE 1 C 2 1 6 f C 2 1 8 G13 20DB RD C 2 1 5 1 GENERAL ILLUMINATION C 2 1 6 Q Q Q 1 T A m A I 1 LAMP INSTRUMENT C L U S T E R Z3 20BK OR 1 0 1 j S 2 0 6 8W 7...

Page 725: ... 8W 50 4 L3 16RD OR S1S3 S121 8W 70 23 8W 70 10 G34 18RD GY G34 18RD GY C133 C133 TURN SIGNAL HAZARD SWITCH 8W 50 5 8W 52 5 WITH DRL G34 18RD GY 634 18RD GY S206 8W 70 29 L61 20LG YL L60 20TN BK 634 18RD GY Z3 20BK OR Z3 12BK OR 12 LEFT TURN SIGNAL IND 14 RIGHT TURN SIGNAL IND 13 HIGH BEAM IND 10 G201 8W 15 13 C216 INSTRUMENT CLUSTER 8040d090 J968W 9 ...

Page 726: ... A L 8 W 2 0 3 4 RIGHT B A T T E R Y POSITIVE T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 AO 6RD G29 22BK TN 18BK TN 8 C 2 1 5 3 C 2 1 6 5 UPSHIFT vQj 7 MAI NT REQ C 2 1 5 9 LOW WASHER vQj C 2 1 6 AIRBAG INSTRUMENT C L U S T E R SPARE WITH GAS ENG WITH DIESEL ENG j 8040d092 J968W 9 ...

Page 727: ...s in the ACCESSORY or RUN position it connects circuit A l from fuse 3 in the Power Distribution Center PDC to circuit A31 Circuit A31 powers circuit F30 through fuse 5 in the fuse block Circuit F30 supplies current to the cigar lighter When the operator presses the lighter contacts inside of the lighter element CLOSE and voltage flows through the heating element to ground on cir cuit Z3 HELPFUL I...

Page 728: ...ge Cigar Lighter 8W 41 3 Fusel PDC 8W 41 4 Fuse 3 PDC 8W 41 3 Fuse 5 8W 41 3 Fuse B 8W 41 4 Ground Joint 8W 41 4 Component Page Horn Relay 8W 41 4 Horns 8W 41 4 Ignition Switch 8W 41 3 Power Outlet 8W 41 3 Vehicle Speed Control Horn Switch 8W 41 4 8040d094 J968W 9 ...

Page 729: ... AO 14PK S P L I C E S 1 4 8 MOTOR 8 W 7 0 2 1 8 W 2 1 3 4 4 5 4 9 A l 12RD C 2 4 1 FUSE 1 20A C 2 4 1 F U S E BLOCK F130 18RD YL 1 C 2 4 1 FUSE 5 ft C 2 4 1 4 1 20A 1 39 1 F U S E BLOCK A 3 1 12BK WT C 2 3 5 FUSED IGN S W OUTPUT ACC RUN GND POWER O U T L E T F30 18RD 0R S 2 1 5 235 8W 70 33 Z 3 18BK 0R 2 Z3 18BK 0R Z3 12BK OR G202 8W 15 13 WITH GAS ENG WITH DIESEL ENG 8040 1095 J968W 9 ...

Page 730: ... i 50A 1 C18Q A7 10RD BK S 1 4 7 8W 70 21 POWER D I S T R I B U T I O N C E N T E R X2 18DG RD X2 18DG RD X3 22BK RD LOW NOTE HORN HIGH NOTE HORN Z l 18BK Z l 18BK 1 C 1 3 3 C I 2 3 GND GND 4 X3 20BK RD X3 22BK RD WITH POWER WINDOWS AND POWER LOCKS V E H I C L E S P E E D C O N T R O L HORN SWITCH GROUND J O I N T C 1 2 3 G1Q1 8W 15 3 C 2 0 3 r b wmSmm I t n n Z l 12BK Z l 14BK WITH MEDIUM LINE AN...

Page 731: ...t connect from the blower motor resis tor block and then through the fan switch in the A C heater controls to circuit Z3 The blower motor resistor block consists of three resistors connected in series Each resistor in blower motor resistor block is spliced to the fan switch on separate circuits C4 C5 C6 and C7 Depending on fan switch position volt age passes through one or more resistors to ground...

Page 732: ...cavities 2 8W 02 for a complete list of all components shown in and 3 of the PDC the wiring diagrams Check the 30 amp fuse located in cavity F2 of the fuse block Check the 10 amp fuse located in cavity 9 of the fuse block S C H E M A T I C S A N D D I A G R A M S WIRING DIAGRAM INDEX The following index covers all components found in this section of the wiring diagrams If the component ...

Page 733: ...h 8W 42 6 A C Heater Control Switch 8W 42 6 Blower Motor 8W 42 4 5 Blower Motor Resistor Block 8W 42 4 5 F2 8W 42 4 5 Fusel PDC 8W 42 7 8 Fuse 2 PDC 8W 42 4 5 Fuse 3 PDC 8W 42 8 Fuse 9 8W 42 8 Fuse 1 3 8W 42 7 Fuse 18 8W 42 7 Fuse B 8W 42 8 Headlamp Switch SW 42 7 Heater Controi Switch 8W 42 4 Ignition Switch 8W 42 4 5 8 Joint Connector A 8W 42 7 Joint Connector C 8W 42 7 Powertrain Control Module...

Page 734: ...INAL WITH DIESEL ENG C8M 20 4 ENGINE STARTER MOTOR 8W 21 3 4 SPLICE S148 C8W 70 21 POWER DISTRIBUTION CENTER S201 FUSE BLOCK C241 FUSE F2 C241 O r A22 12BK 0R 12 30A I D 8W 70 26 A22 12BK 0R J 4 xS C212 ACC P C212 OFF 4 5 START IGNITION SWITCH HEATER JOINT CONNECTOR C 8W 42 6 8W 12 6 WITH GAS ENG WITH DIESEL ENG 8040d09b J968W 9 ...

Page 735: ... 14PK B A T T E R Y POSITIVE TERMINAL 8 W 2 0 3 4 R I G H T J A T T E R Y P O S I T I V E T E R M I N A L WITH DIESEL ENG C 8 W 2 0 4 S P L I C E S 1 4 8 8 W 7 0 2 1 A C H E A T E R CONTROL SWITCH 8 W 4 2 6 WITH GAS ENG WITH DIESEL ENG 8040d09c J968W 9 ...

Page 736: ...BK TN 1 f 6 5 Kf 3 C5 16LG YL 4 C4 16TN C237 C5 16LG C4 16TN BLOWER MOTOR RESISTOR BLOCK 8W 42 5 H2 1 F A N H I G H S W I T C H Ml L O W f 7 DEF 1 HEAT 1 H I a L O I A C MAX OFF DEF ILLUMINATION A C HEATER CONTROL SWITCH C133 C90 22LG C227 2 A C REQUEST C22 POWERTRAIN CONTROL MODULE C137 C20 18BR 1 4 C185 2 A C LOW PRESSURE CUTOUT SWITCH C182 JOINT CONNECTOR C C8W 42 7 8W 12 6 E2 220R 1 S215 Y C22...

Page 737: ...HEATER CONTROL SWITCH 8W 42 6 AO 14PK AO OOERD ENGINE STARTER MOTOR 8W 21 3 4 SPLICE S148 8W 70 21 S147 I FUSE 1 8W 70 21 C180 A7 10RD BK 1 50A 1 WITH POWER S204 S E A T POWER DISTRIBUTION CENTER 8W 70 28 A7 12RD BK I A7 12RD BK OVERDRIVE SWITCH ILLUMINATION LAMP 8W 31 7 E2 200R WITH FOG LAMPS E2 220R FOG LAMP SWITCH 8W 50 10 8040d0ae WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 738: ... T E R 3 0 C 1 8 0 A C COMPRESSOR CLUTCH R E L A Y A7 12RD BK 1 C 1 8 0 F18 20LG BK A7 10RD BK 3 C 1 8 0 S 1 4 7 8W 70 21 A l 12RD C 1 3 3 C3 18DB BK t C3 18DB BK C13 22DB OR A l 12RD F18 C 1 3 3 C 1 2 6 1 C 1 2 5 2 0 L G j S 1 1 4 B K F18 22LG BK 8W 70 7 C 1 6 4 A C C13 M COMPRESSOR 20DB CLUTCH OR 2 C 1 6 4 3 3 C 2 4 1 FUSE 9 10A I 3 1 N 241 C 1 3 7 Z l l 18BK WT Cl A C CMP CLUTCH RELAY CONTROL P...

Page 739: ...irbag impact sensors provide input to the Air bag Control Module ACM Each sensor has two cir cuits that connect to the ACM From the left impact sensor Circuit R47 connects to the ACM at cavity 6 of the 13 way connector Cir cuit R49 connects to cavity 5 of the 13 way connector From the right impact sensor Circuit R46 connects to the ACM at cavity 13 of the 13 way connector Cir cuit R48 connects to ...

Page 740: ...a Link Connector 8W 43 4 Driver Side Airbag 8W 43 4 Fuse 2 PDC 8W 43 3 Fuse 3 PDC 8W 43 3 Fuse 12 8W 43 3 SYSTEM B R Component Page Fuse 1 6 8W 43 3 Ignition Switch 8W 43 3 Instrument C l u s t e r 8W 43 4 Left Airbag Sensor 8W 43 4 Right Airbag Sensor 8W 43 4 8 0 4 0 d 0 b l J968W 9 ...

Page 741: ... Y P O S I T I V E T E R M I N A L WITH DIESEL ENG 8 W 2 0 4 F23 F14 18DB 18LG YL YL S 2 0 9 8W 70 30 H HHfc8 hf fc C 2 3 2 2 FUSED IGN SW OUTPUT RUN 1 FUSED IGN SW OUTPUT START RUN GND 11 A I R B A G CONTROL MODULE C 2 3 2 L_ C 1 3 3 Z6 18BK 0R 16 18BK 0R G108 8W 15 9 8040d0b3 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 742: ...MPACT LT IMPACT SENSOR LINE 2 SENSOR LINE 1 5 6 RT IMPACT RT IMPACT SENSOR LINE 2 SENSOR LINE 1 12 13 Dl 18VT BR D2 18WT BK R41 18BK TN R49 18LB C232 11 9 C 2 1 8 AIRBAG SYSTEM WARN LAMP DRIVER J INSTRUMENT CLUSTER C223 DATA LINK CONNECTOR R47 18DB LB R48 18TN C133 R46 18BR LB C133 R49 18LB WT R47 18DB LB R48 18TN R46 18BR 1 2 CllO LT IMPACT LT IMPACT SENSOR SENSOR LINE LINE 2 1 d LEFT AIRBAG SENS...

Page 743: ...cuit supplies current to the key in switch halo lamp Cir cuit Z3 provides ground for the lamp page KEY IN SWITCH HALO LAMP 1 SEAT BELT SWITCH 2 TIME DELAY RELAY 1 UNDERHOOD LAMP 1 VISOR VANITY LAMPS 2 SCHEMATICS AND DIAGRAMS WIRING DIAGRAM INDEX 2 1L0 E 101 LAiP Circuit M l from the IOD fuse fuse 17 in the fuse block powers the glove box lamp A switch in series after the lamp CLOSES when the glove...

Page 744: ...uzzer module operation Power for the buzzer module is supplied on circuit M l from fuse 17 a 15 amp in the fuse block This fuse is the Ignition Off Draw fuse IOD and is HOT at all times Power for the fuse is supplied on circuit A7 This circuit is protected by a 50 amp fuse located in cavity 1 of the Power Distribution Center PDC When the parking lamps or headlamps are ON the headlamp switch connec...

Page 745: ... 6 Fuse 11 8W 44 6 Fuse 15 8W 44 9 Fuse 17 8W 44 4 7 8 Glove Box Lamp Switch 8W 44 8 Component Page Headlamp Switch 8W 44 5 7 Ignition Switch 8W 44 6 9 Instrument Cluster 8W 44 7 Joint Connector A 8W 44 5 Joint Connector B 8W 44 8 Joint Connector C 8W 44 6 9 Key ln Switch Halo Lamp 8W 44 5 7 Seat Belt Switch 8W 44 7 Time Delay Relay 8W 44 4 5 Underhood Lamp 8W 44 8 Visor Vanity Lamps 8W 44 4 8040d...

Page 746: ...ERIOR LIGHTING mm POWER B A T T E R Y P O S I T I V E T E R M I N A L 8W 20 3 4 RIGHT BATTERY P O S I T I V E T E R M I N A L WITH DIESEL ENG C8W 20 4 DOME LAMP C 8 W 4 4 5 8040d0b9 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 747: ...B B 8W 44 INTERIOR LIGHTING _ 8W 44 5 FUSE BLOCK FUSE BLOCK 8W 44 4 C8W iQ 10 JOINT CONNECTOR A 8040d0ba J968W 9 ...

Page 748: ...2 20DB WT S P L I C E S 1 4 8 8 W 7 0 2 1 E N G I N E S T A R T E R MOTOR C 8 W 2 1 3 4 C 2 4 1 F U S E i i C 2 4 1 m s j m 3 5 10A 3 1 F U S E B L O C K A21 12DB F12 22DB WT 1 2 G16 22BK LB G16 18BK LB L E F T DOOR J A M B S W I T C H C 8 W 4 9 4 2 0 2 2 C 2 0 9 2 1 J O I N T C O N N E C T O R C C 2 0 9 G16 22BK LB G16 22BK LB B U Z Z E R K E Y I N H E A D L A M P M O D U L E S W I T C H S W I T ...

Page 749: ...8 W 2 0 3 P 4 RIGHT BATTERY POSITIVE T E R M I N A L WITH DIESEL ENG tf 20 4 POWER D I S T R I B U T I O N C E N T E R C E N T E R HIGH MOUNTED STOP LAMP NO 1 8 W 5 1 9 8040d0be C E N T E R HIGH COUNTED STOP LAMP NO 2 C8W 51 9 WITH GAS ENG WITH DIESEL E J968W ...

Page 750: ... R M I N A L 8W 20 3 4 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG C8W 20 4 FUSE 1 C180 50A I 1 A7 10RD BK S147 8W 70 21 POWER DISTRIBUTION CENTER S P L I C E S 1 4 8 8 W 7 0 2 1 ENGINE STARTER MOTOR 8 W 2 1 3 4 BLACK 40d0c0 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 751: ...f 2 7 1 0 A A 2 2 1 2 B K 0 R 23 FUSE BLOCK ACCm C212 OFF H 0 4 1 S T A R T R U N j 5 A 2 2 1 2 B K 0 R C212 2 8 C209 3 0 C209 JOINT CONNECTOR C S117 8W 70 9 C126 LI 18VT BK f L I 1 8 V T B K LI 18VT BK LI 18VT BK L l 18VT BK BACK UP LAMP SWITCH 8W 51 6 PARK NEUTRAL POSITION SWITCH 8W 51 6 C133 WITH AUTO TRANS LI 22VT BK C208 LI 22VT BK r i FUSED BACK UP IGN SW LAMP OUTPUT SWITCH RUN OUTPUT GND C3...

Page 752: ......

Page 753: ... on all engine packages Circuit G85 is connected from the message center to the PCM and is used for the WAIT TO START lamp The WAIT TO START lamp is only used with the diesel engines Circuit G85 connects to cavity B20 of the PCM Circuit G86 is connected from the message center to the PCM and is used for the WATER IN FUEL lamp The WATER IN FUEL lamp is only used on vehicles equipped with the diesel...

Page 754: ...SSAGE CENTER BR Page Component Page SW 46 2 DIAGRAM INDEX Component Fuse 3 PDC 8W 46 3 Fuse 12 8W 46 3 Ignition Switch 8W 46 3 Message C e n t e r 8W 46 3 Powertrain Control M o d u l e 8W 46 3 8040d0c3 J968W 9 ...

Page 755: ...RIVER DIESEL G86 20TN OR WAIT TO START WARNING LAMP DRIVER DIESEL 4 C224 G85 200R BK C133 G86 18TN OR G85 180R BK C125 G86 18TN OR C137 G85 180R BK C136 SRI LAMP DRIVER GAS G24 22GY PK TRANS TEMP LAMP DRIVER AUTO TRANS 8 J C224 T G14 20PK BK MESSAGE CENTER G24 20GY PK C126 G24 20GY PK k C133 G14 18PK BK C125 G14 18PK BK C137 C18 B20 C18 C7 i WATER WAIT SRI TRANS I N TO LAMP TEMP i FUEL START DRIVE...

Page 756: ......

Page 757: ...lock powers circuit E2 which feeds the radio illumination lamp Circuit E l from the headlamp switch supplies power to fuse 13 Circuit L7 supplies voltage for the radio lamps Circuit Z2 supplies the ground path for the illumination and park lamp cir cuits RADIO CHOKE PREMIUM RADIO ONLY The radio choke relay supplies voltage to the amplifier circuits in the speakers The radio supplies power to the c...

Page 758: ... the 8W 02 for a complete list of all components shown in PDC the wiring diagrams Check the 10 amp fuse located in cavity 7 of the fuse block Check the ground at the rear of the radio Check the IOD fuse in the fuse block S C H E M A T I C S A N D D I A G R A M S WIRING DIAGRAM INDEX The following index covers all components found in this section of the wiring diagrams If the component ...

Page 759: ...8W 47 4 6 Joint Connector B 8W 47 4 6 7 Joint Connector C 8W 47 4 6 Left Door Premium Speaker 8W 47 8 Component Page Left Door Speaker 8W 47 5 Left Door Tweeter 8W 47 8 Left Rear Premium Speaker 8W 47 7 Left Rear Speaker 8W 47 5 Radio 8W 47 4 thru 9 Radio Choke 8W 47 7 Right Door Premium Speaker 8W 47 9 Right Door Speaker 8W 47 5 Right Door Tweeter 8W 47 9 Right Rear Premium Speaker 8W 47 7 Right ...

Page 760: ...I C E S 1 4 8 C8W 70 21 ENGINE S T A R T E R MOTOR 811 21 3 4 A7 12RD BK C 1 3 3 S 1 2 4 8W 70 12 A l 12RD C 1 3 3 A l 12RD A7 12RD BK A7 12RD BK S 2 0 4 8W 70 28 WITH POWER SEAT A7 1 2 R D B K A7 12RD BK O V E R D R I V E F i L4MP SWITCH I L L i i H A T l i l SWITCH LAMP C8W 50 10 8W 31 7 J O I N T CONNECTOR C A7 12RD BK E2 220R 3 9 WITH FOG LAMPS 4 3 FUSE FUSED PARK FUSED PANEL i IGNITION B LAMP...

Page 761: ...T FRONT DOOR SPEAKER X54 20VT X54 20VT C345 X54 18VT C240 r X54 20VT 5 C230 RIGHT FRONT DOOR SPEAKER OPTIONAL i X56 20DB RD X56 18DB RD r X56 20DB RD C345 C24Q V X56 20DB RD 3 C229 RIGHT FRONT DOOR SPEAKER RADIO LEFT REAR SPEAKER 6 V LEFT REAR SPEAKER J i i l j g 230 X57 X51 20BR 20BR LB YL C202 C202 X57 X51 18BR 18BR LB YL A B C306 REAR SPEAKER RIGHT REAR SPEAKER RIGHT REAR SPEAKER X58 X52 20DB 2...

Page 762: ... 124 50A 1 FUSE 3 A7 10RD BK 147 8W 70 21 40A 3 8W 70 12 Al 12RD t Al 12RD A7 12RD BK C 1 3 3 POWER D I S T R I B U T I O N C E N T E R C133 A7 12RD BK A7 12RD BK S 2 0 4 8W 70 28 WITH POWER SEAT FOG LAMP SWITCH SW 50 10 s A7 12RD BK OVERDRIVE SWITCH I L L U M I N A T I O N LAMP C8W 31 7 A7 12RD BK J O I N T CONNECTOR C FUSE IGNITION SWITCH OUTPUT ACC RUN FUSED B PARK LAMP SWITCH OUTPUT FUSED PANE...

Page 763: ...BK RD C 2 0 2 X13 18BK RD 4 T i l l C 3 0 5 X51 X57 18BR 18BR YL LB 4 X52 X58 18DB 18DB WT OR C 2 Q 2 C 2 0 2 C 3 0 1 Z2 18BK LG S 3 0 1 S 2 I 3 8W 70 32 T X51 20BR YL A X13 18BK RD LEFT REAR SPEAKER FUSED B T X57 20BR LB X52 20DB WT Ml 20PK C 2 3 1 LEFT REAR SPEAKER RADIO 12 VOLT OUTPUT J S P L I C E S 2 0 5 C 8 W 4 7 6 8 W 7 0 2 8 8040d0ce J968W 9 ...

Page 764: ...3 1 8 D G X53 20DG ZQ Rf 4 C 2 3 0 2 C 2 2 9 LEFT FRONT DOOR SPEAKER LEFT FRONT DOOR SPEAKER RADIO CHOICE 8M 47 7 WITH ABS RADIO Z2 18BK LG Z2 18BK LG 0107 8W 15 9 WITH RWAL Z2 18BK LG Z2 18BK LG G 1 0 3 8W 15 5 C 3 4 7 Z2 18BK LG Z2 18BK LG Z2 18BK LG C 2 0 1 Z2 18BK LG S 2 1 2 8W 70 31 Z2 Z2 18BK 18BK LG LG T C133 Z2 Z2 18BK 18BK LG LG 122 8W 70 11 8040d0d0 J968W 9 ...

Page 765: ... 8W 47 AUDIO SYSTEM PREMIUM STEREO RADIO 8W 47 9 RIGHT DOOR PREMIUM SPEAKER RADIO CHOKE 8 W 4 7 7 T T Z2 Z2 18BK 18BK LG LG I CI33 8W 70 11 8040d0d2 J968W 9 ...

Page 766: ......

Page 767: ...it Z4 grounds the reading lamps and map lamps Circuit M2 provides ground for the dome lamp The M2 circuit supplies ground for the overhead console dome lamp in two ways One way is through the door jamb switches Circuit M2 connects to the door jamb switches The door jamb switches connect to ground on circuit Z3 When a door is OPENED the plunger in the switch CLOSES completing a path to ground The s...

Page 768: ...W 49 3 Fuse 13 8W 49 3 Fuse 17 8W 49 3 Fuse 18 8W 49 3 Headlamp Switch 8W 49 3 4 AD CONSOLE BR Component Page Ignition Switch 8W 49 3 Joint Connector A 8W 49 3 4 5 Joint Connector C 8W 49 3 4 Lett Door Jamb Switch 8W 49 4 Overhead Console 8W 49 3 4 5 Overhead Map Courtesy Lamp 8W 49 5 Right Door Jamb Switch 8W 49 4 8040d0d4 J968W 9 ...

Page 769: ...DRIVE SWITCH ILLUMINATION LAMP W I T H M 31 7 FOG L A M P S W I T H POWER S E A T A 2 1 1 2 D B 3 1 3 5 F U S E 11 10A K 1 5 A S 1 7 18 F U S E 1 8 1 5 A 25 21 Ml 18PK S205 F33 20PK RD E2 220R JOINT CONNECTOR C C209 E2 200R 5 r M l 2 0 P K I 8W 70 28 F12 22DB WT C208 Ml 20PK SPLICE S320 8W 49 4 8W 70 41I B 2 0 F F r R I H E A D I A A A r C206 HEADLAMP SWITCH JOINT CONNECTOR A P A R K C206 C217 L7 ...

Page 770: ... 3 3 8 M2 2 2 Y L 6 M2 22YL OVERHEAD NAP COURTESY LAMP 8W 49 5 OVERHEAD NAP COURTESY LAMP 8W 49 5 M2 22YL C208 M2 22YL JOINT CONNECTOR A C217 f 7 1 M2 20YL 8 2 C217 M2 M2 22YL 22YL C201 M2 18YL C240 M2 18YL 2 Z3 12BK OR LEFT FRONT DOOR JAMB SWITCH SENSE OPTIONAL Z3 Z3 20BK 18BK OR OR 1 C 3 1 9 RIGHT DOOR JAMB SWITCH C319 G201 I8W 15 13 I I G302 8W 15 14I Z3 18BK OR G303 8W 15 15 8040d0d8 J968W 9 ...

Page 771: ...OW LINE CLUSTER 14 18BK C217 L7 20BK YL f 10 5 JOINT CONNECTOR A i C217 L7 20BK YL S208 C208 8W 70 30 Z l l 20BK WT L7 20BK YL L7 18BK YL WITH CLEARANCE AND I D LAMPS C208 Zll 20BK W T S317 8W 70 40 L7 18BK YL 9 0 GROUND 2 T _ _ _ i PARK LAMP SWITCH OUTPUT SENSOR 1 2 114 G31 G32 18VT 18BK LG VTX C133 G31 22VT LG G32 22BK VT C208 G31 22VT LG G32 22BK LB 5 4 C338 OVERHEAD CONSOLE WITH HIGH LINE CLUS...

Page 772: ......

Page 773: ...RAMS WIRING DIAGRAM INDEX 2 HEADLAMP GROUND Although circuit Z l provides ground for both the right and left headlamps it has different termination points for each FOG LAMPS The fog lamps are controlled by the fog lamp switch and fog lamp relays The fog lamps operate only when the headlamp switch is in the PARK or ON position and the operator has selected low beam operation When the headlamps are ...

Page 774: ...ps with the stalk of the multi function switch the DRL senses voltage on circuit L3 and stops supplying power to the low beams on circuit L4 Circuit Z l provides ground for the DRL module S C H E M A T I C S A N D D I A G R A M S WIRING DIAGRAM INDEX The following index covers all components found in this section of the wiring diagrams If the component you are looking for is not found here refer t...

Page 775: ...se 6 PDC 8W 50 4 12 Fuse 13 8W 50 8 Fuse 15 8W 50 11 Fuse 18 8W 50 7 Fuse A 8W 50 9 Component Page Ground Joint 8W 50 5 Headlamp Dimmer Switch 8W 50 4 Headlamp Switch 8W 50 4 8 Headlamps 8W 50 5 Ignition Switch 8W 50 11 Instrument Cluster 8W 50 4 5 11 Joint Connector A 8W 50 5 6 8 Joint Connector C 8W 50 8 11 Outboard Clearance Lamps 8W 50 6 Outboard Identification Lamps 8W 50 6 Overhead Console 8...

Page 776: ... 14PK B A T T E R Y P O S I T I V E T E R N I N A L 8 W 2 0 3 4 RIGHT B A T T E R Y P O S I T I V E T E R N I N A L WITH DIESEL ENG C 8 W 2 0 4 S P L I C E S 1 4 8 8 W 7 0 2 1 RIGHT HEADLAMP 8W 50 5 8040d0de WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 777: ... RIGHT HEADLAMP C 1 0 2 L3 16RD OR l L 4 16VT WT Ar NORMAL HAZARD S 1 0 1 8W 70 3 1 4 HAZARD SWITCH C 2 1 0 17 1 3 C 2 1 0 S 1 0 6 L7 20BK YL I 8W 70 4 Z l 18BK C 1 3 3 r L7 18BK YL L7 18BK YL L7 2 0 B K Y L L7 2 0 B K Y L 3 L4 16VT WT C 1 3 3 L4 16VT WT I S 1 0 7 Z l 20BK L E F T HEADLAMP C 1 1 3 L 3 16RD 0R C 1 L4 16VT WT 8W 70 4 L4 16VT WT DAYTIME RUNNING LAMP MODULE C A V I T Y 1 0 8 W 5 0 1 2...

Page 778: ...LINE CLUSTER L7 18BK YL L7 18BK YL L7 18BK YL L E F T OUTBOARD C L E A R A N C E LAMP L E F T OUTBOARD I D E N T I F I C A T I O N LAMP C 3 3 6 C E N T E R I D E N T I F I C A T I O N LAMP C 3 3 9 1 C 3 3 9 2 RIGHT OUTBOARD I D E N T I F I C A T I O N LAMP C 3 4 0 1 C 3 4 0 2 RIGHT OUTBOARD C L E A R A N C E LAMP C 3 4 1 1 C 3 4 1 2 Z4 18BK Z4 18BK S 3 1 8 I8W 70 40 Z4 18BK Z4 18BK Z4 18BK Z4 18BK...

Page 779: ...OTOR 8 W 2 1 3 4 S P L I C E S 1 4 8 8 W 7 0 2 1 AO AO OERD 6RD FUSE 1 C 1 8 0 k l 10RD BK I 50A 1 I 147 POWER D I S T R I B U T I O N C E N T E R 8W 70 21 j A7 12RD BK A7 12RD BK A7 12RD BK A7 12RD BK A7 12RD BK S 2 0 4 A7 12RD C 1 3 3 8W 70 28 d 4 C 2 4 1 I c I 1 8 v FUSE 18 i i 15A C 2 4 i WITH POWER SEAT FUSE BLOCK F33 20PK RD HEADLAMP SWITCH 8 W 5 0 8 WITH GAS ENG WITH DIESEL ENG 8040d0e4 J96...

Page 780: ...NG BR F U S E BLOCK 8 W 5 0 7 C8W 10 11 LEFT PARK TURN S I G N A L LAMP C8W 50 5 R I G H T P A R K TURN S I G N A L LAMP rf 50 A 5 f 17 18BK YL 1 S101 8W 70 3 DAYTIME RUNNING LAMP MODULE C A V I T Y 4 C8W 50 12 8040d0e6 J968W 9 ...

Page 781: ... W 5 0 8 8 W 1 1 1 3 1 4 L139 20LB WT C180 FUSE A M M A2 15A A l L38 20LB BK 8 6 8 7 8 5 T T I1 5 30 Sci80 L35 22BR WT A7 12RD BK 1 50A C 1 8 0 C 1 8 0 FOG LANP R E L A Y NO 2 L39 20LB S 1 0 4 8W 70 3 L39 20LB C 1 3 3 L35 22BR WT L39 20LB FOG LANP SWITCH 8 W 5 0 1 0 S 1 4 7 A7 10RD BK 8W 70 21 C 1 0 5 4 L39 20LB L39 20LB POWER D I S T R I B U T I O N C E N T E R RIGHT FOG LANP 8 W 5 0 1 0 L E F T ...

Page 782: ...8W 50 10 8W 50 FRONT LIGHTING BR OVERDRIVE SWITCH ILLUMINATION LAMP 8W 31 7 FOG LAMP G201 8W 15 13 G202 8W 15 13 8040d0ea J968W 9 ...

Page 783: ...ARK BRAKE SWITCH SENSE _ J 5 2 1 6 Gil 22WT BK INSTRUMENT C L U S T E R A22 12BK 0R 23 C241 27 FUSE 15 4 10A C241 1 0 L10 22BR LG 1 2 8 C 2 0 9 29 3 0 L10 22BR LG 11 C 2 0 8 L LIO 22BR LG C 1 3 3 WITH HIGH LINE CLUSTER L10 22BR LG D A Y N I G H T MIRROR 8 W 4 4 9 Gil 22WT BK I C 2 0 9 J O I N T CONNECTOR C C 1 3 3 L10 18BR LG C 1 2 6 L10 18BR LG S 1 2 0 L10 20BR LG 8W 70 10 L10 C 1 2 6 L10 WITH DR...

Page 784: ...03 8W 50 4 8W 70 27 C133 Gil 22WT BK A3 12RD LG i Gil 20WT BK JOINT CONNECTOR C 8W 50 11 8W 12 7 LIO 18BR LG SPLICE S120 8W 50 I1 8W 70 10 C131 6 FUSED B DIMMER SWITCH HIGH BEAM OUTPUT 1 GND 3 PARK BRAKE SWITCH SENSE GND 9 5 FUSED IGNITION SWITCH OUTPUT RUN HIGH BEAM INDICTOR LAMP DRIVER 4 DIMMER SWITCH LOW BEAM OUTPUT 10 DAYTINE RUNNING LAMP NODULE k df _ JI C131 z 18 1 Z BK 18 1 BK 16RD OR SPLIC...

Page 785: ...in the fuse block One of the four circuits powered by the bus bar is circuit F33 Circuit F33 connects to the headlamp switch Fuse 1 page TAIL LAMPS AND REAR LICENSE PLATE LAMPS 1 SCHEMATICS AND DIAGRAMS WIRING DIAGRAM INDEX 2 in the PDC protects the A7 circuit Fuse 18 a 15 amp in the fuse block protects circuit F33 The headlamp switch has three positions OFF PARK parking lamps and ON plus a dimmer...

Page 786: ...ers circuit L10 through fuse 15 Circuit L10 supplies power to the back up lamp switch On automatic transmission equipped vehicles the back up lamp switch is part of an assembly that includes the PARK NEUTRAL position switch When the operator puts the transmission in REVERSE the back up lamp switch connects circuit L10 to circuit L I Circuit L I feeds the back up lamps GROUND CIRCUIT Circuit Z13 pr...

Page 787: ...se 17 8W 51 9 Fuse 18 8W 51 4 10 11 Fuse 20 8W 51 8 LIGHTING 8W 51 3 Component Page Headlamp Switch 8W 51 4 10 11 Ignition Switch 8W 51 6 Joint Connector A 8W 51 4 9 10 11 Joint Connector B 8W 51 8 Joint Connector C 8W 51 6 License Lamps 8W 51 4 10 Stop Lamp Switch 8W 51 8 Park Neutral Position Switch 8W 51 6 Rear Fender Lamps 8W 51 12 Stop Lamp Switch 8W 51 8 Tail Stop and Turn Signal Lamps 8W 51...

Page 788: ...R MOTOR 8 W 2 1 3 4 A7 A7 12RD 12RD BK 1 BK i POWER D I S T R I B U T I O N C E N T E R A7 12RD BK C 1 3 3 A7 12RD BK RIGHT L I C E N S E L E F T T A I L STOP AND TURN S I G N A L LAiP 8 W 5 1 5 L7 18BK YL L E F T L I C E N S E LAMP C 3 4 2 C 3 3 3 R I G H T T A I L STOP AND TURN S I G N A L LAMP 8 W 5 1 5 1 0 C 3 4 3 Z13 18BK S P L I C E S 3 1 2 8 W 5 1 5 8 W 7 0 3 8 8 0 4 0 d 0 f 2 WITH DUAL REA...

Page 789: ...mm REAR LIGHTING 8W 51 5 RIGHT LEFT L I C E N S E L I C E N S E LAMP LAMP 8 W 5 1 4 C 8 W 5 1 4 LEFT BACIC UP LAMP 8 W 5 1 7 8050cd3c J968W 9 ...

Page 790: ...1 8W 70 26 BLOCK A22 12BK OR S 1 2 0 WITH DRL CONNECTOR C 8W 70 10 C 1 3 3 L10 2 2 B R L G L10 20BR LG L10 18BR LG C 1 2 6 L I 18VT BK L I 18VT BK L10 18BR LG P A R K V N E U T R A L P O S I T I O N SWITCH Cl 9r l C169 L I 1 8 V T B K f f T 1 1 0 18BR LG _ T J L10 18BR LG WITH AUTO TRANS C 1 2 6 3 1 1 B A C K U P LAMP SWITCH C 1 6 1 v C 1 6 1 WITH MAN TRANS L I 18VT BK 4 L10 18BR LG 1 2 L10 18BR L...

Page 791: ...1 P A R K LAMP NEUTRAL SWITCH P O S I T I O N 8 W 5 1 6 SWITCH 8 W 5 1 6 WITH AUTO TRANS Ll 18VT BK Ll 18VT BK Z13 18BK Ll 18VT BK 313 8W 70 38 18BK 4 0 2 8W 70 41 Z13 18BK 312 8W 70 38 Z13 18BK C 3 2 9 Z13 16BK Z13 12BK WITH TRAILER TOW 3 1 1 8W 70 37 Z13 12BK C 1 2 8 Z13 16BK Z13 16BK C 1 2 8 Z13 12BK WITH TRAILER TOW f 115_ 8W 70 8 I Zl 16BK A G106 8W 15 6 7 8 8050cd3e J968W 9 ...

Page 792: ...RD C 1 8 0 40A 6 POWER D I S T R I B U T I O N C E N T E R AO 14PK ENGINE S T A R T E R MOTOR 8 W 2 1 3 4 S P L I C E S 1 4 8 8 W 7 0 2 1 S203 8W 70 27 A3 12RD LG A3 12RD LG C 1 3 3 A3 12RD LG WITH DRL A3 12RD LG 118 8W 70 9 A3 12RD LG A3 12RD LG A3 12RD LG J O I N T CONNECTOR B C 2 3 1 F32 18PK DB SPLICE S207 8N 51 9 8 W 7 0 2 9 8050cd3f WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 793: ... 34 M2 20YL C 1 3 3 M2 18YL 2 M2 20YL 6 C 2 1 7 COURTESY LAMP DRIVER J O I N T CONNECTOR A S 1 4 9 8W 70 21 r M l 20PK C 1 3 3 Ml 20PK 1 Ml 20PK S 2 0 5 J 8W 70 28 Ml 18PK 1 7 1 C241 1 1 FUSE j I c 1 7 15A F U S E BLOCK Z l 20BK 4 NO CONNECTION S 1 1 5 0 L8W 70 8 S E A T B E L T SWITCH 8 W 4 4 7 Z l 18BK HOT A T A L L T I M E S G 1 0 4 8W 15 6 G301 8W 15 14 8050cd40 J968W 9 ...

Page 794: ...E S T A R T E R MOTOR C8W 21 3 4 50A i A 7 10RD BK S 1 4 7 8W 70 21 POWER D I S T R I B U T I O N C E N T E R A7 12RD BK F U S E BLOCK WITH POWER SEAT A7 1 S 2 0 4 A7 12RD BK C 1 3 3 8W 70 28 2RD BK A7 12RD BK A7 12RD BK A7 12RD BK J O I N T CONNECTOR A L F33 20PK RD t f Z13 Z13 16BK 12BK C 1 2 8 X C 1 2 8 Z13 Z13 WITH 12BK 16BK TRAILER I TOW S311 8W 70 37 Z13 Z l 16BK 12E i I Z13 12BK S 3 1 2 8W ...

Page 795: ...6BK Z 1 3 12BK A7 12RD BK HEADLAMP SWITCH C 2 0 6 C 2 1 7 L7 20BK YL A7 12RD BK CONNECTOR A 314 8W 70 39 311 r 8W 70 37 7 C 1 2 8 Z13 1 2 B K f Z 1 3 16BK C 1 2 8 Z13 1 6 B K Z 1 3 12BK L7 18BK YL 3 1 2 8W 70 38 WITH TRAILER TOW Z13 18BK C 3 4 3 WITH TRAILER TOW Z l 16BK S 1 1 5 8W 70 8 C 3 4 3 L7 18BK YL L7 18BK YL L7 18BK YL S 4 0 6 8W 70 42 G 1 0 6 8 W 1 5 6 7 8 L E F T T A I L G A T E LAMP C 4...

Page 796: ...3 18BK Z13 18BK 1 L E F T R E A R C404 FENDER LAMP C 4 2 2 v C 4 2 2 L7 1 8 B K Y L f L 7 18BK YL 2 C 4 0 4 z l 3 18BK Z13 18BK 1 S 4 0 5 S406 8W 70 42 RIGHT R E A R FENDER LAMP C 4 0 5 C 4 2 3 L7 1 8 B K Y L L 7 18BK YL 2 S 3 1 2 C 4 2 3 C 4 0 5 Z13 1 8 B K Z13 18BK 1 C 3 4 3 Z13 18BK Z13 18BK 8W 70 42 8W 70 38 1 f Z13 16BK Z13 12BK WITH TRAILER TOW S311 WITH TRAILER TOW 8W 70 37 C 1 2 8 Z13 1 6 ...

Page 797: ...parking lamps turn tail stop lamps and rear license plate lamps HELPFUL INFORMATION Check the 40 amp fuse located in cavity 3 of the PDC Check the 15 amp fuse located in cavity 6 of the fuse block Check the lamp filaments HAZARD FLASHERS Circuit A15 from the battery positive post supplies power to the hazard flasher fuse fuse C in the Power Distribution Center PDC Circuit L9 from the hazard flashe...

Page 798: ...C PDC 8W 52 3 Hazard Warning Flasher 8W 52 3 Ignition Switch 8W 52 3 SIGNALS B R Component Page Instrument Cluster 8W 52 5 Joint Connector B 8W 52 4 Park Turn Signal Lamps 8W 52 6 Stop Lamp Switch 8W 52 4 Tail Stop and Turn Signal Lamps 8W 52 6 Turn Signal Hazard Switch 8W 52 5 Turn Signal Flasher 8W 52 3 8050cd44 J968W 9 ...

Page 799: ...mm 8W 52 TURN SIGNALS BW 52 3 B A T T E R Y P O S I T I V E T E R N I N A L 8W 20 3 4 148 RIGHT BATTERY POSITIVE TERMINAL WITH DIESEL ENG 8W 20 4 WITH GAS ENG WITH DIESEL ENG 8050cd45 J968W 9 ...

Page 800: ...S T A R T E R MOTOR S P L I C E S 1 4 8 8 W 5 2 3 8 W 2 1 3 4 8 W 7 0 2 1 A3 L2RD LG A3 12RD LG WITH DRL 118 8W 70 9 A3 1 2 R D LG C241 FUSE 20 241 H H 20 15A 16 F U S E BLOCK S 2 0 3 8W 70 27 C133 A3 12RD LG A3 12RD LG A3 12RD LG F32 18PK DB STOP LAMP SWITCH J O I N T CONNECTOR B C 2 3 1 f 4 C 2 3 1 F32 18PK DB 5 S 2 0 7 L L50 18WT TN 8W 70 29 L50 18WT TN TURN S I G N A L HAZARD SWITCH 8 W 5 2 5 ...

Page 801: ...MULTI FUNCTION SWITCH C 1 3 3 15 C 2 1 0 L63 L62 18DG 18BR RD PK C 1 3 3 C133 C 1 3 3 129 L 6 2 18BR PK L63 18DG RD C 1 2 9 L60 20TN BK L61 20LG YL L62 18BR PK L 6 3 18DG RD S 1 0 2 1 S 1 2 3 8W 70 3 8W 70 11 L63 18DG RD f WITH 1 TRAILER L63 TOW 18DG RD i S 3 1 6 8W 70 39 L62 18BR PK f 1 WITH Ut TRAILER L62 TOW 18BR P K S 3 1 S 8W 70 39 L60 18LG TN L61 18LG TN L63 18DG RD C 3 3 3 RIGHT P A R K TUR...

Page 802: ... L63 18DG RD TURN S I G N A L HAZARD SWITCH 8 W 5 2 5 L62 18BR PK 3 3 1 C 1 3 3 L62 18BR PK L62 18BR PK S 3 1 5 8W 70 39 WITH TRAILER TOW C 1 2 9 L62 18BR PK L62 18BR PK L62 18BR PK L62 18BR PK L E F T P A R K T U R N S I G N A L LAMP S P L I C E 1 2 3 8W 52 5 C 8 W 7 0 1 1 C 1 1 2 Z l 18BK 1 C 1 1 2 L61 18LG TN 3 1 0 3 J 1 0 1 i RIGHT P A R K T U R N S I G N A L LAMP C 1 0 1 8W 70 3 NT 3 _ C l f ...

Page 803: ...he wiper motor LOW speed brushes As the windshield wiper motor turns the park switch internal to the motor moves from its grounded position down to the powered RUN up position Circuit V7 provides an input to the inter mittent wiper control module when the wiper switch is in the OFF position The intermittent wiper con trol module powers the park switch in the wiper motor on circuit V5 The intermitt...

Page 804: ... 4 Ignition Switch 8W 53 3 4 Instrument Cluster 8W 53 4 Intermittent Wiper Control Module 8W 53 3 4 Component Page Intermittent Wiper Switch 8W 53 3 Low Washer Fluid Switch 8W 53 4 Windshield Washer Pump Motor 8W 53 4 Windshield Wiper Motor 8W 53 4 8050cd49 J968W 9 ...

Page 805: ...F LOW DELAY 6 V17 18DG 5 A n i i a i O F F LOW T D E L A Y 2 WINDSHIELD W I P E R MOTOR 8 W 5 3 4 V3 V4 W I N D S H I E L D 18BR 16RD WASHER WT YL PUMP MOTOR I 8 W 5 3 4 C 1 3 3 V4 18RD YL VIO I 18BR f J WINDSHIELD filM W I P E R MOTOR 8 W 5 3 4 VIO 18BR L_ V6 18DB BK C 2 1 9 6 7 WIPER WIPER PARK SW SW DELAY SENSE OUTPUT 1 WIPER SW MODE SIGNAL GND 5 8 3 2 WIPER FUSED WIPER SW IGNITION SW MODE SW M...

Page 806: ... C124 C108 18BK TN J 1 C212 START V U N J OFF ACC y 3 1 2 4 1 V3 V6 18DB BK V5 18DG YL C133 C133 WITH SPEED CONTROL HIGH LINE CLUSTER 6 IGNITION SWITCH T C212 V6 18DB BK C133 V5 18DG YL V3 _ 1 8 B R 1 8 B R WT WT V4 I V4 H 8 R D 1 6 R D 1 YL YL INTERMITTENT WIPER SWITCH 8W 53 3 S103 8W 70 3 Z l 20BK BLACK Z l 18BK 1 _ S115 8W 70 8 I Zl 16BK G 1 0 6 A 8W 15 6 A31 12BK WT 39 C241 4 4 FUSE 8 20A C241...

Page 807: ... the relay is energized the contacts in the relay CLOSE connecting circuits A6 and L76 Circuit L76 connects from the relay to the trailer tow con nector TIAILER TOW C0I1ECT0R The following circuits connect to the trailer tow connector A6 for a battery feed L76 for a battery feed from the trailer tow relay for the park license and side marker lamps L l as a back up lamp input L62 for the right turn...

Page 808: ... 8W 54 TRAILER TOW B R DIAGRAM INDEX Component Page Fuse 7 P D C 8W 54 3 Joint Connector A 8W 54 3 Trailer Brake Provision 8W 54 4 Component Page Trailer Tow 8W 54 4 Trailer Tow Relay 8W 54 3 8050cd4c J968W 9 ...

Page 809: ...M LEFT OF I P T R A I L E R TOW R E L A Y A6 12RD TN C 1 8 0 1 30 8 6 it 11 C 1 8 0 r L 7 6 12BK 0R POWER D I S T R I B U T I O N C E N T E R C 1 2 9 8 7 Z l 20BK 8 5 S 1 1 9 8W 70 9 A6 12RD TN C 1 2 9 A6 12RD TN C 3 3 2 A6 12RD TN L7 20BK YL S 1 0 6 8W 70 4 L7 18BK YL C 1 3 3 L7 18BK YL 4 C 2 1 7 PARK LAMP SWITCH OUTPUT S 1 0 8 8W 70 5 Z l 12BK G 1 0 1 m 8W 15 3 J O I N T CONNECTOR L76 12BK OR C ...

Page 810: ...C8W 70 9 A6 12RD TN C 1 2 9 TURN S I G N A L HAZARD SWITCH C8W 52 5 L62 18BR PK X T L62 18BR PK L62 18BR PK C133 C 1 2 9 S31S 8W 70 39 L62 18BR PK C331 L62 18BR PK B A C K U P LAMP SWITCH P A R K N E U T R A L P O S I T I O N SWITCH 8W 5 1 6 8 W 5 1 6 Ll 18VT BK Ll 18VT BK B40 14LB L l 18VT BK C 1 2 8 B40 14LB TRAILER TOW i i T R A I L E R i B R A K E 0 U T P U T i P R O V I S I O N Zl 16BK ilis 8...

Page 811: ...uit connects from the master switch to the right window switch A bus bar internal to the right switch passes the voltage through the switch to circuit Q22 Circuit Q22 con nects from the switch to the right window motor Grounding is provided on circuit Q12 from the motor back to the right switch The ground is passed through the switch on a bus bar to circuit Q16 Circuit Q16 then connects to the mas...

Page 812: ...S DIAGRAM INDEX Component Page Component Circuit Breaker 1 8W 60 3 4 Left Power Window Switch Fuse 2 8W 60 3 4 Right Power Window Motor Ignition Switch 8W 60 3 4 Right Power Window Switch Left Power Window Motor 8W 60 3 8050cd4f ...

Page 813: ... 2 4 1 8 OPTIONAL V 347 F21 14TN 8W 70 26 f F 2 1 14TN F21 14TN F U S E B L O C K 5 A22 1 2 B K O R 1 RIGHT POWER WINDOW SWITCH 8 W 6 0 4 C 3 1 6 F21 14TN L E F T POWER WINDOW MOTOR 016 14BR WT RIGHT POWER WINDOW SWITCH 8 W 6 0 4 Q26 14VT WT C 3 1 8 l OPTIONAL Q16 14BR WT C 2 0 7 C 2 3 9 1 0 1 6 14BR WT Q16 14BR WT C 3 4 8 C 2 0 7 i 0 1 6 14BR WT Q16 14BR WT 01 I C 3 4 8 C 2 0 7 Q26 1 4 V T W T Q ...

Page 814: ... 2 1 1 4 T N C 2 0 7 FUSE BLOCK 5 A22 12BK OR 1 C 2 1 2 OPTIONAL C 3 4 5 F21 1 4 T N F 2 1 14TN F21 14TN F21 14TN 1 C 2 3 9 RIGHT POWER WINDOW SWITCH 016 1 4 B R W T f Q 1 6 14BR WT C 2 3 9 C 3 4 6 f Q 1 6 14BR WT f Q16 14BR WT Q16 Q16 1 4 B R U w f C 3 4 6 mm Q 2 6 1 4 V T W T 016 026 14BR 14VT WT WT C 3 4 8 C 2 3 9 5 0 1 6 14BR WT OPTIONAL WT X 026 14VT WT C 2 3 9 Q26 14VT WT 4 Q16 14BR WT Q16 1...

Page 815: ...The P33 circuit connects back to the right door switch LOCK side and passes through the internal bus bar to the P35 circuit The P35 circuit connects back to the left door switch and passes through the switch to ground on circuit Z3 RIGHT DOOR SWITCH OPERATION LOCK When the switch is moved to the LOCK position voltage is supplied to the P33 circuit and then to the door lock motors The ground path i...

Page 816: ...R DOOR LOCKS DIAGRAM INDEX Component Page Component Fusel PDC 8W 61 3 4 Left Power Door Lock Switch Fuse 19 8W 61 3 4 Right Power Door Lock Motor Left Power Door Lock M o t o r 8W 61 5 Right Power Door Lock Switch 8050cd52 ...

Page 817: ...R DOOR LOCKS SW 61 3 B A T T E R Y P O S I T I V E TERNINAL 8W 20 3 4 RIGHT B A T T E R Y POSITIVE TERNINAL WITH DIESEL ENG 8W 20 4 S 2 4 ENGINE STARTER NOTOR 8W 21 3 4 8050cd53 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 818: ...R BATTERY POSITIVE TERNINAL 8W 20 3 4 RIGHT BATTERY POSITIVE TERNINAL WITH DIESEL ENG 8W 20 4 ENGINE STARTER NOTOR C8W 21 3 4 WITH POWER SEAT SPLICE S 3 i i C8W 61 5 C8W 70 37 P33 160R BK WITH GAS ENG WITH DIESEL ENG 8050cd54 J968W 9 ...

Page 819: ...ER DOOR LOCKS 8W 61 5 RIGHT POWER DOOR LOCK SWITCH 8 W 6 1 4 RIGHT POWER DOOR LOCK MOTOR n P34 16PK BK RIGHT POWER DOOR LOCK SWITCH 8 W 6 1 4 P33 160R BK LEFT POWER DOOR LOCK MOTOR P3 4 16PK BK 8050cd55 J968W 9 ...

Page 820: ......

Page 821: ...rror RIGHT movement is selected the power and ground are reversed When the switch is moved to the RIGHT position and mirror movement UP is selected voltage is sup plied through the P72 circuit and the ground path is through circuit P70 When the DOWN movement is selected the power and ground are reversed If a RIGHT door mirror movement LEFT is selected voltage is supplied through the P74 circuit an...

Page 822: ... 62 POWER MIRRORS B R DIAGRAM INDEX Component Page Component Page Fuse 1 PDC 8W 62 3 Power Mirror Switch 8W 62 3 Fuse 17 8W 62 3 Right Power Mirror Motors 8W 62 3 Left Power Mirror Motors 8W 62 3 8050cd56 J968W 9 ...

Page 823: ...N L 5 2 LT LEFT MIRROR Y Y P75 P72 20DB 20YL WT BK 7 Y P73 20YL PK 3 RIGHT MIRROR L E F T POWER NIRROR NOTORS O i l C347 1 P72 20YL BK 3 VERTICAL O UP N nw O L T v _ x R T HORIZONTAL C 3 1 1 2 P70 20WT C 3 4 J P70 20WT 1 RT C 3 1 0 Ml 18PK 13 18BK 0R 8 C 3 1 0 C 2 0 1 P70 20WT C 2 4 0 P70 20WT C 3 4 5 P71 P74 20YL 20DB 4 C34Z P74 20DB C 2 0 1 RIGHT POWER NIRROR NOTORS 7 WITH Z 3 POWER 14BK WINDOWS...

Page 824: ......

Page 825: ... the cir cuits are reversed P21 is the feed and P19 is the ground When the operator selects the HORIZONTAL FOR WARD function power is passed on the F37 circuit through the CLOSED contacts in the switch to the P15 circuit The P15 circuit connects to the motor Ground is provided on the P17 circuit back to the switch A ground bus bar internal to the switch then connects to the Z3 circuit For HORIZONT...

Page 826: ... 3 POWER SEAT ilAORAi INDEX Component Page Circuit Breaker 2 8W 63 3 Forward Backward Seat Motor 8W 63 3 Front Up Down Seat Motor 8W 63 3 Component Fuse 1 PDC Power Seat Switch Rear Vertical Seat Motor 8050cd58 ...

Page 827: ...BR 8W 63 POWER SEAT 8W 63 3 BATTERY POSITIVE TERNINAL 8W 20 3 4 AO OERD A 0 RIGHT I 20BK BATTERY POSITIVE TERNINAL WITH DIESEL ENG 8W 20 4 POWER 8050cd59 WITH GAS ENG WITH DIESEL ENG J968W 9 ...

Page 828: ......

Page 829: ...R A T I O N INTRODUCTION This section identifies all splices in the wiring dia grams It also shows the splices in their entirety All circuits that are part of the splices are shown and the systems they affect are referenced For viewing the location of each splice in the vehicle refer to Sec tion 8W 95 ...

Page 830: ...70 21 5149 8W 70 21 5150 8W 70 22 5151 8W 70 22 5152 8W 70 22 5153 8W 70 23 5154 8W 70 23 5155 8W 70 24 Page 8W 70 24 S157 8W 70 25 S158 8W 70 25 S159 8W 70 26 S 1 60 8W 70 26 S201 8W 70 26 5202 8W 70 27 5203 8W 70 27 5204 8W 70 28 5205 8W 70 28 5206 8W 70 29 5207 8W 70 29 5208 8W 70 30 5209 8W 70 30 S210 8W 70 31 S212 8W 70 31 S213 8W 70 32 S214 8W 70 32 S215 8W 70 33 5216 8W 70 33 5217 8W 70 34 ...

Page 831: ...TN BK L60 18TN BK GROUND JOINT TURN SIGNAL HAZARD SWITCH 8W 52 5 8W 50 5 INSTRUNENT 3 Zl 18BK C123 Zl 18BK C106 Zl 18BK 4 Zl 20BK S103 Zl 18BK Zl 20BK Zl 20BK Zl 20BK Zl 20BK Zl 18BK RIGHT PARK TURN SIGNAL LANP 8W 52 6 8W 50 5 WINDSHIELD WASHER PUNP NOTOR 8W 53 4 FOG LANP RELAY NO 1 8W 50 8 8W 11 13 14 FOG LANP RELAY NO 2 8W 50 9 8W 11 12 C105 L39 20LB L39 20LB L39 20LB S104 C105 L39 20LB L39 20LB...

Page 832: ... 3 3 C 2 1 7 L7 18BK YL L7 18BK YL L7 18BK YL 4 PARK LAMP SWITCH OUTPUT J O I N T CONNECTOR S l i t 1 8 B K Y L 1 8 B K Y L L7 20BK YL L7 20BK YL L7 20BK YL S P L I C E S 1 0 1 8W 70 3 T R A I L E R TOW R E L A Y 8 W 5 4 3 C8W 11 6 L E F T HEADLAMP 8 W 5 0 5 HEADLAMP DIMMER SWITCH 8W 50 4 L4 16VT WT C 1 3 1 f DIMMER SWITCH 10 LOW BEAM OUTPUT L4 16VT WT S107 L4 16VT WT C 1 3 3 L4 L4 16VT t 1 6 V T ...

Page 833: ...BK Z l 18BK Z l 18BK TRAILER TOW RELAY C8W S4 3 8W 11 6 WITH TRAILER TOW WITH DRL G101 8W 15 3 VACUUN SENSOR C8W 34 4 8W 35 5 BRAKE SWITCH 8W 34 4 C8W 35 S G9 20GY BK P BLACK WITH DIESEL ENG S109 G9 16GY BK G9 20GY BK C133 G9 22GY BK G9 20GY BK C209 26 j C121 RED BRAKE WARNING LAMP DRIVER f 25 RED BRAKE WARNING LAMP DRIVER JOINT COiiEOTOR CONTROLLER ANTI LOCK BRAKE ABS WITH ABS 8050cd5f WITH MEDIU...

Page 834: ...18RD DB WITH DIESEL ENG A20 18RD DB A20 18RD DB A20 18RD DB S l l O A20 18RD DB A20 18RD DB VACUUM SENSOR 8 W 3 5 5 A20 18RD DB A20 18RD DB A B S PUMP MOTOR R E L A Y 8 W 3 5 6 C 8 W 1 1 1 0 A B S WARNING LAMP R E L A Y 8 W 3 5 6 8 W 1 1 1 6 V40 20WT PK C 1 2 S V40 C 1 3 7 r i BRAKE 20WT f H C24 SWITCH PK f SENSE j POWERTRAIN MODULE 8050cd60 WITH ABS J968W 9 ...

Page 835: ...BR T40 12BR T40 12BR C 1 1 9 T 4 0 1 2 B R S i l l T40 12BR F U E L SHUT DOWN R E L A Y C 8 W 3 0 4 7 ENGINE S T A R T E R MOTOR 8 W 2 1 4 HOT IN S T A R T R U N F U S E 1 10A 3 3 C 2 4 1 BLOCK F18 18LG BK F18 22LG BK AUTOMATIC SHUT DOWN RELAY C8W 30 12 C8W 11 10 C 1 3 3 F18 20LG BK C 1 2 6 F18 18LG BK F18 20LG BK F18 20LG BK F18 20LG BK F18 20LG BK TRANSMISSION R E L A Y C 8 W 3 1 4 C8W 11 9 S P ...

Page 836: ...DSHIELD WIPER MOTOR 8 W 5 3 4 C128 WITH TRAILER TOW FUEL PUNP NODULE 8 W 3 0 2 1 4 2 Z l l 20BK WT C 1 2 8 Z l l 20BK WT Z l l 16BK WT C 1 2 7 Z l l 16BK WT S 1 1 6 Z l l 18BK WT C 1 3 3 Z l l 18BK WT S P L I C E S 1 4 0 C 8 W 7 0 1 8 S P L I C E S 2 0 8 C 8 W 7 0 3 0 8050cd62 J968W 9 ...

Page 837: ... 1 2 9 L l 18VT BK WITH AUTO TRANS S P L I C E S 2 0 3 8 W 7 0 2 7 A3 12RD LG C 1 3 3 A3 12RD LG A3 12RD LG D A Y N I G H T NIRROR 8 W 4 4 9 S P L I C E S 3 1 3 8 W 7 0 3 8 POWER T R A I L E R TOW 8 W 5 4 4 A6 12RD TN A C 3 3 2 T R A I L E R TOW R E L A Y 8 W 5 4 3 8 W 1 1 6 A6 12RD TN A6 12RD TN C 1 2 9 A6 12RD TN M i l 1 POWER D I S T R I B U T I O N C E N T E R A6 12RD TN WITH TRAILER TOW WITH ...

Page 838: ... POSITION SWITCH 8W 51 6 BACK UP LIO yujp 1 R I SWITCH b T 8W 51 6 WITH MAN TRANS INSTRUMENT CLUSTER WITHOUT DRL FOG LAMP RELAY NO 1 8W 50 8 8W 11 14 LEFT HEADLAMP 8W 50 5 G34 18RD GY C133 G34 18RD GY C216 13 S121 C133 L3 16RD 0R L3 16RD 0R L3 16RD 0R L3 16RD 0R L3 16RD 0R HIGH BEAM INDICATOR LAMP DRIVER HEADLAMP DIMMER SWITCH 8W 50 4 RIGHT HEADLAMP 8W 50 S WITH DRL L3 16RD 0R C131 DIMMER SWITCH 1...

Page 839: ...ARK TURN SIGNAL LAMP 8W 52 6 8W 50 5 Z8 10BK PK 12 18BK LG 12 18BK LG C133 12 18BK LG WITH STANDARD SPEAKERS Z2 18BK LG WITH ABS WITH STANDARD SPEAKERS RADIO 8W 47 5 7 8 9 INSTRUMENT CLUSTER LEFT TURN SIGNAL 1 C216 12 L61 20LG YL S123 C133 L61 18LG TN L61 20LG YL L61 18LG YL TURN SIGNAL HAZARD SWITCH 8W 52 5 8W 50 5 WITH PREMIUM SPEAKERS WITH MEDIUM LINE AND HIGH LINE CLUSTER 8050cd65 J968W 9 ...

Page 840: ... C13S 129 SENSOR GROUND A 4 K4 20BK LB S P L I C E S 1 5 4 8 W 7 0 2 3 K4 18BK LB K4 18BK LB ENGINE COOLANT T E M P E R A T U R E SENSOR 8 W 3 0 2 6 I N T A K E A I R T E M P E R A T U R E SENSOR 8 W 3 0 2 3 WITH 3 9 L 5 2 L AND 5 9 L ENG C 1 3 6 5 VOLT SUPPLY B 3 1 t i T R A N S M I S S I O N SOLENOID A S S E M B L Y 5 VOLT SUPPLY K7 180R K7 180R 130 K7 180R V E H I C L E S P E E D SENSOR 8 W 3 0...

Page 841: ...W 30 14 C135 F18 18LG BK SPLICE S114 8W 70 7 DUTY CYCLE EVAP PURGE SOLENOID 8W 30 20 EXHAUST GAS RECIRCULATION SOLENOID 8W 30 20 F18 18LG BK F18 20LG BK F18 20LG BK F18 20LG BK WITH DIESEL ENG F18 20LG BK F18 20LG BK WITH 5 2L AND 5 9L ENG WITH DIESEL ENG FU L HEATER RELAY 8W 30 47 FUEL SHUT D O W N SOLENOID C8ltf 30 47 HEATED INTAKE AIR SYSTEM RELAY NO 1 8W 30 48 HEATED INTAKE AIR SYSTEM RELAY NO...

Page 842: ... 2 L AND 5 9 L ENG A142 16DG 0R A142 16DG 0R A142 16DG 0R WITH 8 0 L ENG SPLICE 1 3 8 C 8 W 7 0 1 7 A142 14DG 0R WITH 3 9 L 5 2 L AND 5 9 L ENG I N J E C T O R NO S 8 W 3 0 3 0 3 4 3 9 RIGHT UPSTREAM HEATED OXYGEN SENSOR C 8 W 3 0 3 7 WITH 5 2 L 5 9 L AND 8 0 L ENG I N J E C T O R I N J E C T O R NO 9 NO 7 C 8 W 3 0 3 9 8 W 3 0 3 4 3 9 POWERTRAIN CONTROL MODULE GENERATOR FIELD BlOl DRIVER C 1 3 6 ...

Page 843: ... 3 0 3 5 4 0 A142 16DG OR IGNITION COIL 4 PACK C S i f 3 3 IGNITION COIL 6 P A C K 8 W 3 0 3 6 A142 14DG 0R WITH 8 0 L ENG A142 14DG 0R WITH 5 2 L 5 9 L AND 8 0 L ENG WITH 3 9L 5 2 L AND 5 9 L ENG A142 A142 A142 14DB 14DG 14DG I OR OR GENERATOR 8 W 2 0 3 C 8 W 3 0 2 8 S P L I C E S 1 3 8 8 W 7 0 1 7 I G N I T I O N C O I L 8W 30 28 WITH GAS ENG 8050cd69 J968W 9 ...

Page 844: ... T HEATED OXYGEN SENSOR 8 W 3 0 3 8 K4 18BK LB K4 18BK LB DOWNSTREAM HEATED OXYGEN SENSOR 8 W 3 0 2 9 3 2 WITH 3 9 L 5 2 L AND 5 9 L ENG EXCEPT HEAVY DUTY K4 18BK LB C R A N K S H A F T P O S I T I O N SENSOR 8 W 3 0 2 7 WITH 3 9 L 5 2 L AND 5 9 L ENG T H R O T T L E P O S I T I O N SENSOR 8 W 3 0 2 4 S P L I C E S 1 5 4 8 W 7 0 2 3 MANIFOLD A B S O L U T E P R E S S U R E 8 W 3 0 2 3 8050cd6a WIT...

Page 845: ... WITH EGR K6 20VT WT WITH GAS ENG CAMSHAFT P O S I T I O N SENSOR 8 W 3 0 2 2 EGR CONTROL MODULE C A V I T Y 1 2 8 W 3 0 4 9 MANIFOLD A B S O L U T E P R E S S U R E 8 W 3 0 2 3 S P L I C E 133 8W 70 14 P R E C A T A L Y S T HEATED OXYGEN SENSOR 8 W 3 0 3 8 POST C A T A L Y S T HEATED OXYGEN SENSOR C8W 30 38 AUTOMATIC SHUT DOWN R E L A Y 8W 30 12 8W 11 10 I A142 14DG 0R A142 16DG 0R A142 16DG 0R W...

Page 846: ... CATALYST HEATED OXYGEN SENSOR C8W 30 38 PRE CATALYST HEATED OXYGEN SENSOR 8W 30 38 UPSTREAM HEATED OXYGEN SENSOR 8W 30 29 32 33 DOWNSTREAM HEATED OXYGEN SENSOR 8W 30 29 32 33 WITH 8 0L ENG 18BK WT SPLICE S150 8W 70 22 SPLICE S142 8 W 7 0 1 9 WITH DIESEL ENG DATA LINK CONNECTOR C8W 30 13 SPLICE S I 1 6 8W 70 8 A C COMPRESSOR CLUTCH 8W 42 8 LEFT UPSTREAM HEATED OXYGEN SENSOR 8W 30 37 RIGHT UPSTREAM...

Page 847: ...CE 139 8W 70 18 SPLICE S1S2 8W 70 22 Z12 10BK TN S142 Z12 16BK TN Z12 14BK TN Z12 14BK TN Z l l 16BK WT FUEL i HEATER 8W 30 47 SPLICE 140 8W 70 18 G119 8W 15 12 AUTOMATIC SHUT DOWN RELAY 8W 30 12 8W 11 10 EXHAUST GAS RECIRCULATION SOLENOID 8W 30 49 EGR CONTROL MODULE CAVITY 1 8W 30 49 C127 POWERTRAIN A142 14DG 0R f A142 14DG 0R i A142 16DG 0R A142 18DG 0R A142 20DG 0R A142 14DB 8050cd6d GENERATOR ...

Page 848: ...RELAY 8W 30 473 FUEL SHUT DOWN FEED 8W 30 47 S145 A18 16DB A 1 8 10RD BK FUEL SHUT DOWN RELAY 8W 30 47 2 T P K E 40A C180 S146 A2 12PK BK POWER DISTRIBUTION CENTER C133 A2 12PK BK A2 12PK BK IGNITION SWITCH 8W 30 11 A2 12PK BK ENGINE STARTER MOTOR RELAY 8W 21 3 4 8W 11 17 8050cd6e WITH DIESEL ENG J968W 9 ...

Page 849: ... 8W 21 3 4 POWER DISTRIBUTION CENTER 8W 11 6 THRU 2 0 S148 AO 20BK A15 16PK S148 s AO 14PK A15 20BK AO OERD WITH DIESEL ENG RIGHT BATTERY POSITIVE TERNINAL WITH DIESEL ENG 8W 20 4 A7 1 2 R D BK A7 12RD BK A7 12RD BK 1 1 4 C241 k FUSE k FUSE r 1 9 r 1 7 c i 1 2 0 A 1 15A s FUSE J 18 j I 15A FUSE BLOCK UNDERHOOD LANP 8W 44 8 S149 C183 Ml 20PK M l 20PK C133 Ml 20PK M l 20PK NO CONNECTION SPLICE S205 ...

Page 850: ...8W 11 17 SPLICE S139 C8W 70 18 DATA LINIC CONNECTOR 8W 30 13 SPLICE S141 8W 70 19 T41 20BK WT C126 Z12 20BK TN Z12 20BK TN C125 I T41 22BK WT ENGINE STARTER MOTOR RELAY 81 21 4 8W 11 17 C133 Z12 20BK TN S152 c Z12 14BK TN WITH M A N TRANS WITH EGR Z12 18BK TN EGR CONTROL MODULE CAVITY 10 8W 30 49 Z12 18BK TN FUEL SHUT D O W N RELAY 8W 30 47 Z12 20BK TN FUEL HEATER RELAY 8W 30 47 Z12 20BK TN DATA L...

Page 851: ...ULE G34 18RD GY f FOG LAMP RELAY NO 1 8W 11 13 14 8W 50 8 LEFT UPSTREAM HEATED OXYGEN SENSOR 8W 30 37 RIGHT UPSTREAM HEATED OXYGEN SENSOR 8W 30 37 UPSTREAM HEATED OXYGEN SENSOR 8W 30 29 32 33 VEHICLE SPEED SENSOR 8W 30 14 K4 18BK LB 1 TRANSMISSION SOLENOID ASSEMBLY WITH 5 9 L ENG WITH HEAVY DUTY WITH 3 9 L 5 2 L AND 5 9 L ENG SPLICE S136 8W 70 16 SPLICE S156 8W 70 24 SPLICE 129 C8W 70 12 DOWNSTREA...

Page 852: ...ESSOR CLUTCH RELAY 8W 42 8 8W 11 8 BATTERY TEMPERATURE SENSOR 8W 30 24 45 K4 20BK LB K4 20BK LB C125 K4 20BK LB C133 K4 20BK LB K 4 18BK LB C128 K4 20BK LB K4 20BK LB VEHICLE SPEED CONTROL HORN SWITCH 8W 33 3 FUEL PUMP MODULE 8W 30 21 42 K4 20BK LB SPLICE S154 8W 70 23 SPLICE K4 20BK LB S157 8W 70 25 WITH DIESEL ENG 8050cd72 J968W 9 ...

Page 853: ...DULE C135 K4 20BK LB SENSOR GROUND 117 C125 K4 20BK LB K4 20BK LB SPLICE S156 C8W 70 24 TRANSMISSION SOLENOID ASSEMBLY K4 18BK LB 167 f SENSOR GROUND VEHICLE SPEED SENSOR 8W 30 14 ABS WARNING LAMP RELAY 8W 35 6 8W 11 16 INSTRUMENT CLUSTER 158 C133 C215 G19 20LG RD G19 20LG RD G19 22LG RD f G19 20LG RD 14 ABS WARNING LAMP DRIVER CONTROLLER ANTI LOCK BRAKE CAVITY 24 8W 35 6 8W 11 16 WITH DIESEL ENG ...

Page 854: ...C125 C90 18LG C90 18LG C133 C90 22LG A C HEATER CONTROL SWITCH 8W 42 6 S160 C90 18LG A C HIGH PRESSURE CUTOUT SWITCH 8W 42 6 8W 30 15 POWERTRAIN CONTROL MODULE C90 18LG C137 f A C PRESSURE SWITCH OUTPUT C23 ACC START I p IIGNITION SWITCH C212 C241 OFF RUN J 5 A22 12BK 0R A22 12BK 0R J f A22 12BK 0R f 23 F2 FUSE BLOCK A22 12BK 0R J y 1 1 30A CB1 7 30A FUSE 1 4 20A FUSE 15 r j 10A FUSE 16 r j O 15A ...

Page 855: ...3 3 WINDSHIELD W I P E R MOTOR 8 W 5 3 4 V6 18DB BK V6 16DB BK HOT IN A C C R U N 4 F U S E BLOCK 4 4 S 2 0 2 V6 16DB BK FUSE 8 20A C 2 4 1 V6 18DB BK V6 18DB BK C 1 3 3 C 1 3 3 S 2 0 3 A3 12RD LG A3 12RD LG A3 12RD LG A3 12RD LG HEADLAMP SWITCH 8 W 5 0 4 t t A3 12RD LG A3 12RD LG S 1 1 8 8W 70 9 A3 12RD LG A3 12RD LG WITH DRL 8050cd75 J968W 9 ...

Page 856: ... 0 2 1 J O I N T CONNECTOR B r C 2 3 1 FUSED B SPLICE S 1 4 9 8 W 7 0 2 1 Ml 18PK Ml 18PK C208 Ml 20PK Ml 20PK H O T AT ALL T I M E S 4 P O W E R MIRROR SWITCH C8W 62 3 SPLICE S 3 2 0 8 W 7 0 4 1 SPLICE S 3 0 3 8 W 7 0 3 5 TIME DELAY RELAY 8 W 4 4 4 5 WITH POWER SEAT WITH CONSOLE 8050cd76 J968W 9 ...

Page 857: ...AMP 8W 44 5 Z3 20BK 0R C218 GND BUZZER MODULE Z3 16BK 0R C228 SPLICE S215 8W 70 33 i 1 0 GND J CONTROLLER ANTI LOCK BRAKE WITH RWAL L50 18WT TN L50 18WT TN L50 18WT TN CENTER HIGH MOUNTED STOP LAMP NO 1 8W 51 9 CENTER HIGH MOUNTED STOP LAMP NO 2 8W 51 9 C202 S207 L50 18WT TN C133 L50 18WT TN L50 18WT TN s i c m NO CONNECTION STOP LAMP SWITCH 8W 51 8 8W 52 4 L50 18WT TN TURN SIGNAL HAZARD SWITCH 8W...

Page 858: ...7 Z l l 20BK WT Z l l 18BK WT 0202 8W 15 13 GND OVERHEAD CONSOLE 9 C338 Z l l 20BK WT C208 WITH OVERHEAD CONSOLE Z l l 18BK WT C133 S P L I C E S116 8W 70 8 AIRBAG CONTROL MODULE FUSED IGNITION SWITCH IJ OUTPUT START RUN C232 F14 18LG YL FUSED IGNITION SWITCH OUTPUT START RUN INSTRUMENT CLUSTER 8 C215 HOT IN START RUN 4 FUSE BLOCK F14 20LG YL S209 F14 18LG YL F14 20 LG YL MESSAGE CENTER CWf 4 6 3 ...

Page 859: ... 47 7 Z2 18BK LG t Z2 18BK LG Z2 18BK L6 C202 SPLICE S301 6 N 7 0 S 4 LEFT DOOR PREMIUM SPEAKER C8M 47 8 OPTIONAL C345 Z2 18BK L6 Z2 18BK L6 RIGHT DOOR PREMIUM SPEAKER 8W 47 9 Z2 18BK LG Z2 18BK LG j Z2 18BK LG Z2 18BK LG RADIO 8W 47 5 7 8 9 I Z8 10BK PK WITH STANDARD SPEAKERS WITH LOW LINE CLUSTER ABS 2 MAY POWER FEED C8W 35 9 133 SIM Z2 1 8 B K L G f Z2 1 8 B K L 6 8 W 7 0 l l WITH RWAL 8050cd79...

Page 860: ...OPTIONAL I w RADIO CHOKE RELAY 8W 47 7 C202 SPLICE S302 8W 70 34 X 1 3 18BK RD X13 C34i 18BK R D X13 18BK RD RIGHT DOOR PREMIUM SPEAKER 8W 47 9 C207 F21 14TN OPTIONAL F21 14TN F21 14TN C347 F21 14TN LEFT POWER WINDOW SWITCH C8W 60 3 F21 14TN OPTIONAL 4 F21 14TN C345 F21 14TN F21 14TN RIGHT POWER WINDOW SWITCH 8W 60 4 HOT IN RUN WITH PREMIUM SPEAKERS 8050cd7a J968W 9 ...

Page 861: ... x 1 8 W 4 4 8 H E A T E R CONTROL SWITCH C8W 42 4 i OR A C H E A T E R CONTROL SWITCH 8 W 4 2 6 O V E R D R I V E SWITCH ILLUMINATION LAMP C8W 31 7 L E F T POWER DOOR LOCK SWITCH 8 W 6 1 3 RIGHT POWER DOOR LOCK SWITCH 8W 61 4 F35 14RD OPTIONAL i F35 14 RD C 3 4 8 F35 14RD F35 14RD F35 14RD C 2 0 7 HOT A T ALL T I M E S 4 F U S E BLOCK F35 16RD F35 16RD F35 16RD S216 F35 16RD 4 OPTIONAL F35 16RD C...

Page 862: ...ONNECTION C183 C133 M2 18YL M2 20YL S218 C217 M2 20YL f 6 DOME LAMP 8W 44 5 COURTESY LAMPS DRIVER JOINT CONNECTOR SPLICE S212 8W 70 31 C202 Z2 18BK LG Z2 18BK LG 1 Z2 18 BK LG S301 Z2 18BK LG LEFT REAR PREMIUM SPEAKER 8W 47 7 RIGHT REAR PREMIUM SPEAKER CSW 47 7 SPLICE S213 C8W 70 32 X13 18BK RD C202 X13 18BK RD X13 18BK RD S302 X13 18BK RD LEFT REAR PREMIUM SPEAKER 8W 47 7 RIGHT REAR PREMIUM SPEAK...

Page 863: ...8DG X53 20DG 4 X53 18DG C347 X53 18DG y f X53 18DG OPTIONAL RADIO X53 18DG S304 X53 18DG X53 18D6 LEFT DOOR TWEETER 8W 47 8 LEFT DOOR PREMIUM SPEAKER 8W 47 8 X55 18BR RD C201 X55 20BR RD X55 18BR RD X55 18BR RD 3 4 7 C229 j LEFT i i FRONT DOOR i 2 SPEAKER j i X55 18BR RD RADIO X55 18BR RD X55 18BR RD S305 X55 18BR RD LEFT DOOR TWEETER C8W 47 8 LEFT DOOR PREMIUM SPEAKER 8W 47 8 OPTIONAL 8050cd7d WI...

Page 864: ...PTIONAL Z3 Z3 20BK 18BK OR OR 1 G302 8W 15 14 X54 18VT C240 C230 X54 20VT 5 X54 18VT C345 X54 1 8 y T j f X 5 4 18VT t OPTIONAL C240 C229 X56 1 8 D B R D X56 2 0 D B R D 3 X56 18DB RD C345 a X 5 6 18DB RD f X56 18DB RD t RIGHT FRONT DOOR SPEAKER RADIO X54 18VT X54 18VT S307 X54 18VT RADIO X56 18DB RD X56 18DB RD S308 X56 18DB RD RIGHT DOOR TWEETER 8W 47 9 RIGHT DOOR PRENIUN SPEAKERS 8W 47 9 RIGHT ...

Page 865: ...K P33 160R BK P33 160R BK C348 OPTIONAL P33 160R BK P33 160R BK P34 16PK BK P34 16PK BK C348 OPTIONAL P34 16PK BK LEFT POWER DOOR LOCK MOTOR 8W 61 5 RIGHT POWER DOOR LOCK MOTOR SW 61 5 LEFT POWER DOOR LOCK MOTOR 8W 61 5 RIGHT POWER DOOR LOCK SWITCH 8W 61 4 SPLICE S115 8W 70 8 P34 16PK BK 310 C128 Z13 1 6 B K Z 1 3 12BK C128 Z13 1 2 B K Z 1 3 16BK P34 16PK BK FUEL PUMP MODULE 8W 30 21 42 Z13 16BK 3...

Page 866: ...W 51 4 SPLICE S401 8W 70 41 Z13 16BK Z13 12BK SPLICE S311 C8W 70 37 117 WITH HIGH LINE CLUSTER WITH TRAILER TOW 8 W 7 0 9 L l 1 8 V T BK L l 18VT BK C126 L l 18VT BK L l 18VT BK L l 18VT BK L l 18VT BK BACK UP LANP SWITCH 8W 51 6 L l 18VT BK PARK NEUTRAL POSITION SWITCH C8W 51 6 WITH AUTO TRANS r C129 TRAILER TOW 8W S4 4 L l 16VT BK L l 18VT BK WITH TRAILER TOW C331 1 L l 18VT BK 313 C329 L l 18VT...

Page 867: ...70 4 RIGHT LICENSE LANP 8W 51 4 10 SPLICE 406 8W 70 42 L 18BK YL LEFT LICENSE LANP 8W 51 4 C129 L62 18BR PK TRAILER TOM 8W 54 4 L62 18BR PK 3 3 1 L62 18BR PK L62 18BR PK 3 1 5 L62 1 8 B R PK C133 L62 18BR PK 329 Ay L62 18DG BR TURN SIGNAL HAZARD SWITCH 8W 52 5 RIGHT TAIL STOP AND TURN SIGNAL LANP 8W 51 5 8W 52 6 L63 18DG RD TRAILER TOW 8W 54 4 3 3 1 L63 18DG RD L63 18DG RD S316 L63 i 1 8 D G RD C3...

Page 868: ... 4 DAY NIGHT MIRROR 8W 44 9 WITH HIGH LINE CLUSTER OVERHEAD MAP COURTESY LAMP 8W 49 5 CENTER IDENTIFICATION LAMP 8W 50 6 7 Z4 2 2 B K _ S319 PARK LAMP SWITCH OUTPUT L7 18BK YL L7 18BK YL WITH HIGH LINE CLUSTER Z4 18BK Z4 18BK 1 Z 4 183K Z4 18BK JOINT CONNECTOR RIGHT OUTBOARD CLEARANCE LAMP 8W 50 6 RIGHT OUTBOARD IDENTIFICATION LAMP 8W 50 6 LEFT OUTBOARD CLEARANCE LAMP 8W 50 6 RIGHT OUTBOARD CLEARA...

Page 869: ...I L LEFT j S 4 0 1 STOP AND B A C K U P Z13 18BK Z13 18BK TURN L A M P S I G N A L LAMP C8W S1 7 8 W 5 1 5 8 W 5 2 6 S P L I C E Z13 18BK S 3 1 2 vI7c329 8 W 7 0 3 8 T Z13 18BK I RIGHT T A I L RIGHT I S 4 Q g STOP AND B A C K U P Z13 18BK Z13 18BK TURN L A M P S I G N A L LAMP 8 W 5 1 7 8 W 5 1 5 C 8 H 5 2 6 B A T T E R Y P O S I T I V E T E R M I N A L WITH DIESEL ENG 8 W 3 0 4 8 S 4 0 3 A19 12BK...

Page 870: ...8BK S P L I C E S 3 1 2 8 W 7 0 3 8 S P L I C E S 3 1 4 8 W 7 0 3 9 L7 18BK YL Z13 18BK L E F T FORWARD FENDER LANP 8 W 5 1 1 2 L7 18BK YL Z13 18BK RIGHT FORWARD FENDER LANP 8 W 5 1 1 2 L7 18BK YL C 4 0 4 L7 18BK YL L7 18BK YL L7 18BK YL C 3 4 3 C 4 0 2 C 4 0 3 L7 18BK YL L7 18BK YL L7 18BK YL C 4 0 6 L7 18BK YL L7 18BK YL S 4 0 6 4 0 7 Z13 18BK L7 18BK YL L7 18BK YL RIGHT T A I L G A T E LAMP C8W...

Page 871: ...B R 8W 70 SPLICE INFORMATION SW 70 43 C 1 0 5 Zl 20BK Zl 20BK L E F T FOG LAMP i 8 W 5 0 1 0 S409 Zl 20BK Zl 20BK S P L I C E mm 8 W 7 0 3 R I G H T FOG LAMP 8 W 5 0 1 0 8050cd86 WITH FOG LAMPS J968W 9 ...

Page 872: ......

Page 873: ...IN OUTS D E S C R I P T I O N A N D O P E R A T I O N INTRODUCTION The pages referenced in this section show the con nector the circuits in the connector and the pin that circuit occupies Individual connector numbers are referenced on diagram pages throughout Group 8W ...

Page 874: ... 8W 80 29 0148 8W 80 30 C 1 4 9 8W 80 30 C150 8W 80 31 C151 8W 8Q 31 C152 8W 80 31 C153 8W 80 32 C154 8W 80 32 8050cd88 Connector Page C155 8W 80 32 C156 8W 80 32 C157 8W 80 32 C158 8W 80 33 C 1 5 9 8W 80 33 C160 8W 80 33 C161 8W 80 33 C162 8W 80 34 C163 8W 80 34 C164 8W 80 34 C165 8W 80 34 C167 8W 80 35 C 1 6 8 8W 80 35 C169 8W 80 35 C170 8W 80 35 C171 8W 80 35 C172 8W 80 36 C173 8W 80 36 C174 8W...

Page 875: ...7 C324 SW 80 57 C325 8W 80 57 C326 8W 80 58 C327 8W 80 58 C328 8W 80 58 C329 8W 80 58 C330 8W 80 58 C331 8W 80 59 Connector Page C 3 3 2 8W 80 59 C333 8W 80 59 C334 8W 80 59 C335 8W 80 59 C 3 3 6 8W 80 60 C337 8W 80 60 C338 8W 80 60 C339 8W 80 60 C340 8W 80 61 C341 8W 80 61 C342 8W 80 61 C343 8W 80 61 C345 8W 80 62 C346 8W 80 62 C347 8W 80 62 C348 8W 80 63 C352 8W 80 63 C353 8W 80 63 C401 8W 80 63...

Page 876: ... SWITCH LOW BEAM OUTPUT C L3 16RD 0R DIMMER SWITCH HIGH BEAM OUTPUT BLACK RIGHT AIRBAG SENSOR C103 CAV CIRCUIT FUNCTION 1 R48 18TN RIGHT IMPACT SENSOR LINE 2 2 R46 18BR LB RIGHT IMPACT SENSOR LINE 1 GREEN RIGHT FRONT WHEEL SPEED SENSOR C104 CAV CIRCUIT FUNCTION 1 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR 2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR BLACK 1 2 3 am BLACK CAV CIRCUIT 1 L39 20LB 2 L39 20L...

Page 877: ...IRCUIT FUNCTION 1 G29 18BK TN WASHER FLUID SWITCH SENSE 2 Z l 18BK GROUND LOW WASHER FLUID SWITCH BLACK VEHICLE SPEED CONTROL SERVO C 1 0 9 CAV CIRCUIT FUNCTION 1 V36 20TN RD SPEED CONTROL VACUUM SOLENOID CONTROL 2 V35 20LG RD SPEED CONTROL VENT SOLENOID CONTROL 3 V30 20DB RD SPEED CONTROL ON OFF SWITCH OUTPUT 4 Z l 20BK GROUND BLACK C 1 1 0 LEFT AIRBAG SENSOR CAV CIRCUIT FUNCTION 1 R49 18LB WT LE...

Page 878: ...C SIGNAL 12 K6 20VT WT 5 VOLT SUPPLY 13 14 K35 18GY YL EGR SOLENOID CONTROL 1 2 3 H3 BLACK LEFT PARK TURN SIGNAL LAMP C U 2 CAV CIRCUIT FUNCTION 1 Z l 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT 3 161 18LG TN LEFT TURN SIGNAL BLUE LEFT HEADLAMP C113 CAV CIRCUIT FUNCTION A Z l 20BK GROUND B L4 16VT WT DIMMER SWITCH LOW BEAM OUTPUT C L3 16RD 0R DIMMER SWITCH HIGH BEAM OUTPUT BLACK AMBIENT TEMPE...

Page 879: ...L DUMP SOLENOID C 1 1 7 WITH ABS CAV CIRCUIT FUNCTION A B252 18BR TN REAR ISOLATION VALVE CONTROL B B120 12BR WT ABS PUMP MOTOR RELAY OUTPUT C B19 20LB REAR VALVE RESET SWITCH SENSE D B254 16DG 0R REAR DUMP VALVE CONTROL BLACK LEFT FRONT WHEEL SPEED SENSOR C 1 1 8 WITH ABS CAV CIRCUIT FUNCTION 1 B8 20RD GY LEFT FRONT WHEEL SPEED SENSOR 2 B9 20RD LEFT FRONT WHEEL SPEED SENSOR BLACK C 1 1 9 CAV CIRC...

Page 880: ...USED IGNITION SWITCH OUTPUT RUN 13 B47 20RD LB ABS WARNING LAMP RELAY CONTROL 14 B114 20WT VT RIGHT REAR WHEEL SPEED SENSOR 15 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR 16 B8 20RD GY LEFT FRONT WHEEL SPEED SENSOR 17 A20 18RD DB FUSED IGNITION SWITCH OUTPUT RUN 18 B18 20VT LG RIGHT FRONT RESET SWITCH SENSE 19 B19 20LB REAR VALVE RESET SWITCH SENSE 20 17 18BK RD GROUND 21 A20 18RD DB FUSED IGNITION ...

Page 881: ...B5 20VT RD LEFT FRONT RESET SWITCH SENSE 10 B120 12BR WT ABS PUMP MOTOR RELAY OUTPUT C123 GROUND JOINT BLACK CAV CIRCUIT FUNCTION 1 Z l 18BK GROUND 1 Z l 18BK GROUND 2 Z l 12BK GROUND 2 Z l 14BK GROUND 3 Z l 18BK GROUND 3 Z l 18BK GROUND 4 Z l 14BK GROUND 4 Z l 1 2 B K GROUND 5 Z l 18BK GROUND _ J l L _ m m BLACK WINDSHIELD WIPER MOTOR 0124 CAV CIRCUIT FUNCTION 1 V4 18RD YL WIPER SWITCH HIGH SPEED...

Page 882: ...0PK YL 13 K4 20BK LB 15 T16 18RD 16 K30 20PK C 1 2 6 GRAY 16 V J J 13 CAV CIRCUIT 1 F18 18LG BK 2 V32 20YL RD 3 V37 20RD LG 4 Z12 20BK TN 5 C3 18DB BK 6 L l 18VT BK 7 V35 20LG RD 8 G3 22BK PK 9 V36 20TN RD 10 LIO 18BR LG 11 D20 20DG 12 D21 D20PK DB 13 G24 20GY PK 14 K226 20DB WT 15 Z l l 20BK WT GRAY 13 i i ti II uu un uu c 16 CAV CIRCUIT 1 F18 18LG BK 2 V32 20YL RD 3 V37 20RD LG 4 Z12 20BK TN 5 C...

Page 883: ... 5 8 CAV CIRCUIT 1 B113 20RD VT 2 B114 20WT VT 3 Z13 12BK 3 Z13 16BK 4 Z l l 20BK WT 5 G4 20DB 0R 6 B40 14LB 7 K4 20BK LB 8 K104 20DB WT 3 nrin EEb BLACK 1 4 7 CAV CIRCUIT 1 B113 20RD VT 2 B114 20WT VT 3 Z13 16BK 3 Z13 12BK 4 Z l l 20BK WT 5 G4 20DB 6 B40 14LB 7 K4 20BK LB 8 K226 20DB WT C129 3 n n n D c i D BLACK 1 4 7 CAV CIRCUIT 1 L7 18BK YL 2 3 L76 12BK 0R 4 L63 18DG RD 5 L l 18VT BK 6 A6 14RD...

Page 884: ...H BEAM INDICATOR LAMP DRIVER 5 LIO 18BR LG FUSED IGNITION SWITCH OUTPUT RUN 6 A3 12RD LG FUSED B 7 8 Z l 18BK GROUND 9 Z l 18BK GROUND 10 L4 16VT WT DIMMER SWITCH LOW BEAM OUTPUT GREEN BYPASS JUMPER C132 WITH AUTO TRANS CAV CIRCUIT 1 T141 14YL RD 2 A41 18DB YL GREEN m BYPASS JUMPER CAV CIRCUIT 1 T141 20YL RD 2 T141 20YL RD GREEN CLUTCH PEDAL POSITION SWITCH C132 WITH MAN TRANS CAV CIRCUIT FUNCTION...

Page 885: ... L7 18BK YL BLACK 1 13 25 37 41 45 49 61 73 m n a u u u uuuuatni DDDDDDDDDDDD DDDDDDDDDDDD DDODD DD DD DD DD O DDDDDD DDDDDD DDDDDD DDDDDD nnnnnn nnnnnnj 12 24 36 40 44 48 60 72 84 CAV CIRCUIT 1 R47 18DB LB 2 G12 20TN YL 3 G4 20DB 4 L62 18BR PK 5 L63 18DG RD 6 T6 220R WT 7 T18 22LG 0R 8 G20 22VT YL 9 G21 22GY LB 10 G24 20GY PK 11 L35 22BR WT 12 R48 18TN 13 L50 18WT TN 14 C90 18LG 15 G3 22BK PK 16 ...

Page 886: ...0 20DG 75 76 D12 220R 77 D l l 22WT RD 78 79 V32 22YL RD 80 V37 22RD LG 81 K4 18BK LB 82 83 84 BLACK 1 13 25 37 41 45 49 61 73 DUUUUU DDUUDD DDDDDDDDDDDD DDDDDD DDDDDD DD DD DD O DD DD DD DDDDDDDDDDDD DDDDDDDDDDDD innnnnn nnnnnm 12 24 36 40 44 48 60 72 84 CAV CIRCUIT 41 A20 18RD DB 42 A l 12RD 43 A2 12PK BK 44 L9 18BK VT 45 V4 18RD YL 46 B108 18WT 47 A3 12RD LG 48 A7 12RD BK 49 Z2 18BK LG 50 G19 2...

Page 887: ...8 K24 20GY BK CRANK POSITION SENSOR SIGNAL A9 A10 K60 18YL BK IDLE AIR CONTROL MOTOR NO 2 DRIVER A l l K40 18BR WT IDLE AIR CONTROL MOTOR NO 3 DRIVER A12 A13 A14 A15 K21 18BK RD INTAKE AIR TEMPERATURE SIGNAL A16 K2 18TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL A17 K6 20VT WT 5 VOLT SUPPLY A18 K44 20TN YL CAMSHAFT POSITION SENSOR SIGNAL A19 K39 18GY RD IDLE AIR CONTROL MOTOR NO 1 DRIVER A20 K59 ...

Page 888: ...15 K21 18BK RD INTAKE AIR TEMPERATURE SIGNAL A16 K2 18TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL A17 K6 20VT WT 5 VOLT SUPPLY A18 K44 20TN YL CAMSHAFT POSITION SENSOR SIGNAL A19 K39 18GY RD IDLE AIR CONTROL MOTOR NO 1 DRIVER A20 K59 18VT BK IDLE AIR CONTROL MOTOR NO 4 DRIVER A21 A22 A14 16RD WT FUSED B A23 K22 180R DB THROTTLE POSITION SENSOR SIGNAL A24 K141 18TN WT UPSTREAM HEATED OXYGEN SENS...

Page 889: ...MOTOR NO 2 DRIVER A l l K40 18BR WT IDLE AIR CONTROL MOTOR NO 3 DRIVER A12 A13 A14 A15 K21 18BK RD INTAKE AIR TEMPERATURE SIGNAL A16 K2 18TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL A17 K6 20VT WT 5 VOLT SUPPLY A18 K44 20TN YL CAMSHAFT POSITION SENSOR SIGNAL A19 K39 18GY RD IDLE AIR CONTROL MOTOR NO 1 DRIVER A20 K59 18VT BK IDLE AIR CONTROL MOTOR NO 4 DRIVER A21 A22 A14 16RD WT FUSED B A23 K22 ...

Page 890: ...WITCH SENSE A7 S21 20YL BK AIR INTAKE HEATER RELAY NO 1 CONTROL A8 K24 20GY BK ENGINE SPEED SENSOR SIGNAL A9 S22 200R BK AIR INTAKE HEATER RELAY NO 2 CONTROL A10 A l l A12 D28 20LG RD EGR ON OFF SIGNAL A13 A14 _ A15 K21 16BK RD INTAKE AIR TEMPERATURE SIGNAL A16 A17 K6 20VT WT 5 VOLT SUPPLY A18 _ A19 A20 A21 A22 A14 16RD WT FUSED B A23 K22 20OR DB THROTTLE POSITION SENSOR SIGNAL A24 A25 A26 A27 Kl ...

Page 891: ...0R BK UPSHIFT LAMP DRIVER B l l K54 200R BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL B12 K58 18BR DB INJECTOR NO 6 DRIVER B13 B14 B15 K12 18TN INJECTOR NO 2 DRIVER B16 K14 18LB BR INJECTOR NO 4 DRIVER B17 _ B18 B19 B20 B21 T60 20BR OVERDRIVE SOLENOID CONTROL B22 K221 18TN PK FUEL TEMPERATURE SENSOR SIGNAL B23 B24 B25 T13 18DB BK OUTPUT SHAFT SPEED SENSOR GROUND B26 B27 G7 20WT 0R VEHICLE SPEED SEN...

Page 892: ... LAMP DRIVER B l l K54 200R BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL B12 K58 18BR DB INJECTOR NO 6 DRIVER B13 K28 18GY LB INJECTOR NO 8 DRIVER B14 B15 K12 18TN INJECTOR NO 2 DRIVER B16 K14 18LB BR INJECTOR NO 4 DRIVER B17 B18 _ B19 B20 _ B21 T60 20BR OVERDRIVE SOLENOID CONTROL B22 K221 18TN PK FUEL TEMPERATURE SENSOR SIGNAL B23 _ B24 B25 T13 18DB BK OUTPUT SHAFT SPEED SENSOR GROUND B26 B27 G7 2...

Page 893: ...NERATOR FIELD DRIVER B l l K54 200R BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL B12 K58 18BR DB INJECTOR NO 6 DRIVER B13 K28 18GY LB INJECTOR NO 8 DRIVER B14 K116 18WT DB INJECTOR NO 10 DRIVER B15 K12 18TN INJECTOR NO 2 DRIVER B16 K14 18LB BR INJECTOR NO 4 DRIVER B17 B18 _ B19 _ B20 _ B21 T60 20BR OVERDRIVE SOLENOID CONTROL B22 B23 B24 B25 T13 18DB BK OUTPUT SHAFT SPEED SENSOR GROUND B26 _ B27 G7 ...

Page 894: ...18DG GENERATOR FIELD DRIVER B l l K54 200R BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL B12 B13 B14 B15 _ B16 B17 B18 B19 B20 G85 180R BK WAIT TO START WARNING LAMP DRIVER B21 T60 20BR OVERDRIVE SOLENOID CONTROL B22 B23 _ B24 B25 T13 18DB BK OUTPUT SHAFT SPEED SENSOR GROUND B26 B27 G7 20WT 0R VEHICLE SPEED SENSOR SIGNAL B28 T14 18LG BK OUTPUT SHAFT SPEED SENSOR SIGNAL B29 T25 20LG WT GOVERNOR PRESS...

Page 895: ...EED C12 A142 16DG 0R AUTO SHUT DOWN RELAY SENSE C13 T6 20OR WT TRANSMISSION OVERDRIVE SWITCH SENSE C14 C15 K118 20PK YL BATTERY TEMPERATURE SENSOR SIGNAL C16 G12 20TN YL GEN LAMP DRIVER C17 G3 20BK PK MALFUNCTION INDICATOR LAMP DRIVER C18 G24 20GY PK SERVICE REMINDER INDICATOR LAMP DRIVER C19 K31 20BR WT FUEL PUMP RELAY CONTROL C20 K52 20PK EVAPORATIVE EMISSION SOLENOID CONTROL C21 C22 C20 18BR A ...

Page 896: ...OL FEED C12 A142 16D6 0R AUTO SHUT DOWN RELAY SENSE C13 T6 200R WT TRANSMISSION OVERDRIVE SWITCH SENSE C14 C15 K118 20PK YL BATTERY TEMPERATURE SENSOR SI6NAL C16 G12 20TN YL GEN LAMP DRIVER C17 G3 20BK PK MALFUNCTION INDICATOR LAMP DRIVER C18 624 20GY PK SERVICE REMINDER INDICATOR LAMP DRIVER C19 K31 20BR WT FUEL PUMP RELAY CONTROL C20 K52 20PK EVAPORATIVE EMISSION SOLENOID CONTROL C21 C22 C20 18B...

Page 897: ...EED C12 A142 16DG 0R AUTO SHUT DOWN RELAY SENSE C13 T6 200R WT TRANSMISSION OVERDRIVE SWITCH SENSE C14 C15 K118 20PK YL BATTERY TEMPERATURE SENSOR SIGNAL C16 G12 20TN YL GEN LAMP DRIVER C17 G3 20BK PK MALFUNCTION INDICATOR LAMP DRIVER C18 G24 20GY PK SERVICE REMINDER INDICATOR LAMP DRIVER C19 K31 20BR WT FUEL PUMP RELAY CONTROL C20 K52 20PK EVAPORATIVE EMISSION SOLENOID CONTROL C21 C22 C20 18BR A ...

Page 898: ...D29 20PK DG EGR DIAGNOSTIC SIGNAL CIO C l l V32 20YL RD SPEED CONTROL FEED C12 A142 16DG OR AUTO SHUT DOWN RELAY SENSE C13 T6 200R WT TRANSMISSION OVERDRIVE SWITCH SENSE C14 C15 K118 20PK YL BATTERY TEMPERATURE SENSOR SIGNAL C16 G12 20TN YL GEN LAMP DRIVER C17 G3 20BK PK MALFUNCTION INDICATOR LAMP DRIVER C18 G86 18TN 0R WATER IN FUEL WARNING LAMP DRIVER C19 C20 C21 C22 C20 18BR A C REQUEST C23 C90...

Page 899: ...ACK C13S WITH DIESEL ENG CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K24 20GY BK CRANK POSITION SENSOR SIGNAL 3 K4 20BK LB SENSOR GROUND BLACK ENGINE OIL PRESSURE SENSOR C139 WITH GAS ENG CAV CIRCUIT FUNCTION 1 G6 16GY OIL PRESSURE SENSE 2 G60 16GY YL OIL PRESSURE SENSOR SIGNAL 1 3 9 WITH DIESEL ENG CAV CIRCUIT FUNCTION 1 66 18GY OIL PRESSURE SENSE 2 660 18GY YL OIL PRESSURE SENSOR SIGNAL 80...

Page 900: ...42 14DG 0R AUTO SHUT DOWN RELAY OUTPUT 3 K18 18RD BK IGNITION COIL NO 3 DRIVER BLACK INJECTOR NO 8 V 8 V 1 0 OR INJECTOR NO 6 V 6 142 CAV CIRCUIT FUNCTION 1 K28 18GY LB INJECTOR NO 8 DRIVER 1 K58 18BR DB INJECTOR NO 6 DRIVER 2 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT BLACK 1 4 3 WITH 5 2 L 5 9 L AND 8 0 L ENG CAV CIRCUIT FUNCTION 1 K58 18BR DB INJECTOR NO 6 DRIVER 2 A142 16DG 0R AUTO SHUT DOWN REL...

Page 901: ...CULATION SOLENOID CAV CIRCUIT FUNCTION 1 K14 18LB BR INJECTOR NO 4 DRIVER 2 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT C 1 4 6 WITH 5 2 L AND 5 9 L ENG CAV CIRCUIT FUNCTION 1 K35 20GY YL EGR SOLENOID CONTROL 2 F18 20LG BK FUSED IGNITION SWITCH OUTPUT START RUN C 1 4 6 WITH DIESEL ENG CAV CIRCUIT FUNCTION 1 K35 18GY YL EGR SOLENOID CONTROL 2 A142 18DG 0R AUTO SHUT DOWN RELAY OUTPUT BLACK C 1 4 7 CAV ...

Page 902: ...SENSOR SIGNAL 3 K4 18BK LB SENSOR GROUND 148 WITH 8 0 L ENG CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND 2 K6 20VT WT 5 VOLT SUPPLY 3 K l 18DG RD MAP SENSOR SIGNAL 149 WITH GAS ENG CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K22 180R DB THROTTLE POSITION SENSOR 3 K4 18BK LB SENSOR GROUND 14 WITH DIESEL ENG WITH AUTO TRANS OR EGR CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 2 K22 200R D...

Page 903: ...R BLACK o 1 2 GENERATOR C1S1 WITH GAS ENG CAV CIRCUIT FUNCTION 1 K20 18DG GENERATOR FIELD DRIVER 2 A142 14DB AUTO SHUT DOWN RELAY OUTPUT 3 Zl 6BK GROUND BLACK O 1 2 GENERATOR J3 4 B 0 3 C151 WITH DIESEL ENG CAV CIRCUIT FUNCTION 1 K20 18DG GENERATOR FIELD DRIVER 2 A142 14DB AUTO SHUT DOWN RELAY OUTPUT 3 A l l 6BK GENERATOR OUTPUT 4 Zl 6BK GROUND BLACK CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND...

Page 904: ... RELAY OUTPUT C155 CAV CIRCUIT FUNCTION 1 K26 18VT TN INJECTOR NO 7 DRIVER 1 K38 18GY INJECTOR NO 5 DRIVER 2 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT C156 WITH 5 2 L 5 9 L AND 8 0 L ENG CAV CIRCUIT FUNCTION 1 K38 18GY INJECTOR NO 5 DRIVER 2 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT BLACK INTAKE AIR TEMPERATURE SENSOR C157 WITH GAS ENG CAV CIRCUIT FUNCTION A K4 18BK LB SENSOR GROUND B K21 18BK RD IN...

Page 905: ...0R AUTO SHUT DOWN RELAY OUTPUT INJECTOR NO 1 BLACK 2 4 UPSTREAM HEATED OXYGEN SENSOR C l f O WITH 5 9 L ENG HEAVY DUTY CAV CIRCUIT FUNCTION 1 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT 2 Z l l 18BK WT GROUND 3 K4 18BK LB SENSOR GROUND 4 K41 18BK DG UPSTREAM HEATED SENSOR SIGNAL BLACK C161 WITH MAN TRANS CAV CIRCUIT FUNCTION 1 L l 18VT BK BACK UP LAMP SWITCH OUTPUT 2 2 LIO 18BR LG FUSED IGNITION SWIT...

Page 906: ... HEATED OXYGEN SENSOR B L A C K C 1 6 3 CAV CIRCUIT FUNCTION 1 K7 180R 5 VOLT SUPPLY 2 K4 18BK LB SENSOR GROUND 3 G7 18WT 0R VEHICLE SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR BLACK A C COMPRESSOR CLUTCH C 1 6 4 CAV CIRCUIT FUNCTION 1 C3 18DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 2 Z l l 18BK WT GROUND C 1 6 5 BLACK A C HIGH PRESSURE CUTOUT SWITCH CAV CIRCUIT FUNCTION 1 C90 18LG A C PRESSURE SWITCH ...

Page 907: ...CK PARK NEUTRAL POSITION SWITCH BLACK cira CAV CIRCUIT FUNCTION 1 K204 20BK WT EGR I A T 2 K321 20BK PK EGR I A T C1H9 WITH AUTO TRANS CAV CIRCUIT FUNCTION 1 LIO 18BR LG FUSED IGNITION SWITCH OUTPUT 2 T41 18BK WT PARK NEUTRAL POSITION SWITCH SENSOR 3 L l 18VT BK BACK UP LAMP SWITCH OUTPUT C170 WITH 3 9 L 5 2 L AND 5 9 L ENG CAV CIRCUIT FUNCTION 1 K19 16BK GY IGNITION COIL NO 1 DRIVER 2 A142 14DG 0...

Page 908: ... CAV CIRCUIT FUNCTION 1 A18 10RD BK FUSED B 2 T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT 3 Z12 18BK TN GROUND 4 A123 10RD VT FUEL SHUT DOWN RELAY OUTPUT C 1 7 4 CAV CIRCUIT FUNCTION 1 K l 20DG RD WATER IN FUEL SENSOR SIGNAL 2 K4 20BK LB SENSOR GROUND 1 7 5 CAV CIRCUIT FUNCTION A F18 20LG BK FUSED IGNITION SWITCH OUTPUT START RUN B A123 10RD VT FUEL SHUT DOWN RELAY OUTPUT C Z12 10BK TN GROUND BLACK...

Page 909: ...R RELAY NO 1 CONTROL BLACK BLACK C 1 7 9 WITH DIESEL ENG HEATER INTAKE AIR SYSTEM RELAY NO 2 CAV CIRCUIT FUNCTION 1 F18 20LG BK FUSED IGNITION SWITCH OUTPUT START RUN 2 S22 200R BK AIR INTAKE HEATER RELAY NO 2 CONTROL C 1 8 0 POWER D I S T R I B U T I O N C E N T E R S E E 8 W 1 1 3 BLACK OJ B ENGINE STARTER MOTOR C 1 8 1 CAV CIRCUIT FUNCTION A T40 12BR STARTER RELAY OUTPUT B AO 6RD B BLACK C1S2 A...

Page 910: ...C185 WITH 3 9 L 5 2 L AND 5 9 L ENG EXCEPT HEAVY DUTY CAV CIRCUIT FUNCTION 1 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT 2 Z l l 18BK WT GROUND 3 K4 18BK LB SENSOR GROUND 4 K341 180R BK DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL BLACK PRE CATALYST HEATED OXYGEN SENSOR C186 WITH CALIFORNIA CAV CIRCUIT FUNCTION 1 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT 2 Z l l 18BK WT GROUND 3 K4 18BK LB SENSOR GROUND 4 K...

Page 911: ... K6 20VT WT 5 VOLT SUPPLY 3 K242 20DG LB FUEL PRESSURE SENSOR SIGNAL IMJ BLACK C189 CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND 2 K221 18TN PK FUEL TEMPERATURE SENSOR SIGNAL FUEL TEMPERATURE SENSOR BLACK 2 1 LOW PRESSURE FUEL SHUT OFF SENSOR C190 CAV CIRCUIT FUNCTION 1 Z12 18BK TN GROUND 2 A142 14DG 0R AUTO SHUT DOWN RELAY OUTPUT BLACK 2 1 BATTERY TEMPERATURE SENSOR C191 CAV CIRCUIT FUNCTION 1...

Page 912: ...Z l l 18BK WT GROUND 3 K4 18BK LB SENSOR GROUND 4 K141 18TN WT LEFT UPSTREAM HEATED OXYGEN SENSOR SIGNAL C 1 9 4 WITH CALIFORNIA B L A C K l C o 2 CAV CIRCUIT FUNCTION 1 A142 16DG 0R AUTO SHUT DOWN RELAY OUTPUT 2 Z l l 18BK WT GROUND 3 K4 18BK LB SENSOR GROUND 4 K341 180R BK POST CATALYST HEATED OXYGEN SENSOR SIGNAL POST CATALYST HEATED OXYGEN SENSOR BLACK DOWNSTREAM HEATED OXYGEN SENSOR C I 9 5 W...

Page 913: ...PK DB 7 X58 18DB 0R 8 M2 20YL 9 G10 20LG RD 10 L50 18WT TN 11 X13 18BK RD 12 X52 18DB WT BLACK CAV CIRCUIT 1 F37 14RD LB 2 X57 20BR LB 3 Ml 18PK 4 Z2 18BK LG 5 X51 20BR YL 6 M3 22PK DB 7 X58 20DB 0R 8 M2 20YL 9 G10 22LG RD 10 L50 18WT TN 11 X13 18BK RD 12 X52 20DB WT C 2 0 3 llnnn X L HO VEHICLE SPEED CONTROL HORN SWITCH BLACK CAV CIRCUIT FUNCTION 1 V32 22YL RD SPEED CONTROL ON OFF SWITCH SENSE 2 ...

Page 914: ...8LB KEY IN IGNITION SWITCH SENSE D M3 22PK DB CARGO LAMP SWITCH GROUND H L2 16LG HEADLAMP SWITCH OUTPUT I El 20TN 0R PANEL LAMPS DIMMER SWITCH SIGNAL P L20 16LG WT FUSED B R L7 20BK YL PARK LAMP SWITCH OUTPUT U G16 22BK LB LEFT FRONT DOOR JAMB SWITCH SENSE BLACK 1 4 5 8 C 2 0 7 CAV CIRCUIT 1 F35 16RD 2 F21 14TN 3 Q16 14BR WT 4 Q26 14VT WT 5 P33 160R BK 6 P34 16PK BK 7 P35 160R VT 8 P36 16PK VT _BL...

Page 915: ... SENSE 11 G i l 22WT BK PARK BRAKE SWITCH SENSE 12 F12 22DB WT FUSED IGNITION SWITCH OUTPUT START RUN 13 F12 20DB WT FUSED IGNITION SWITCH OUTPUT START RUN 14 F12 22DB WT FUSED IGNITION SWITCH OUTPUT START RUN 15 F12 22DB WT FUSED IGNITION SWITCH OUTPUT START RUN 16 17 V32 20YL RD SPEED CONTROL FEED 18 V32 22YL RD SPEED CONTROL FEED 19 V32 22YL RD SPEED CONTROL FEED 20 G16 22BK LB LEFT FRONT DOOR ...

Page 916: ...N BK RIGHT TURN SIGNAL 12 L62 18BR PK RIGHT REAR TURN SIGNAL 13 L19 18PK WT HAZARD FLASHER OUTPUT 14 L50 18WT TN STOP LAMP SWITCH OUTPUT 15 L63 18DG RD LEFT REAR TURN SIGNAL 16 L61 20LG YL LEFT TURN SIGNAL 16 L61 18LG YL LEFT TURN SIGNAL 17 L6 20RD GY TURN SIGNAL FLASHER OUTPUT 18 L4 16VT WT DIMMER SWITCH LOW BEAM OUTPUT 19 L2 16LG HEADLAMP SWITCH OUTPUT 20 L3 16RD OR DIMMER SWITCH HIGH BEAM OUTPU...

Page 917: ...H OUTPUT 6 F32 18PK DB FUSED B C215 BLACK 14 L U J J L ITU INSTRUMENT CLUSTER CAV CIRCUIT FUNCTION 1 E2 220R FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 2 3 G21 22GY LB TACHOMETER SIGNAL 4 66 22GY OIL PRESSURE SENSE 5 G12 22TN YL GEN LAMP DRIVER 6 G3 22BK PK MALFUNCTION INDICATOR LAMP DRIVER 7 G29 22BK TN WASHER FLUID SWITCH SENSE 8 F14 20LG YL FUSED IGNITION SWITCH OUTPUT START RUN 9 Z l l 20BK WT GRO...

Page 918: ...K RIGHT TURN SIGNAL C 2 1 7 BLACK T I f i I U JOINT CONNECTOR A 5 10 CAV CIRCUIT FUNCTION 1 M2 20YL COURTESY LAMPS DRIVER 2 M2 22YL COURTESY LAMPS DRIVER 3 M2 22YL COURTESY LAMPS DRIVER 4 L7 18BK YL PARK LAMP SWITCH OUTPUT 5 L7 20BK YL PARK LAMP SWITCH OUTPUT 6 M2 20YL COURTESY LAMPS DRIVER 7 M2 22YL COURTESY LAMPS DRIVER 8 M2 22YL COURTESY LAMPS DRIVER 9 L7 20BK YL PARK LAMP SWITCH OUTPUT 10 L7 2...

Page 919: ...ROUND 6 V7 18DG WT WIPER PARK SWITCH SENSE 7 V17 18DG WIPER SWITCH DELAY OUTPUT 8 V8 18VT WIPER SWITCH MODE SIGNAL C 2 2 3 y BLACK 1 _ 8 T L 9 16 DATA LINK CONNECTOR CAV CIRCUIT FUNCTION 1 _ 2 3 Dl 18VT BR CCD BUS 4 Z12 20BK TN GROUND 5 Z l l 20BK WT GROUND 6 D20 20DG SCI RECEIVE 7 D21 20PK DB SCI TRANSMIT 8 9 B113 20RD VT RIGHT REAR WHEEL SPEED SENSOR 10 11 D2 18WT BK CCD BUS 12 D l l 22WT RD SCI...

Page 920: ...6 220R WT TRANSMISSION OVERDRIVE SWITCH SENSE 2 Z3 20BK OR GROUND 3 F12 22DB WT FUSED IGNITION SWITCH OUTPUT START RUN 4 E2 200R FUSED PANEL LAMPS DIMMER SWITCH SENSE 4 E2 220R FUSED PANEL LAMPS DIMMER SWITCH SENSE 5 T18 22LG 0R OVERDRIVE LAMP DRIVER 5 G54 2 2 0 R B K UPSHIFT LAMP DRIVER 6 GRAY FOG LAMP SWITCH C 2 2 6 CAV CIRCUIT FUNCTION 1 L35 22BR WT FOG LAMP RELAY CONTROL 2 Z3 20BK 0R GROUND 3 ...

Page 921: ...DB FUSED IGNITION SWITCH OUTPUT RUN 4 G107 20BK GY 4WD SENSE 4 G107 20BK GY 4WD SENSE 5 Gil 22WT BK PARK BRAKE SWITCH SENSE 6 G9 22GY BK RED BRAKE WARNING LAMP DRIVER 7 V40 22WT PK BRAKE SWITCH SENSE 8 B108 18WT RWAL DUMP SOLENOID 9 F32 20PK DB FUSED B 10 Z3 16BK 0R GROUND 11 B i l l 22LB BK RWAL RESET SWITCH 12 B112 20BK RWAL SERVICE DIAGNOSTIC SIGNAL 13 B114 22WT VT RIGHT REAR WHEEL SPEED SENSOR...

Page 922: ...R B 5 F32 18PK DB FUSED B JOINT CONNECTOR B 6 Ml 18PK FUSED B JOINT CONNECTOR B 7 Ml 20PK FUSED B JOINT CONNECTOR B 8 Ml 18PK FUSED B JOINT CONNECTOR B 9 F32 20PK DB FUSED B JOINT CONNECTOR B 10 C 2 3 2 BLACK 6 1 13 7 AIRBAG CONTROL MODULE CAV CIRCUIT FUNCTION 1 F14 18LG YL FUSED IGNITION SWITCH OUTPUT START RUN 2 F23 18DB YL FUSED IGNITION SWITCH OUTPUT RUN 3 Dl 18VT BR CCD BUS 4 D2 18WT BK CCD B...

Page 923: ...AMPLIFIER 3 X60 22DG RD RADIO 12 VOLT OUTPUT 4 Z2 18BK LG GROUND POWER OUTLET BLACK C 2 3 5 CAV CIRCUIT FUNCTION 1 F130 18RD YL FUSED IGNITION SWITCH OUTPUT ACC RUN 2 Z3 18BK 0R GROUND BLACK CIGAR LIGHTER C236 CAV CIRCUIT FUNCTION A F30 18RD 0R FUSED IGNITION SWITCH OUTPUT ACC RUN B Z3 18BK 0R GROUND 1_ BLACK 1 3 C 2 3 7 CAV CIRCUIT 1 C7 12BK TN 2 C6 14LB 3 C5 16LG 4 C4 16TN BLACK CAV CIRCUIT 1 C7...

Page 924: ...LACK CAV CIRCUIT 1 2 3 F21 14TN 4 Q16 14BR WT 5 Q26 14VT WT 6 P36 16PK VT 7 F35 16RD 8 P33 160R BK 9 P34 16PK BK 10 P35 160R VT C 2 4 0 BLACK 1 5 CAV CIRCUIT 1 X13 18BK RD 2 X54 20VT 3 P70 20WT 4 P72 20YL BK 5 Z2 18BK LG 6 X56 20DB RD 7 M2 22YL 8 P74 20DB BLACK CAV CIRCUIT 1 X13 18BK RD 2 X54 20VT 2 X54 18VT 3 P70 20WT 4 P72 20YL BK 5 Z2 18BK LG 6 X56 18DB RD 6 X56 20DB RD 7 M2 18YL 8 P74 20DB C24...

Page 925: ...UIT FUNCTION A X58 18DB 0R RIGHT REAR SPEAKER B X52 18DB WT RIGHT REAR SPEAKER BLACK 303 CAV CIRCUIT 1 Z3 14BK 0R 2 F37 14RD L3 BLACK D 0 CAV CIRCUIT 1 Z3 14BK 0R 2 F37 14RD LB f BLACK DOME LAMP C 3 0 4 CAV CIRCUIT FUNCTION 1 Ml 18PK FUSED B 2 M2 20YL COURTESY LAMPS DRIVER BLACK 1 LEFT REAR PREMIUM SPEAKER C 3 0 5 CAV CIRCUIT FUNCTION 1 Z2 18BK LG GROUND 2 X57 18BR LB LEFT REAR SPEAKER 3 X51 18BR ...

Page 926: ...T 1 L50 18WT TN 2 Z3 18BK 0R 3 Ml 18PK 4 M3 20PK DB 5 6 BLACK LEFT DOOR JAMB SWITCH 3 0 9 CAV CIRCUIT FUNCTION 1 Z3 18BK 0R GROUND 1 Z3 20BK 0R GROUND 2 M2 18YL COURTESY LAMPS DRIVER 3 G16 18BK LB DOOR JAMB SWITCH SENSE C 3 1 0 BLACK Li r bi_rurJj POWER MIRROR SWITCH CAV CIRCUIT FUNCTION 1 P74 20DB POWER MIRROR LEFT CONTROL 2 P72 20YL BK POWER MIRROR UP CONTROL 3 P70 20WT POWER MIRROR RIGHT DOWN C...

Page 927: ... r B L A L i 1 flWlP 4 CAV CIRCUIT FUNCTION 1 Z2 18BK LG GROUND 2 X55 18BR RD LEFT DOOR SPEAKER 3 X53 18DG LEFT DOOR SPEAKER 4 X13 18BK RD PREMIUM SPEAKER AMPLIFIER PREMIUM SPEAKER BLACK LEFT DOOR TWEETER C 3 1 4 PREMIUM CAV CIRCUIT FUNCTION 1 X55 18BR RD LEFT DOOR SPEAKER 2 X53 18DG LEFT DOOR SPEAKER BLACK 4 C 3 1 5 3 5 LEFT POWER DOOR LOCK SWITCH CAV CIRCUIT FUNCTION 1 P35 160R VT DOOR LOCK SWIT...

Page 928: ...R WINDOW SWITCH OUTPUT DOWN BLACK LEFT POWER DOOR LOCK MOTOR C 3 1 7 CAV CIRCUIT FUNCTION 1 P34 16PK BK DOOR UNLOCK DRIVER 2 P33 160R BK DOOR LOCK DRIVER BLACK LEFT POWER WINDOW MOTOR C 3 1 8 CAV CIRCUIT FUNCTION 1 Q l l 14LB POWER WINDOW UP CONTROL 2 Q21 14WT POWER WINDOW DOWN CONTROL BLACK RIGHT DOOR JAMB SWITCH C 3 1 9 CAV CIRCUIT FUNCTION 1 Z3 18BK 0R GROUND 2 M2 18YL COURTESY LAMPS DRIVER BLA...

Page 929: ...ACK RIGHT DOOR PREMIUM SPEAKER C 3 2 3 CAV CIRCUIT FUNCTION 1 Z2 18BK LG GROUND 2 X56 18DB RD RIGHT DOOR SPEAKER 3 X54 18VT RIGHT DOOR SPEAKER 4 X13 18BK RD PREMIUM SPEAKER AMPLIFIER BLACK RIGHT DOOR TWEETER C 3 2 4 PREMIUM CAV CIRCUIT FUNCTION 1 X56 18DB RD RIGHT DOOR SPEAKER 2 X54 18VT RIGHT DOOR SPEAKER C 3 2 5 3 5 RIGHT POWER DOOR LOCK SWITCH CAV CIRCUIT FUNCTION 1 P33 160R BK DOOR LOCK DRIVER...

Page 930: ... DOOR UNLOCK DRIVER 2 P33 160R BK DOOR LOCK DRIVER C328 cm czi CZJ cm cz3 BLACK 1 4 FUEL PUMP MODULE CAV CIRCUIT FUNCTION 1 A61 16DG BK AUTO SHUT DOWN RELAY OUTPUT 2 K104 20DB WT FUSED B 3 G4 20DB 0R FUEL LEVEL SENSOR SIGNAL 4 Z l l 20BK WT GROUND 5 K4 20BK LB SENSOR GROUND 6 Z13 16BK GROUND BLACK C329 CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK 3 L62 18DG BR 4 L l 18VT BK BLACK CAV CIRCUIT 1 L7 18BK YL 2...

Page 931: ...4RD TN 2 B40 14LB 3 Z13 12BK 4 L76 12BK 0R 333 CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK 3 L63 18DG BR 4 L l 18VT BK CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK 3 L63 18DG RD 4 L l 18VT BK BLACK DAY NIGHT MIRROR 334 CAV CIRCUIT FUNCTION 1 LIO 22BR LG FUSED IGNITION SWITCH OUTPUT RUN 2 Z4 22BK GROUND 3 L l 22VT BK BACK UP LAMP SWITCH OUTPUT BLACK L LL_iV 2 1 LEFT OUTBOARD CLEARANCE LAMP 335 rCAV CIRCUIT FUNCTION...

Page 932: ...V CIRCUIT FUNCTION 1 E2 220R FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 2 L7 20BK YL PARK LAMP SWITCH OUTPUT 2 L7 18BK YL PARK LAMP SWITCH OUTPUT 3 4 G32 22BK LB SENSOR GROUND 5 G31 22VT LG AMBIENT TEMPERATURE SENSOR SIGNAL 6 M2 22YL COURTESY LAMPS DRIVER 7 F12 22DB WT FUSED IGNITION SWITCH OUTPUT START RUN 8 9 Z l l 20BK WT GROUND 10 11 Z4 18BK GROUND 12 Ml 18PK FUSED B 13 Ml 18PK FUSED B BLACK j 2 1...

Page 933: ...FUNCTION 1 17 18BK YL PARK LAMP SWITCH OUTPUT 2 Z4 18BK GROUND C 3 4 1 CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP SWITCH OUTPUT 2 Z4 18BK GROUND BLACK 342 CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL BLACK CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL BLACK C 3 4 3 CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL BLACK CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL J968W 9 ...

Page 934: ...16PK BK 6 P35 160R VT 7 P36 16PK VT BLACK 4 10 CAV CIRCUIT 1 F35 16RD 2 Q16 14BR WT 3 Q26 14VT WT 4 P33 160R BK 5 P34 16PK BK 6 P35 160R VT 7 P36 16PK VT C34 BLACK CAV CIRCUIT 1 Ml 20PK 2 X53 18DG 3 P70 20WT 4 P72 20YL BK 5 X55 18BR RD 6 X13 18BK RD 7 P74 20DB 9 F21 14TN 10 Z3 14BK 0R 10 Z3 18BK 0R 11 Z2 18BK LG BLACK CAV CIRCUIT 1 Ml 20PK 2 X53 18DG 2 X53 20DG 3 P70 20WT 4 P72 20YL BK 5 X55 18BR ...

Page 935: ...R BK 5 P34 16PK BK 6 P35 160R VT 7 P36 16PK VT BLACK 1 2 C352 CAV CIRCUIT 1 Ml 20PK 2 Z4 20BK BLACK n C r D 2 1 CAV CIRCUIT 1 Ml 20PK 2 Z4 20BK BLACK 1 2 C353 CAV CIRCUIT 1 Ml 20PK 2 Z4 20BK BLACK X L 2 1 CAV CIRCUIT 1 Ml 20PK 2 Z4 20BK BLACK 2 3 C401 BLOWER MOTOR RESISTOR BLOCK CAV CIRCUIT FUNCTION 1 C7 12BK TN HI BLOWER MOTOR DRIVER 2 C6 14LB M2 BLOWER MOTOR DRIVER 3 C5 16LG MI BLOWER MOTOR DRIV...

Page 936: ... 18BK YL 2 Z13 18BK BLACK CAV CIRCUIT 1 L7 18BK YL 2 ZI3 18BK BLACK Z H D 2 C404 CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK BLACK CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK BLACK ZHD 2 C405 CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK BLACK nnz CAV CIRCUIT 1 L7 18BK YL 2 Z13 18BK BLACK C406 CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL BLACK CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL 8050cdc7 J968W 9 ...

Page 937: ... SENSOR C409 CAV CIRCUIT FUNCTION 1 B114 20WT VT RIGHT REAR WHEEL SPEED SENSOR 2 B113 20RD VT RIGHT REAR WHEEL SPEED SENSOR BLACK i l CARGO LAMP NO 1 C410 CAV CIRCUIT FUNCTION 1 Ml 18PK FUSED B 2 M3 18PK DB CARGO LAMP SWITCH GROUND 11 CARGO LAMP NO 2 BLACK C411 CAV CIRCUIT FUNCTION 1 Ml 18PK FUSED B 2 M3 18PK DB CARGO LAMP SWITCH GROUND 8050cdc8 J968W 9 ...

Page 938: ...AMP SWITCH OUTPUT 2 13 18BK 0R GROUND RIGHT LICENSE LAMP BLACK C414 CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP SWITCH OUTPUT 2 Z13 18BK GROUND 1 2 3 O 1 C 4 1 5 BLACK RIGHT T A I L STOP AND TURN SIGNAL LAMP CAV CIRCUIT FUNCTION i Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT 3 L62 18DG BR RIGHT REAR TURN SIGNAL C41S o o GRAY p i a RIGHT BACK UP LAMP CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2...

Page 939: ...YL PARK LAMP SWITCH OUTPUT 3 L63 18DG BR LEFT REAR TURN SIGNAL a g LEFT BACK UP LAMP C419 GRAY CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L l 18VT BK BACK UP LAMP SWITCH OUTPUT BLACK C420 DUAL REAR WHEELS 1 2 LEFT FORWARD FENDER LAMP CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT BLACK C421 DUAL REAR WHEELS CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SW...

Page 940: ...ITCH OUTPUT C423 DUAL REAR WHEELS CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT C424 DUAL REAR WHEELS CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT C425 DUAL REAR WHEELS CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT 2 1 LEFT LICENSE LAMP C426 DUAL REAR WHEELS BLACK CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP ...

Page 941: ...TURN SIGNAL 7 L l 16VT BK BACK UP LAMP SWITCH OUTPUT r BLACK FORWARD BACKWARD SEAT MOTOR C 4 2 8 CAV CIRCUIT FUNCTION 1 P15 14YL LB POWER SEAT HORIZONTAL FORWARD 2 P17 14DB RD POWER SEAT HORIZONTAL BACKWARD RED REAR VERTICAL SEAT MOTOR C 4 2 9 CAV CIRCUIT FUNCTION 1 P13 14RD WT POWER SEAT REAR DOWN 2 P l l 14YL WT POWER SEAT REAR UP RED FRONT UP DOWN SEAT MOTOR C430 CAV CIRCUIT FUNCTION 1 P21 14RD...

Page 942: ...AR DOWN 11 P15 14YL LB POWER SEAT HORIZONTAL FORWARD 12 P21 14RD LG POWER SEAT FRONT DOWN BLACK 432 2 O RIGHT FOG LAMP CAV CIRCUIT FUNCTION 1 Z l 20BK GROUND 2 L39 20LB FRONT FOG LAMP SWITCH OUTPUT BLACK 2 t C433 CAV CIRCUIT FUNCTION 1 Z l 20BK GROUND 2 L39 20LB FRONT FOG LAMP SWITCH OUTPUT LEFT FOG LAMP BLACK EGR ENGINE COOLANT TEMPERATURE SENSOR C434 CAV CIRCUIT FUNCTION 1 K304 20BK LG EGR COOLA...

Page 943: ...UTS 8 W 80 71 BLACK O L Z Z B LEFT VISOR VANITY LAMP C435 CAV CIRCUIT FUNCTION A Ml 2QPK FUSED B B Z4 20BK GROUND BLACK r f C436 CAV CIRCUIT FUNCTION A Ml 20PK FUSED B B Z4 20BK GROUND RIGHT VISOR VANITY LAMP 8050cdce J968W 9 ...

Page 944: ......

Page 945: ...r Cylinder 3 C118 BK Left Fender Side Shield 3 C119 BK Below PDC 3 C120 BK At Controller Antilock Brakes 3 C121 BK At Controller Antilock Brakes 3 C122 BK Rear of ABS Pump 3 C123 BK Near PDC N S C124 BK At Wiper Motor N S C125 BK Left Side of Dash Panel 3 4 C126 GY Left Side of Dash Panel 3 4 C127 GY Left Side of Dash Panel 3 4 C128 BK Above Left Front Body cushion 2 20 Conn Color Location Fig C12...

Page 946: ...nsmission 2WD Rear of Transfer Case 4WD 10 11 C203 BK Behind Switch 15 C163 BK Rear of Transmission 2WD Rear of Transfer Case 4WD C204 BK Near Headlamp Switch 14 C163 BK Rear of Transmission 2WD Rear of Transfer Case 4WD C205 BK Rear of Airbag 14 15 C164 BK Rear of A C Compressor V 6 V 8 Diesel N S C206 BK Rear of Headlamp Switch 14 C164 BK Rear of A C Compressor V 6 V 8 Diesel BK Left Kick Panel ...

Page 947: ... 17 18 BK Behind Front of Headliner 16 C303 BK Below Driver s Seat 17 18 C 3 4 2 BK Right Rear of Frame 20 22 C304 BK Behind Dome Lamp 17 18 0 3 4 3 BK Right Rear of Frame 20 22 C305 BK At Left Rear Speaker 17 18 0 3 4 5 BK Right Door N S C306 BK At Left Rear Speaker 17 18 0 3 4 6 BK Right Door N S C307 BK In Body Behind Left Door Opening 17 18 0 3 4 7 BK Left Door N S C307 BK In Body Behind Left ...

Page 948: ... N S G114 Left Side of Engine Block Diesel N S C427 BK On Trailer Hitch N S Left Side of Engine Block Diesel N S C428 BK Below Driver s Seat N S Q115 Near Left Battery Diesel 25 C429 RD Below Driver s Seat N S G116 From Left Battery Diesel N S C430 RD Below Driver s Seat N S G117 Near Right Battery Diesel 25 C431 BK Left Side of Driver s Seat N S G118 Right Side of Engine Block Diesel N S C432 BK ...

Page 949: ...Fig 1 Engine Compartment Connectors ...

Page 950: ...RROW Z C107 BLACK VIEW IN DIRECTION OF ARROW Y GROUND LOW WASHER FLUID SWITCH C108 BLACK G101 G102 LEFT FENDER SIDE SHIELD FRONT BUMPER ASSEMBLY TO ENGINE HORNS COMPARTMENT WIRING C112 BLACK PARK AND TURN SIGNAL LAMP G106 C113 BLUE HEADLAMP VIEW IN DIRECTION OF ARROW Y C116 BLACK C115 BLACK C128 BLACK C129 BLACK LEFT FRONT BODY CUSHION 804facfb Fig 2 Engine Compartment Connectors Front ...

Page 951: ...OCK BRAKES VIEW IN DIRECTION OF ARROW Y G104 POWER DISTRIBUTION CENTER C121 BLACK CONTROLLER ANTI LOCK BRAKES VIEW IN DIRECTION OF ARROW Z C118 BLACK ABS FRONT WHEEL SENSOR CONNECTOR BRAKE WARNING LAMP SWITCH CONNECTOR VIEW IN DIRECTION OF ARROW V HEADLAMP AND DASH WIRING HARNESS C117 BLACK VIEW IN DIRECTION OF ARROW X POWERTRAIN CONTROL MODULE 0135 C136 C137 Fig 3 Engine Compartment Connectors Le...

Page 952: ...CK AMBIENT AIR TEMPERATURE SENSOR C125 BLACK 0126 GRAY 0127 GRAY 0134 BLACK VACUUM SENSOR DIESEL ONLY 0109 BLACK SPEED CONTROL SERVO LEFT FENDER VIEW IN DIRECTION OFARROW X VIEW B N DIRECTION OF ARROW Y POWER DISTRIBUTION CENTER VIEW IN DIRECTION OF ARROW T Fig 4 Engine Compartment Connectors Left Side ...

Page 953: ......

Page 954: ...CH 0146 BLACK MiGR SOLENOID TRANSDUCER 0145 BLACK FUEL INJECTOR 4 0157 GRAY INTAKE AIR TEMPERATURE SENSOR EVAP PURGE SOLENOID 0153 BLACK C171 BLACK CAMSHAFT POSITION SENSOR 0152 BLACK ENGINE COOLANT TEMPERATURE SENSOR A C COMPRESSOR G119 G113 CRANKSHAFT POSITION SENSOR G111 0170 BLACK DISTRIBUTOR IGNITION COIL VIEW IN DIRECTION OF ARROW Y 0151 BLACK GENERATOR ENGINE COOLANT TEMPERATURE SENDING UNI...

Page 955: ...ING UNIT SWITCH C143 BLACK FUEL INJECTOR 6 0156 BLACK FUEL INJECTOR 5 TO GENERATOR DISCONNECT A 0 COMPRESSOR C145 BLACK FUEL INJECTOR 4 0147 BLACK FUEL INJECTOR 2 0155 BLACK FUEL INJECTOR 7 CRANKSHAFT POSITION SENSOR 0171 BLACK CAMSHAFT POSITION SENSOR 0152 BLACK ENGINE COOLANT TEMPERATURE SENSOR G119 G113 0170 BLACK DISTRIBUTOR IGNITION COIL VIEW IN DIRECTION OF ARROW Z ENGINE COOLANT TEMPERATURE...

Page 956: ...RE SENSOR COOLANT G113 TEMPERATURE SENDING UNIT 0152 BLACK ENGINE COOLANT TEMPERATURE SENSOR 0164 BLACK A C COMPRESSOR CLUTCH 0166 BLACK CAMSHAFT POSITION SENSOR 0155 BLACK INJECTOR 7 0154 BLACK INJECTOR 9 0158 BLACK INJECTOR 3 G110 5 BLACK A C HIGH PRESSURE SWITCH 0159 BLACK INJECTOR 1 G109 0141 BLACK IGNITION COIL PACK 4 0148 BLACK MAP SENSOR 0 1 5 0 BLACK IDLE AIR CONTROL MOTOR 0144 BLACK IGNIT...

Page 957: ...13 V EWIM_mRECTJOM OF ARROW Z G119 G112 VIEW IN DIRECTION OF ARROW T AIR HEATER ASSEMBLY 0174 BLACK WATER IN FUEL SENSOR 0157 BLACK INTAKE AIR TEMPERATURE SENSOR 0138 BLACK ENGINE SPEED SENSOR CONNECTOR VIEW IN DIRECTION OFARROW T 0175 BLACK FUEL SHUT OFF SOLENOID VIEW IN DIRECTION OF ARROW X 0152 BLACK ENGINE COOLANT TEMPERATURE SENSOR VIEW IN DIRECTION OF ARROWY Fig 9 Engine Connectors Diesel ...

Page 958: ...LE SPEED SENSOR TO ENGINE WIRING 0160 BLACK O o 3 5 c a 0161 BLACK BACK UP LAMP SWITCH C163 BLACK VEHICLE SPEED SENSOR 0161 BLACK BACK UP LAMP SWITCH TO ENGINE WIRING 0162 BLACK HEATED OXYGEN HEATED 0163 BLACK VEHICLE SPEED SENSOR 5 9L HD DIESEL ENGINE o f t O X m a 5 m z W eo c o o O O 3 0 O a i o o o m 80500504 Fig 10 Manual Transmission Connectors ...

Page 959: ...ENSOR 0160 BLACK 0169 BLACK PARK NEUTRAL POSITION SWITCH HEATED OXYGEN SENSOR 0163 BLACK VEHICLE SPEED SENSOR 3 9L 5 2L AND 5 9L 0169 BLACK PARK NEUTRAL POSITION SWITCH HEATED OXYGEN SENSOR 0167 BLACK HEATED OXYGEN SENSOR C195 BLACK 5 2L AND 5 9L HEAVY DUTY 0163 BLACK VEHICLE SPEED SENSOR TRANSFER CASE 0163 BLACK VEHICLE SPEED SENSOR Fig 11 Automatic Transmission Connectors ...

Page 960: ... AND DASH WIRING SEE VIEW X 0219 BLACK INTERMITTENT WIPER MODULE 0236 BLACK CIGAR LIGHTER CONTROLLER ANTILOCK BRAKES RWAL SEE VIEWY VIEW IN DIRECTION OF ARROW Y VIEW IN DIRECTION OF ARROW X INSTRUMENT PANEL SUPPORT INSTRUMENT PANEL ASSEMBLY 0133 BLACK INSTRUMENT PANEL TO HEADLAMP AND DASH WIRING CONNECTOR RADIO CHOKE AND RELAY ASSEMBLY 0232 BLACK AIRBAG CONTROL MODULE C234 BLACK INSTRUMENT PANEL W...

Page 961: ...CH C208 BLACK ROOF WIRING CONNECTOR C238 BLACK BLOWER MOTOR TO PARK BRAKE SWITCH C214 BLACK STOP LAMP SWITCH C210 BLACK MULTI FUNCTION SWITCH INSTRUMENT PANEL HARNESS C212 BLACK IGNITION SWITCH TO CLOCKSPRING C237 BLACK RESISTOR BLOCK C213 BLACK IGNITION SWITCH C223 BLACK DATA LINK CONNECTOR TO FUSE BLOCK VIEW IN DIRECTION OF ARROW Z 80500507 Fig 13 Instrument Panel Connectors ...

Page 962: ...C229 GRAY 80500508 Fig 14 Instrument Panel Ground Connections m so ...

Page 963: ...80500509 CO Fig 15 Steering Column Connectors ...

Page 964: ...53 BLACK RIGHT C338 BLACK OVERHEAD CONSOLE C334 BLACK AUTOMATIC DAY NIGHT MIRROR C435 BLACK LEFT C436 BLACK RIGHT VISOR VANITY MIRROR LAMP C241 FUSE TO FUSE v BLOCK VIEW IN DIRECTION OF ARROW Y VIEW IN DIRECTION OF ARROW Z Fig 16 Overhead Console Connectors ...

Page 965: ...m m Fig 17 Cab Connectors ...

Page 966: ...8 1 Fig 18 Extended Cab Connectors m 30 ...

Page 967: ...NGE DOOR SPEAKER LEFT DOOR C314 BLACK RIGHT DOOR C324 BLACK DOOR SPEAKER LEFT DOOR C312 BLACK OR C313 BLACK RIGHT DOOR C320 BLACK OR C323 BLACK TO INSTRUMENT PANEL WIRING POWER WINDOW 10TOR 0318 BLACK LEFT DOOR C321 BLACK RIGHT DOOR DOOR AJAR SWITCH C201 BLACK POWER DOOR LOCK MOTOR C317 BLACK LEFT DOOR C327 BLACK RIGHT DOOR C207 BLACK G302 LEFT G303 RIGHT VIEW IN DIRECTION OFARROW X 8050050d Fig 1...

Page 968: ...REAR WHEEL SPEED SENSOR TO C409 BLACK FRAME ASSEMBLY FUEL TANK X MEMBER C333 BLACK LEFT TAIL LAMP CHASSIS WIRING HARNESS m o X 2 H ro o z a a 0 30 f 00 O 0 3 C O o o 3 C a z o o c a r o o o C129 BLACK C328 BLACK FUEL TANK MODULE J958W 17 Fig 20 Frame Connectors ...

Page 969: ...B R 8W 90 CONNECTOR GROUND LOCATIONS SCHEMATICS AND DIAGRAMS Continued 8W 90 25 J958W 236 Fig 21 Center High Mounted Stop Lamps CHMSL and Cargo Lamps ...

Page 970: ...C406 BLACK READ IDENTIFICATION LAMPS W DUAL REAR WHEELS ONLY C351 BLACK RIGHT CAB AND CHASSIS C414 BLACK RIGHT C417 BLACK LEFT C416 BLACK RIGHT C419 BLACK LEFT Fig 22 Rear Lamps ...

Page 971: ...B R 8W 90 CONNECTOR GROUND LOCATIONS SCHEMATICS AND DIAGRAMS Continued Fig 23 Four Wheel Drive Switch ...

Page 972: ...Fig 24 Battery Connections 09 33 ...

Page 973: ...8 0 5 0 0 5 1 2 C O Fig 25 Diesei Battery Connections ...

Page 974: ...C194 BLACK POST CATALYST HEATED RIGHT SIDE OXYGEN SENSOR Fig 26 Heated Oxygen Sensor Connectors V 10 Engine 03 30 ...

Page 975: ...4 6 8 V 6 V 8 2 S109 Before Branch for Controller Antilock Brakes CAB 2 S130 Near Branch to Injectors 2 4 6 8 10 V 10 2 S110 In Branch to Controller Antilock Brakes 2 S130 After T O to Engine Coolant Temperature Sending Unit Diesel 5 S111 In Branch to Controller Antilock Brakes 2 S131 After Branch to Injectors 2 4 6 8 V 6 V 8 2 S112 In T O to Hydraulic Control Unit 2 S131 After Branch to Injectors...

Page 976: ...ess Connectors V 6 V 8 S201 In Fuse Block N S S140 After Branch to Injectors 1 3 5 7 9 V 10 S202 In Fuse Block N S S140 After Branch to Injectors 1 3 5 7 9 V 10 S203 In Headlamp Switch T O 7 S140 Between T Os for Intake Air Heaters and Fuel Heater Diesei 5 S204 In Headlamp Switch T O 7 S140 Between T Os for Intake Air Heaters and Fuel Heater Diesei S205 Near Headlamp Switch T O 7 S141 In Branch to...

Page 977: ...ht Rear Lamps 11 S314 After Branch to Right Rear Lamps 11 S315 In T O to Trailer Tow Harness Connectors 11 S316 In T O to Trailer Tow Harness Connectors 11 Splice Number Location Fig S317 After T O for Left Outboard Clearance Lamp 8 S318 After T O for Left Outboard Clearance Lamp 8 S319 Before T O to Center Identification Lamp 8 S320 Before T O to Center Identification Lamp 8 S401 In Tail Lamp Jum...

Page 978: ...8 0 5 0 0 5 1 3 Fig 1 Engine Compartment Wiring Splices Front ...

Page 979: ...ION OF ARROW W VIEW IN DIRECTION OFARROW Z S121 S156 S159 DIES S129 S154 V 6 V 8 S152 DIESEL S114 S160 V 6 V 8 V 10 S140 S131 DIESEL DIESEL S131 V 6 V 8 V 10 0 X m m 1 W a m m m CO C O CJ1 o o 3 co 3 O c E e n O ft 1 O o o CO oo Fig 2 Engine Compartment Wiring Splices Rear co C J l ...

Page 980: ...8W 95 6 8W 95 SPLICE LOCATIONS SCHEMATICS AND DIAGRAMS Continued ...

Page 981: ......

Page 982: ......

Page 983: ...B R 8W 95 SPLICE LOCATIONS SCHEMATICS AND DIAGRAMS Continued 8W 95 9 Fig 6 Transmission Wiring Splices 80500540 ...

Page 984: ...8W 95 10 _ _ _ _ _ 8W 95 SPLICE LOCATIONS S C H E M A T I C S AND D I A G R A M S Continued ...

Page 985: ......

Page 986: ......

Page 987: ......

Page 988: ...8W 95 1 4 _ _ _ _ _ _ _ 8W 95 SPLICE LOCATIONS S C H E M A T I C S AND D I A G R A M S C o n t i n u e d B R ...

Page 989: ......

Page 990: ......

Page 991: ...bes Mois ture in the air causes the sealant material to cure This material is normally used on flexible metal flanges The tubes have a shelf life of one year and the power tubes two years shelf life and will not page MEASURING WITH PLASTIGAGE 2 SERVICE PROCEDURES HONING CYLINDER BORES 6 HYDROSTATIC LOCK 6 REPAIR DAMAGED OR WORN THREADS 5 properly cure if over aged Always inspect the pack age for t...

Page 992: ...ed hot oily etc Record cylinder number of each spark plug for future reference e Disconnect coil wire from distributor or from both coil packs V 10 and secure to good ground to prevent a spark from starting a fire f Be sure throttle blades are fully open during the compression check g Insert compression gauge adaptor into the No l spark plug hole Crank engine until maxi mum pressure is reached on ...

Page 993: ...p bolts of the bear ing being checked to 115 N m 85 ft lbs torque DO NOT rotate the crankshaft or the Plastigage may be smeared giving inaccurate results 2 Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package Fig 2 Plastigage generally comes in two scales one scale is in inches and the other is a metric scale Locate the band closest to the...

Page 994: ...rade which indicates the cold to hot tempera ture viscosity range Select an engine oil that is best suited to your area s particular temperature range and variation Fig 3 ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines They are designated as either ENERGY CONSERVING or ENERGY CONSERV ING II iTT mmmm 0W 30 5W 30 i l i F 20 0 10 20 32 60 80 100 C 2 9 1 8 1 2 7...

Page 995: ...IFICATION All Dodge Ram engines are equipped with a high quality full flow disposable type oil filter Chrysler Corporation recommends a Mopar or equivalent oil filter be used OIL FILTER RE10WAL 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 6 Fig 6 Oil F...

Page 996: ...es increase the Crosshatch angle 5 After honing it is necessary that the block be cleaned to remove all traces of abrasive Use a brush to wash parts with a solution of hot water and deter gent Dry parts thoroughly Use a clean white lint free cloth to check that the bore is clean Oil the bores after cleaning to prevent rusting HYDROSTATIC LOCK When an engine is suspected of hydrostatic lock regardl...

Page 997: ...E IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine page HYDRAULIC TAPPETS 9 INSPECTION ENGINE OIL LEAKS IN GENERAL 8 INSPECTION FOR REAR SEAL AREA LEAKS 9 INTAKE MANIFOLD LEAKAGE DIAGNOSIS 7 SERVICE DIAGNOSIS DIESEL MECHANICAL 21 SERVICE DIAGNOSIS DIESEL PERFORMANCE 14 SERVICE DIAGNOSIS GAS...

Page 998: ...cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 psi recom mended Perform the test procedure on each cylinder accord ing to the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe or oil filler ...

Page 999: ...ecessary to remove minor nicks or scratches The crankshaft seal flange Is specially machined to complement the function of the rear oil seal 6 For bubbles that remain steady with shaft rotation no further Inspection can be done until dis assembled Refer to the service Diagnosis Mechani cal under the Oil Leak row for components Inspections on possible causes and corrections 7 After the oil leak roo...

Page 1000: ...ick is caused by a tappet check valve not seating or by for eign particles wedged between the plunger and the tappet body This will cause the plunger to stick in the down position This heavy click will be accompa nied by excessive clearance between the valve stem and rocker arm as valve closes In either case tappet assembly should be removed for inspection and clean ing 4 The valve train generates...

Page 1001: ...or shaft 4 Dirty or incorrectly gapped spark plugs 5 Dirt or water in fuel system 6 Faulty fuel pump 7 Incorrect valve timing 8 Blown cylinder head gasket 9 Low compression 10 Burned warped or pitted valves 1 1 Plugged or restricted exhaust system 12 Faulty ignition cables 13 Faulty coil 14 Incorrect cam timing 1 Refer to Group 8D Ignition System 2 Install new distributor rotor 3 Remove and repair...

Page 1002: ...OD NOISE 1 Insufficient oil supply 2 Low oil pressure 3 Thin or diluted oil 4 Excessive bearing clearance 5 Connecting rod journal out of round 6 Misaligned connecting rods 1 Check engine oil level refer to Group 0 Lubrication and Maintenance 2 Check engine oil level Inspect oil pump relief valve and spring 3 Change oil to correct viscosity 4 Measure bearings for correct clearance Repair as necess...

Page 1003: ...seal c Replace the seal d Minor damage can be polished out otherwise replace the part OIL PRESSURE DROP 1 Low oil level 2 Faulty oil pressure sending unit 3 Low oil pressure 4 Clogged oil filter 5 Worn parts in oil pump 6 Thin or diluted oil 7 Excessive bearing clearance 8 Oil pump relief valve stuck 9 Oil pump suction tube loose bent or cracked 10 Oil pump cover warped or cracked 1 Check engine o...

Page 1004: ...INE CRANKS BUT WILL NOT S T A R T NO SMOKE FROM EXHAUST 1 No fuel in supply tank 2 Electrical fuel shutdown solenoid not operating 3 Air intake or exhaust plugged 4 Fuel filter plugged 5 Excessive fuel inlet restriction 6 Injection pump not getting fuel or fuel is aerated 7 Inoperative fuel transfer Lift pump 8 One or more injectors worn or not operating properly 9 Worn or inoperative injection pu...

Page 1005: ...ply is inadequate 5 Check the flow through the filter and bleed the system Locate and eliminate the air source 6 Fuel transfer lift pump 6 Measure transfer pump outlet pressure If needed repair or replace pump 7 Injection pump throttle linkage loose or damaged 7 Visually check the linkage Adjust replace linkage 8 Contaminated fuel 8 Verify by operating the engine with clean fuel from a temporary t...

Page 1006: ...peed is set too low for the accessories 2 Improperly operating injection pump 1 Adjust the idle speed 2 Replace the injector pump ROUGH IDLE IRREGULARLY FIRING OR ENGINE SHAKING 1 If engine is cold intake heater system defective 2 Idle speed too low for the accessories 3 Engine mounts damaged or lose 4 High pressure fuel leaks 5 Air in the fuel system 6 Sticking needle valve in an injector 1 Refer...

Page 1007: ...tachometer correct as required 3 Adjust linkage for stop to stop fuel control lever travel Replace linkage if necessary 4 Check the fuel flow through the system to locate the reason for inadequate fuel supply correct as required 5 Check and repair leak Check AFC tubing for obstruction 6 Repair or replace injection pump LOW POWER 1 Fuel control lever not moving to full throttle 2 High oil level 3 E...

Page 1008: ...ng injectors 15 Check replace injectors 16 Incorrect injection pump timing 16 Verify injection pump timing see Group 14 Fuel System 17 Improperly operating injection pump 17 Repair or replace injection pump EXCESSIVE EXHAUST 1 Engine running too cold white 1 Refer to troubleshooting for coolant SMOKE smoke temperature below normal refer to Group 7 Cooling System Inspect intake manifold heater syst...

Page 1009: ...t this location for emergency shutdown conditions 3 Repair or replace fuel injection pump COOLANT TEMPERATURE ABOVE NORMAL 1 Low coolant level 2 Incorrect improperly operating pressure cap 3 Loose drive belt on water pump fan 4 Inadequate air flow to the radiator 5 Radiator fins plugged 6 Collapsed radiator hose 7 Improperly operating temperature sensor gauge 8 Improperly operating incorrect or no...

Page 1010: ... injector pump refer to Group 14 Fuel System 12 Repair or replace the injection pump 13 Flush the system and fill with clean coolant 14 Verify that the engine load rating is nci being exceeded COOLANT TEMPERATURE BELOW NORMAL 1 Too much air flow across the radiator 2 Incorrect thermostat or contamination in thermostat 3 Temperature sensor or gauge inoperative 4 Coolant not flowing by temperature s...

Page 1011: ... connecting rod or main bearings Check and replace piston cooling nozzles 11 Check oil jet position j LUBRICATING OIL PRESSURE TOO HIGH 1 Pressure switch gauge not operating properly 2 Engine running to cold 3 Oil viscosity too thick 4 Oil pressure relief valve stuck closed or binding 1 Verify the pressure switch is functioning correctly If not replace switch gauge 2 Refer to Coolant Temperature B...

Page 1012: ...tion damper 4 Inspect replace the fan drive 5 Check replace the generator 6 Check correct flywheel alignment 7 Inspect the crankshaft and rods for damage that causes an unbalance repair replace as required 8 Check repair driveline components EXCESSIVE ENGINE NOISES 1 Drive belt squeal insufficient tension or abnormally high loading 2 Intake air or exhaust leaks 3 Excessive valve lash 4 Turbocharge...

Page 1013: ...EAD COVER 48 CYLINDER HEAD 48 OIL PAN 51 OIL PUMP 49 PISTON AND CONNECTING ROD INSPECTION 49 SPECIFICATIONS ENGINE SPECIFICATIONS 52 SPECIAL TOOLS 3 9L ENGINE 56 GENERAL INFORMATION VALVES AND VALVE SPRINGS The valves are arranged in line and are inclined 18 The rocker pivot support and the valve guides are cast integral with the heads OIL PUMP PRESSURE The MINIMUM oil pump pressure is 41 4 kPa 6 ...

Page 1014: ... oil pan The oil is driven between the drive and idler gears and pump body then forced through the outlet to the block An oil gallery in the block channels the oil to the inlet side of the full flow oil filter After passing through the filter element the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery which extends the entire leng...

Page 1015: ...RED THROUGH HYDRAULIC TAPPET OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT DRIP OILING FOR VALVE TIP CYLINDER HEAD BOSS RIGHT OIL GALLERY PASSAGE TO CAMSHAFT REAR BEARING PLUG OIL FROM FILTER TO SYSTEM OIL TO FILTER FROM OIL PUMP HOLLOW PUSH ROD TAPPET TO CONNECTING ROD BEARINGS O m W 0 30 1 O m 30 3 o o 3 5 c a OIL INTAKE OIL FILTER CRANKSHAFT Fig 4 Oil Lubrication System ...

Page 1016: ...ring halves of No l and 3 are interchangeable Upper and lower No 2 bearing halves are flanged to carry the crankshaft thrust loads They are NOT interchangeable with any other bearing halves in the engine Bearing shells are available in standard and the following undersizes 0 25 mm 0 001 in 0 051 mm 0 002 in 0 076 mm 0 003 in 0 254 mm 0 010 in and 0 305 mm 0 012 in Never install an undersize bearin...

Page 1017: ...ton and cylinder wall must be clean and dry Specified clearance between the piston and the cylin der wall is 0 013 0 038 mm 0 0005 0 0015 in at 21 C 70 F Piston diameter should be measured at the top of skirt 90 to piston pin axis Cylinder bores should be measured halfway down the cylinder bore and trans verse to the engine crankshaft center line Pistons and cylinder bores should be measured at no...

Page 1018: ...ent the rings a Arrange top compression ring 90 counter clockwise from the oil ring rail gap Fig 11 CHAMFER TO COMPRESSION RING HAMFER PISTON SECOND COMPRESSION RING J 9 4 0 9 3 7 Fig 10 Compression Ring Chamfer Location Typical b Arrange second compression ring 90 clock wise from the oil ring rail gap Fig 11 OIL RING SPACER GAP TOP COMPRESSION RING GAP SECOND COMPRESSION RING GAP OIL RING RAIL GA...

Page 1019: ... indicates that the No 4 main journal is 0 025 mm 0 001 in undersize R 3 M2 indicates that the No 3 rod journal and the No 2 main journal are 0 025 mm 0 001 in undersize When a crankshaft is replaced all main and con necting rod bearings should be replaced with new bearings Therefore selective fitting of the bearings is not required when a crankshaft and bearings are replaced I f c c l e r s i z e...

Page 1020: ...tall the support cushion bolts and tighten to 41 N m 30 ft lbs torque 5 Remove the transmission jack 6 Lower the vehicle ENGINE ASSEMBLY REMOVAL 1 Remove the battery 2 Drain cooling system Refer to Group 7 Cooling System for the proper procedure 3 Remove the upper crossmember and top core support 4 Remove the transmission oil cooler 5 Discharge the air conditioning system if equipped Refer to Grou...

Page 1021: ... 3 Raise and support the vehicle on a hoist 4 Refer to Group 21 Transmissions for transmis sion installation 5 Install the prop shaft Refer to Group 16 Pro peller Shaft 6 Install the dust shield and transmission cover 7 Install the starter and connect the starter wires Refer to Group 8B Battery Starter Generator Service 8 Install exhaust pipe to manifold 9 Install the transmission cooler line brac...

Page 1022: ...L 1 Disconnect the negative cable from the battery 2 Disconnect closed ventilation system and evap oration control system from cylinder head cover 3 Remove cylinder head cover and gasket The gasket may be used again INSTALLATION 1 Install the cylinder head cover gasket onto the head rail 2 Position the cylinder head cover onto the gas ket Tighten the bolts to 11 N m 95 in lbs torque 3 Install clos...

Page 1023: ...re held in place by eight bolts The spark plugs are located at the peak of the wedge between the valves R E M O V A L 1 Disconnect the negative cable from the battery 2 Drain cooling system Refer to Group 7 Cooling System for the proper procedures 3 Remove the intake manifold to generator bracket support rod Remove the generator 4 Remove closed crankcase ventilation system 5 Disconnect the evapora...

Page 1024: ...ct the negative cable to the battery VALVES AND VALVE SPRINGS CYLINDER HEAD RE10VED REMOVAL 1 Compress valve springs using Valve Spring Compressor Tool MD 998772 A 2 Remove valve retaining locks valve spring retainers valve stem seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent damage to the valve guides Identify valves to ensure installation...

Page 1025: ...Drive bushing and tool into position using a hammer Fig 22 3 As the burnisher is pulled through the bushing the bushing is expanded tight in the block and bur nished to correct size Fig 23 DO NOT ream this bushing Fig 22 Distributor Driveshaft Bushing Installation CAUTION This procedure MUST be followed when installing a new bushing or seizure to shaft may occur Fig 23 Burnishing Distributor Drive...

Page 1026: ...35 ft lbs torque Fig 26 Installing Vibration Damper 4 Install the crankshaft pulley Tighten the pul ley bolts to 23 N m 200 in lbs torque 5 Install the serpentine belt Refer to Group 7 Cooling System 6 Install the cooling system fan Tighten the bolts to 23 N m 17 ft lbs torque 7 Position the fan shroud and install the bolts Tighten the retainer bolts to 11 N m 95 in lbs torque 8 Connect the negati...

Page 1027: ...event the cover from tipping during seal installation 6 Using the vibration damper bolt tighten the bolt to draw the seal into position on the crankshaft Fig 30 7 Loosen the four bolts tightened in Step 4 to allow realignment of front cover assembly 8 Tighten chain case cover bolts to 41 N m 30 ft lbs torque Tighten oil pan bolts to 24 N m 215 in lbs torque 9 Remove the vibration damper bolt and s...

Page 1028: ...limits install a new thrust plate CAMSHAFT This procedure requires that the engine is removed from the vehicle The camshaft has an integral oil pump and distrib utor drive gear Fig 32 REmOWAL 1 Remove Intake manifold 2 Remove cylinder head covers 3 Remove timing case cover and timing chain 4 Remove rocker arms 5 Remove push rods and tappets Identify each part so it can be installed in the original...

Page 1029: ...nstall the camshaft bolt cup washer Tighten bolt to 68 N m 50 ft lbs torque 11 Measure camshaft end play Refer to Specifica tions for proper clearance If not within limits install a new thrust plate 12 Each tappet reused must be installed in the same position at which it was removed When cam shaft is replaced all of the tappets must be replaced CAMSHAFT SEARINGS REMOVAL 1 With engine completely di...

Page 1030: ...Install the oil pan OIL PAN REMOVAL 1 Disconnect the negative cable from the battery 2 Remove engine oil dipstick 3 Raise vehicle 4 Drain engine oil 5 Remove exhaust pipe 6 Remove left engine to transmission strut 7 Loosen the right side engine support bracket cushion through bolt nut and raise the engine slightly Remove oil pan by sliding backward and out 8 Remove the one piece gasket INSTALLATIO...

Page 1031: ...ression ring gaps are stag gered so that neither is in line with oil ring rail gap 2 Before installing the ring compressor be sure the oil ring expander ends are butted and the rail gaps located properly Fig 40 OIL RING S P A C E R GAP TOP COMPRESSION RING GAP SECOND COMPRESSION RING GAP OIL RING RAIL GAP TOP OIL RING RAIL GAP BOTTOM J9309 80 Fig 40 Proper Ring installation 3 immerse the piston he...

Page 1032: ...l oil pump 10 Apply Mopar Silicone Rubber Adhesive Seal ant or equivalent at bearing cap to block joint to provide cap to block and oil pan sealing Fig 42 Apply enough sealant so that a small amount is squeezed out Withdraw nozzle and wipe excess seal ant off the oil pan seal groove 11 install new front crankshaft oil seal 12 Immediately install the oil pan MOPAR SILICONE RUBBER ADHESIVE SEALANT N...

Page 1033: ...ean the cylinder block rear cap mating sur face Be sure the seal groove is free of debris Check for burrs at the oil hole on the cylinder block mating surface to rear cap 2 Lightly oil the new upper seal lips with engine oil 3 Install the new upper rear bearing oil seal with the white paint facing toward the rear of the engine 4 Position the crankshaft into the cylinder block 5 Lightly oil the new...

Page 1034: ... of Loctite 518 or equivalent on each side of the rear main bearing cap Fig 46 DO NOT over apply sealant or allow the sealant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant appli cation Be sure the white paint faces toward the rear of the engine 6 To align the bearing cap use cap slot align ment dowel and cap bolts DO NOT remove excess material after as...

Page 1035: ...DO NOT drive cup plug Into the casting as restricted coolant flow can result and cause seri ous engine problems CYLINDER BLOCK Fig 49 Core Hole Plug Removal 2 Using proper plug drive drive cup plug into hole The sharp edge of the plug should be at least 0 50 mm 0 020 in inside the lead in chamfer 3 It is not necessary to wait for curing of the sealant The cooling system can be filled and the vehic...

Page 1036: ...y hand and clean guide thor oughly before installing new valve Ream the valve guides from standard to 0 381 mm 0 015 in Use a two step procedure so the valve guides are reamed true in relation to the valve seat B R Fig 52 Measuring Valve Guide Wear Reamer O S Valve Guide Size 0 076 mm 8 026 8 052 mm 0 003 in 0 316 0 317 in 0 381 mm 8 331 8 357 mm 0 015 in 0 328 0 329 in J9309 30 Fig 53 Reamer Size...

Page 1037: ...he exhaust seats should be 1 524 2 032 mm 0 060 0 080 in REFACING STONE J Fig 56 Refacing Valve Seats VALVE SPRINGS Whenever valves have been removed for inspection reconditioning or replacement valve springs should be tested As an example the compression length of the spring to be tested is 1 5 16 in Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1 5 16 in mark...

Page 1038: ...bly removed from vehicle 1 Remove the cylinder head 2 Remove the oil pan 3 Remove the piston and connecting rod assem blies ASSEMBLE 1 Install the piston and connecting rod assembly 2 Install the oil pan 3 Install the cylinder head 4 Install the engine into the vehicle G L E A M I M Mm I N S P E C T I O N C f L i i i E i HEAD COWER CLEANING Clean cylinder head cover gasket surface Clean head rail ...

Page 1039: ... 0 001 in Journal grinding should not exceed 0 305 mm 0 012 in under the standard journal diameter DO NOT grind thrust faces of No 2 main bearing DO NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all oil passages CAUTION After any journal grind it is important that the final paper or cloth polish be in the same direction that the eng...

Page 1040: ...ghtedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm 0 004 in or more can be inserted between rotors and the straightedge replace pump assembly Fig 66 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper The relief valve spring has a free length of approx imately 49 5 mm 1 ...

Page 1041: ...r of more than 0 254 mm 0 010 in The cylinder walls are badly scuffed or scored Boring and honing operation should be closely coor dinated with the fitting of pistons and rings so that specified clearances can be maintained OIL LINE PLUi The oil line plug is located in the vertical passage at the rear of the block between the oil to filter and oil from filter passages Fig 68 Improper Installa tion...

Page 1042: ...0005 0 0015 in Nos 2 3 and 4 0 013 0 051 mm 0 0005 0 0020 in Max Allowable Nos 2F 3 4 0 064 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 63 487 63 513 mm 2 4995 2 5005 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cylinder Bore Diameter 99 314 99 365 mm 3 910 3 912 in Out of Round Max 0 127 m...

Page 1043: ...92 6 596 6 grams 20 90 21 04 oz 3 9L ENGINE 9 53 Piston Pins Clearance In Piston 0 00635 0 01905 mm 0 00025 0 00075 in In Rod Interference 0 0178 0 0356 mm 0 0007 0 0014 in Diameter 24 996 25 001 mm 0 9841 0 9843 in End Play NONE Length 75 946 76 454 mm 2 990 3 010 in Piston Rings Ring Gap Compression Rings 0 254 0 508 mm 0 010 0 020 in Oil Control Steel Rails 0 254 1 270 mm 0 010 0 050 in Ring Si...

Page 1044: ...ation 240 Valve Overlap 26 J9309 33 ENGINE SPECIFICATIONS CONT CONDITION IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R o r M M 2 3 etc indicating no 2 and 3 main bearing journal and or R 1 4 etc indicating no 1 and 4 connecting rod journal Steel stamped near notch on no 6 crankshaft counterweight HYDRAULIC TAPPETS OVERSIZE 0 2032 mm 0 008 in Diamond shaped stamp Top pad front o...

Page 1045: ...ke Manifold Bolts Refer to Procedure in Service Manual Oil Pan Bolts 24 N m 215 in lbs Oil Pan Drain Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs DESCRIPTION TORQUE Rear Insulator to Bracket Through Bolt 68 N m 50 ft lbs Rear Insulator to Crossmember Support Bracket Nut 41 N m 30 ft lbs Rear Support Bracket to Crossmember Flange Nuts 41 N m ...

Page 1046: ...9 56 3 9L ENGINE S P E C I A L T O O L S 3 9L ENGINE Valve Spring Compressor MD 998772 A Dial Indicator C 3339 Adapter 6633 Puller C 3688 ...

Page 1047: ...8635 80l1d423 Cam Bearing Remover lnstailer C 3132 A Camshaft Holder C 3509 Distributor Bushing Puller C 3Q52 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 8 0 l 1 c 9 f c i Cylinder Bore Gauge C 119 ...

Page 1048: ...e pistons are elliptically turned so that the diameter at the pin boss is less than its diameter page FRONT CRANKSHAFT OIL SEAL 77 HYDRAULIC TAPPETS 69 OIL PAN 75 OIL PUMP 77 PISTON AND CONNECTING ROD ASSEMBLY 75 ROCKER ARMS AND PUSH RODS 67 TIMING CHAIN COVER 70 TIMING CHAIN 71 VALVE SPRING AND STEM SEAL REPLACEMENT SN VEHICLE 67 VALVES AND VALVE SPRINGS 69 VIBRATION DAMPER 69 DISASSEMBLY AND ASS...

Page 1049: ... the oil pan The oil is driven between the drive and idler gears and pump body then forced through the outlet to the block An oil gallery in the block channels the oil to the inlet side of the full flow oil filter After passing through the filter element the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery which extends the entire ...

Page 1050: ...ED THROUGH HYDRAULIC TAPPET OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT DRIP OILING FOR VALVE TIP CYLINDER HEAD BOSS RIGHT OIL GALLERY PASSAGE TO CAMSHAFT REAR BEARING PLUG OIL FROM FILTER TO SYSTEM OIL TO FILTER FROM OIL PUMP HOLLOW PUSH ROD TAPPET TO CONNECTING ROD BEARINGS D m m 0 2 1 H o 0 1 m 39 o o 3 5 c a OIL INTAKE OIL FILTER CRANKSHAFT Fig 4 Oil Lubrication System ...

Page 1051: ...hould now read from 10 before top dead center to 2 after top dead center Remove spacer CAUTION DO NOT turn crankshaft any further clockwise as valve spring might bottom and result in serious damage If reading is not within specified limits Check sprocket index marks Inspect timing chain for wear Check accuracy of DC mark on timing indicator MEASURING TIMING CHAIN STRETCH NOTE To access timing chai...

Page 1052: ... second compression ring gap should be between 0 508 0 762 m m 0 020 0 030 inch The oil ring gap should be 0 254 1 270 m m 0 010 0 050 inch PISTON PIN BORE DIAMETER A PISTON SIZE A DIA PISTON DIAMETER BORE DIAMETER PISTON SIZE MIN mm IN MAX mm IN MIN mm IN MAI mm IN A 99 280 3 9087 99 294 3 9092 99 306 3 9097 99 319 3 9102 B 99 294 3 9092 99 306 3 9097 99 319 3 9102 99 332 3 9107 C 99 306 3 9097 9...

Page 1053: ...make certain that the V groove in the shell is in line with the V groove in the cap This provides lubrica tion of the cylinder wall 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 to 0 025 mm 0 001 inch Bearings are available in 0 025 mm 0 001 inch ...

Page 1054: ...placed R E M i a i i m m I N S T A L L A T I O N ENGINE FR0IT MOUNTS REMOVAL 1 Disconnect the negative cable from the battery 2 Position fan to assure clearance for radiator top tank and hose CAUTION manifold D O NOT lift the engine by the intake 3 Install engine support lifting fixture 4 Raise vehicle on hoist 5 Lift the engine SLIGHTLY and remove the thru bolt and nut Fig 15 6 Remove engine supp...

Page 1055: ...removed position the transmission support bracket to the transmission Install new attaching bolts and tighten to 102 N m 75 ft lbs torque 2 Position support cushion to transmission sup port bracket Install stud nuts and tighten to 47 N m 35 ft lbs torque 3 Using the transmission jack lower the trans mission and support cushion onto the crossmember Fig 17 4 Install the support cushion bolts and tig...

Page 1056: ...Lower the vehicle CAUTION D O NOT lift the engine by the intake manifold 37 Install an engine lifting fixture 38 Remove engine from vehicle and install engine assembly on a repair stand INSTALLATION 1 Remove engine from the repair stand and posi tion in the engine compartment Position the thru bolt into the support cushion brackets 2 Install an engine support fixture 3 Raise and support the vehicl...

Page 1057: ...ue 3 Install closed crankcase ventilation system and evaporation control system 4 Connect the negative cable to the battery ROCKER ARMS AND PUSH RODS REMOVAL 1 Disconnect spark plug wires by pulling on the boot straight out in line with plug 2 Remove cylinder head cover and gasket 3 Remove the rocker arm bolts and pivots Fig 19 Place them on a bench in the same order as removed 4 Remove the push r...

Page 1058: ...tor sending unit wire 13 Disconnect heater hoses and bypass hose 14 Remove cylinder head covers and gaskets 15 Remove intake manifold and throttle body as an assembly Discard the flange side gaskets and the front and rear cross over gaskets 16 Remove exhaust manifolds 17 Remove rocker arm assemblies and push rods Identify to ensure installation in original locations 18 Remove the head bolts from e...

Page 1059: ...Compressor Tool MD 998772A Install locks and release tool If valves and or seats are ground mea sure the Installed height of springs Make sure the measurement is taken from bottom of spring seat In cylinder head to the bottom surface of spring retainer If spacers are Installed measure from the top of spacer If height is greater than 42 86 mm 1 11 16 Inches install a 1 587 mm 1 16 inch spacer in he...

Page 1060: ...to Group 7 Cooling System 5 Remove power steering pump refer to Group 19 Steering 6 Remove vibration damper 7 Loosen oil pan bolts and remove the front bolt at each side 8 Remove the cover bolts 9 Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket 10 Place a suitable tool behind the lips of the oil seal to pry the oil seal outward Be careful not to damage the...

Page 1061: ...s Tighten the bolts to 11 N m 95 In lbs torque 18 Fill cooling system refer to Group 7 Cooling System for the proper procedure 19 Connect the negative cable to the battery THING CHAIN R E M O V A L 1 Remove Timing Chain Cover Refer to proce dure In this section 2 Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets INSTALLATION 1 Place both camshaf...

Page 1062: ...being careful not to damage cam bearings with the cam lobes INSTALLATION 1 Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm 2 inches of its final position in cylinder block Fig 29 Timing Chain Oil Tab Installation NOTE Whenever an engine has been rebuilt a new camshaft and or new tappets installed add 1 pint of Mopar Crankcase Conditioner or equivalent...

Page 1063: ...C 3132 A by sliding the new camshaft bearing shell over proper adapter Fig 32 Camshaft Bearings Removal Installation with Tool C 3132 A 2 Position rear bearing in the tool Install horse shoe lock and by reversing removal procedure care fully drive bearing shell into place 3 Install remaining bearings in the same man ner Bearings must be carefully aligned to bring oil holes into full register with ...

Page 1064: ...riveshaft Bushing Installation CAUTION This procedure MUST be followed when installing a new bushing or seizure to shaft may occur J 9 2 0 9 8 7 Fig 36 Burnishing Distributor Driveshaft Bushing 4 Install the intake manifold refer to Group 11 Exhaust System and Intake Manifold DISTRIBUTOR INSTALLATION NOTE Before installing the distributor the oil pump drive shaft must be aligned to number one cyli...

Page 1065: ...16 x VI BOLT A y DOWEL SLOT J9509 163 Fig 38 Fabrication of Alignment Dowels 5 Install the dowels in the cylinder block Fig 39 Fig 39 Position of Dowels in Cylinder Block 6 Apply small amount of Mopar Silicone Rubber Adhesive Sealant or equivalent in the corner of the cap and the cylinder block 7 Slide the one piece gasket over the dowels and onto the block 8 Position the oil pan over the dowels a...

Page 1066: ...nting toward front of engine The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet 8 Install rod caps Be sure connecting rod con necting rod cap and cylinder bore number are the same Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N m 45 ft lbs torque 9 Install the oil pan 10 Install the cylinder head 11 Install the engine into the vehi...

Page 1067: ...ced without removing the timing chain cover provided the cover is not mis aligned 1 Disconnect the negative cable from the battery 2 Remove vibration damper 3 If front seal is suspected of leaking check front oil seal alignment to crankshaft The seal installa tion alignment tool 6635 should fit with minimum interference If tool does not fit the cover must be removed and installed properly 4 Place ...

Page 1068: ...ine 7 Apply 5 mm 0 20 in drop of Loctite 518 or equivalent on each side of the rear main bearing cap Fig 46 DO NOT over apply sealant or allow the sealant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant appli cation BEARING CAP J9309 72 Fig 46 Sealant Application to Bearing Cap 8 To align the bearing cap use cap slot align ment dowel and cap bolts DO NOT...

Page 1069: ...Alternately tighten ALL pap bolts to 115 N m 85 ft lbs torque 8 Install oil pump 9 Apply Mopar Silicone Rubber Adhesive Sealant or equivalent at bearing cap to block joint to provide cap to block and oil pan sealing Fig 47 Apply enough sealant until a small amount Is squeezed out Withdraw nozzle and wipe excess sealant off the oil pan seal groove 10 Immediately install the oil pan LOWER SEAL REiOW...

Page 1070: ...ssary to wait for curing of the sealant The cooling system can be filled and the vehicle placed in service immediately D I S A S S E M B L Y A U B A S S E M B L Y HYDRAULIC TAPPETS CAUTION The plunger and tappet bodies are not interchangeable The plunger and valve must always be fitted to the original body It is advisable to work on one tappet at a time to avoid mixing of parts Mixed parts are not...

Page 1071: ...l 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 stems are scuffed or scored 4 Service valves with oversize stems are avail able Fig 53 5 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Ream the valve guides from standard to 0 381 mm 0 015 inch Use a 2 st...

Page 1072: ... Turn table of Universals Valve Spring Tester Tool until surface is in line with the 1 5 16 inch mark on the threaded stud Be sure the zero mark is to the front Fig 57 Place spring over stud on the table and lift compress ing lever to set tone device Pull on torque wrench until ping is heard Take reading on torque wrench at this instant Multiply this reading by 2 This will give the spring load at ...

Page 1073: ... any direction either replace head or lightly machine the head surface FOR EXAMPLE A 305 mm 12 inch span is 0 102 mm 0 004 inch out of flat The allowable out of flat is 305 x 0 00075 12 x 0 00075 equals 0 23 mm 0 009 inch This amount of out of flat is accept able The cylinder head surface finish should be 1 78 3 00 microns 70 125 micro inches Inspect push rods Replace worn or bent rods PISTON AND ...

Page 1074: ...ean sol vent Inspect condition of screen INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads Repair as necessary Inspect oil pan mounting flange for bends or distor tion Straighten flange if necessary OIL PUiP INSPECTION Mating surface of the oil pump cover should be smooth Replace pump assembly if cover is scratched or grooved Lay a straightedge across the pump cover s...

Page 1075: ...inches Replace spring that fails to meet these specifications Fig 67 If oil pressure was low and pump is within specifi cations inspect for worn engine bearings or other reasons for oil pressure loss 8020cd71 Fig 66 Measuring Clearance Over Rotors RN98 Fig 67 Proper Installation of Retainer Cap CYLINDER BLOCK CLEANING Clean cylinder block thoroughly and check all core hole plugs for evidence of le...

Page 1076: ...Plug should be 190 0 to 195 2 mm 7 1 2 to 7 11 16 in from machined surface of block Fig 68 If plug is too high use a suitable flat dowel to posi tion properly 4 If plug is too low remove oil pan and No 4 main bearing cap Use suitable flat dowel to position properly Coat outside diameter of plug with Mopar Stud and Bearing Mount Adhesive or equivalent Plug should be 54 0 to 57 7 mm 2 1 8 to 2 5 16 ...

Page 1077: ... Diametrical Clearance No 1 0 013 0 038 mm 0 0005 0 0015 in Nos 2 3 4 and 5 0 013 0 051 mm 0 005 0 0020 in Max Allowable Nos 2 3 4 5 0 064 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 63 487 63 513 mm 2 4995 2 5005 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cylinder Bore Diameter 99 314 99...

Page 1078: ... Weight 592 6 596 6 grams 20 90 21 04 oz BR Piston Pins Clearance In Piston 0 00635 0 01905 mm 0 00025 0 00075 in In Rod Interference 0 0178 0 0356 mm 0 0007 0 0014 in Diameter 24 996 25 001 mm 0 9841 0 9843 in End Play NONE Length 75 946 76 454 mm 2 990 3 010 in Piston Rings Ring Gap Compression Rings 0 254 0 508 mm 0 010 0 020 in Oil Control Steel Rails 0 254 1 270 mm 0 010 0 050 in Ring Side Cl...

Page 1079: ...Valve Overlap 31 J9409 99 ENGINE SPECIFICATIONS CONT CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R o r M M 2 3 etc indicating no 2 and 3 main bearing journal and or R l 4 etc indicating no 1 and 4 connecting rod journal Milled flat on no 8 crankshaft counterweight HYDRAULIC TAPPETS OVERSIZE 0 2032 mm 0 008 in Diamond shaped stamp top pad fro...

Page 1080: ...il Pan Bolts 23 N m 200 in lbs Oil Pan Drain Plug 34 N m 25ft lbs Oil Pump Attaching Bolts 41 N m 30ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs D E S C R I P T I O N T O R Q U E Rear Mount Support Cushion to Crossmember Nut Rear Mount Support Cushion to Trans Support Bracket Nuts Rear Mount Transmission Support Bracket Bolts Rear Support Plate to Transfer Case Bolts Rocker Arm Bolts Spark Plugs S...

Page 1081: ...mm S P E C I A L T O O L S 5 2L ENGINE Oil Pressure Gauge C 3292 Engine Support Fixture C 3487 A Adapter 6688 5 2L ENGINE 1 9 1 Valve Guide Sleeve C 3973 Dial indicator C 3339 Puller C 3688 ...

Page 1082: ...taller 6635 801W423 Cam Bearing Remover Installer C 3132 A Camshaft Holder C 3509 Distributor Bushing Puller C 3052 mm Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 8011C9T CJ Cylinder Bore Gauge C 119 ...

Page 1083: ...rating temperatures expansion forces the pin bosses away from each other causing the piston to assume a more nearly round shape page FRONT CRANKSHAFT OIL SEAL 112 HYDRAULIC TAPPETS 104 OIL PAN 109 OIL PUMP 112 PISTON AND CONNECTING ROD ASSEMBLY 110 ROCKER ARMS AND PUSH RODS 102 TIMING CHAIN COVER 105 TIMING CHAIN 106 VALVE SPRING AND STEM SEAL REPLACEMENT IN VEHICLE 103 VALVES AND VALVE SPRINGS 10...

Page 1084: ...ll flow oil filter After passing through the filter element the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery which extends the entire length on the right side of the block The oil then goes down to the 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 exte...

Page 1085: ... HYDRAULIC TAPPET OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT DRIP OILING FOR VALVE TIP CYLINDER HEAD BOSS PLUG RIGHT OIL GALLERY PASSAGE TO CAMSHAFT REAR BEARING OIL FROM FILTER TO SYSTEM OIL TO FILTER FROM OIL PUMP CRANKSHAFT ROCKER ARM TO MAIN BEARINGS HOLLOW PUSH ROD TAPPET TO CONNECTING ROD BEARINGS OIL INTAKE OIL FILTER Fig 4 Oil Lubrication System ...

Page 1086: ...otate the crankshaft clockwise normal run ning direction until the valve has lifted 0 863 mm 0 034 inch The timing of the crankshaft should now read from 10 before top dead center to 2 after top dead center Remove spacer CAUTION DO NOT turn crankshaft any further clockwise as valve spring might bottom and result in serious damage If reading is not within specified limits Check sprocket index marks...

Page 1087: ... fitted into the cylinder bore Fig 8 FITTING PISTON RINGS 1 Measurement of end gaps PISTON PIN BORE DIAMETER A PISTON SIZE A DIA PISTON DIAMETER BORE DIAMETER PISTON SIZE MIN m m IN MAX mm IN MIN m m IN MAX m m IN A B 101 580 3 9992 101 592 3 9997 101 605 4 0002 101 618 4 0007 C 101 592 3 9997 101 605 4 0002 101 618 4 0007 101 630 4 0012 D 101 605 4 0002 101 618 4 0007 101 630 4 0012 101 643 4 001...

Page 1088: ... pistons are not interchangeable from one bank to another The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly Each bearing cap has a small V groove across the parting face When installing the lower bearing shell make certain that the V groove in the shell is in line with the V groove in the cap This provides lubrica tion of the cylinder wall in the o...

Page 1089: ...ar taper and scor 5 9L ENGINE 9 99 ing The maximum taper or out of round on any crankshaft journal is 0 025 mm 0 001 inch Journal grinding should not exceed 0 305 mm 0 012 inch under the standard journal diameter DO NOT grind thrust faces of No 3 main bearing DO NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all oil passages CAUTION ...

Page 1090: ...icle ENGINE ASSEMBLY REMOVAL 1 Remove the battery 2 Drain cooling system refer to Group 7 Cooling System for the proper procedure 3 Remove the upper crossmember and top core support 4 Remove the transmission oil cooler 5 Discharge the air conditioning system if equipped refer to Group 24 Heating and Air Condi tioning for service procedures 6 Remove the serpentine belt refer to Group 7 Cooling Syst...

Page 1091: ...t the vehicle on a hoist 4 Refer to Group 21 Transmissions for transmis sion installation wt Cushion Assemblies 5 Install rear transmission support 6 Install the prop shaft refer to Group 16 Pro peller Shaft 7 Install the dust shield and transmission cover 8 Install the starter and connect the starter wires refer to Group 8B Battery Starter Generator Service 9 Install exhaust pipe to manifold 10 I...

Page 1092: ...d ventilation system and evap oration control system from cylinder head cover 3 Remove cylinder head cover and gasket The gasket may be used again INSTALLATION 1 Clean cylinder head cover gasket surface 2 Clean head rail if necessary 3 Inspect cover for distortion and straighten if necessary 4 Check the gasket for use in head cover instal lation If damaged use a new gasket 5 Position the cylinder ...

Page 1093: ...rator bracket support rod Remove the generator 4 Remove closed crankcase ventilation system 5 Disconnect the evaporation control system 6 Remove the air cleaner 7 Disconnect the fuel lines 8 Disconnect accelerator linkage and if so equipped the speed control and transmission kick down cables 9 Remove the return spring 10 Remove distributor cap and wires 11 Disconnect the coil wires 12 Disconnect h...

Page 1094: ...nstall valve springs and valve retainers 4 Compress valve springs with Valve Spring Compressor Tool MD 998772A install locks and release tool If valves and or seats are ground mea sure the installed height of springs Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer If spacers are installed measure from the top of spacer If heig...

Page 1095: ...er bolts to 11 N m 95 in lbs torque 8 Connect the negative cable to the battery TIMING CHAIN COVER R E M O V A L 1 Disconnect the negative cable from the battery 2 Drain cooling system refer to Group 7 Cooling System 3 Remove the serpentine belt refer to Group 7 Cooling System 4 Remove water pump refer to Group 7 Cooling System 5 Remove power steering pump refer to Group 19 Steering 6 Remove vibra...

Page 1096: ... lbs torque Tighten oil pan bolts to 24 N m 215 in lbs torque J 9 3 0 9 4 6 Fig 26 Installing Oil Seal 11 Inspect the seal flange on the vibration damper 12 Install vibration damper 13 Install water pump and housing assembly using new gaskets refer to Group 7 Cooling Sys tem Tighten bolts to 41 N m 30 ft lbs torque 14 Install power steering pump refer to Group 19 Steering 15 Install the serpentine...

Page 1097: ...FT CAMSHAFT SPROCKET J9309 71 Fig 28 Camshaft and Sprocket Assembly REMOVAL 1 Remove intake manifold 2 Remove cylinder head covers 3 Remove timing case cover and timing chain 4 Remove rocker arms 5 Remove push rods and tappets Identify each part so it can be installed in its original location 6 Remove distributor and lift out the oil pump and distributor drive shaft THRUST PLATE REAR SIDE J9209 13...

Page 1098: ...installed in the same position from which it was removed When camshaft is replaced all of the tappets must be replaced CAMSHAFT BEARINGS REMOVAL NOTE This procedure requires that the engine is removed from the vehicle 1 With engine completely disassembled drive out rear cam bearing core hole plug 2 Install proper size adapters and horseshoe washers part of Camshaft Bearing Remover Installer Tool C...

Page 1099: ... main cap slots 3 If present trim excess sealant from Inside the engine 4 Fabricate 4 alignment dowels from 5 16 x 1 1 2 inch bolts Cut the head off the bolts and cut a slot into the top of the dowel This will allow easier installation and removal with a screwdriver Fig 34 5 16 x 172 BOLT A DOWEL SLOT J9509 163 Fig 34 Fabrication of Alignment Dowels 5 Install the dowels in the cylinder block Fig 3...

Page 1100: ...inder block When removing piston and connecting rod assemblies rotate crankshaft to cen ter the connecting rod in the cylinder bore and at BDC Be careful not to nick crankshaft journals 7 After removal install bearing cap on the mat ing rod INSTALLATION 1 Be sure that compression ring gaps are stag gered so that neither is in line with oil ring rail gap 2 Before installing the ring compressor make...

Page 1101: ...ould be checked for excessive wear taper and scor ing The maximum taper or out of round on any crankshaft journal Is 0 025 mm 0 001 inch Journal grinding should not exceed 0 305 mm 0 012 Inch under the standard journal diameter DO NOT grind thrust faces of No 3 main bearing DO NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all oil pa...

Page 1102: ...ttaching bolts Tighten attaching bolts to 41 N m 30 ft lbs torque 3 Install the oil pan FRONT CRANKSHAFT OIL SEAL The oil seal can be replaced without removing the timing chain cover provided the cover is not mis aligned 1 Disconnect the negative cable from the battery 2 Remove vibration damper 3 If front seal is suspected of leaking check front oil seal alignment to crankshaft The seal installa t...

Page 1103: ...er seal lips with engine oil 7 Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine 8 Apply 5 mm 0 20 in drop of Loctite 518 or equivalent on each side of the rear main bearing cap 25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR MAIN CAP J9509 75 Fig 44 Sealant Application to Bearing Cap 9 To align the bearing cap use cap slot ali...

Page 1104: ... small amount is squeezed out Withdraw nozzle and wipe excess sealant off the oil pan seal groove 14 Immediately install the oil pan LOWER SEAL REPLACEMENT 1 Remove the oil pan 2 Remove the oil pump from the rear main bear ing cap 3 Remove the rear main bearing cap and discard the old lower seal 4 Clean the rear main cap mating surfaces including the oil pan seal grooves 5 Carefully install a new ...

Page 1105: ...ig 48 2 Clean varnish deposits from inside of tappet body above plunger cap 3 Invert tappet body and remove plunger cap plunger check valve check valve spring check valve retainer and plunger spring Fig 48 Check valve could be flat or ball ASSEMBLE 1 Clean all tappet parts in a solvent that will remove all varnish and carbon 2 Replace tappets that are unfit for further ser vice with new assemblies...

Page 1106: ...ot 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 stems are scuffed or scored Service valves with oversize stems are available Fig 52 Fig 51 Measuring Waive Guide Wear learner O S Valve Guide Size 0 076 mm 8 026 8 052 mm 0 003 in 0 316 0 317 in 0 381 mm 8 331 8 357 mm 0 015 in 0 328 0 329 in J9309 30 Fig 52 Reamer Sizes S...

Page 1107: ... for inspection reconditioning or replacement valve springs should REFACING STONE MUST NOT CUT VALVE SHROUD RK635 VALVE SEAT Fig 55 Refacing Valve Seats be tested As an example the compression length of the spring to be tested is 1 5 16 inch Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1 5 16 inch mark on the threaded stud Be sure the zero mark is to the front...

Page 1108: ...ge If out of flatness exceeds 0 00075 mm mm 0 00075 inch inch times the span length in inches in any direction either replace head or lightly machine the head surface FOR EXAMPLE A 305 mm 12 inch span is 0 102 mm 0 004 inch out of flat The allowable out of flat is 305 X 0 00075 12 X 0 00075 equals 0 23 mm 0 009 inch This amount of out of flat is acceptable The cylinder head surface finish should b...

Page 1109: ...embly if cover is scratched or grooved Lay a straightedge across the pump cover surface Fig 60 If a 0 038 mm 0 0015 inch feeler gauge can be inserted between cover and straightedge pump assembly should be replaced STRAIGHT EDGE COWER Fig 60 Checking Oii Pump Cover Flatness Measure thickness and diameter of OUTER rotor If outer rotor thickness measures 20 9 mm 0 825 inch or less or if the diameter ...

Page 1110: ...Replace spring that fails to meet these specifications Fig 66 If oil pressure was low and pump Is within specifi cations inspect for worn engine bearings or other reasons for oil pressure loss RN98 Fig 66 Proper Installation of Retainer Cap CYLINDER BL0CI CLEANING Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking INSPECTION Examine block for cracks or fractures ...

Page 1111: ...cal Clearance No 1 0 013 0 038 mm 0 0005 0 0015 in Max Allowable No 1 0 0381 mm 0 0015 in Nos 2 3 4 and 5 0 013 0 051 mm 0 005 0 0020 in Max Allowable Nos 2 2 4 5 0 064 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 71 361 71 387 mm 2 8095 2 8105 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cy...

Page 1112: ...on Pins Clearance In Piston 0 006 0 019 mm 0 00023 0 00074 in Diameter 25 007 25 015 mm 0 9845 0 9848 in End Play NONE Length 67 8 68 3 mm 2 67 2 69 in Piston Rings Ring Gap Compression Ring Top 0 30 0 55 mm 0 012 0 022 in Compression Rings 2nd 0 55 0 80 mm 0 022 0 031 in Oil Control Steel Rails 0 381 1 397 mm 0 015 0 055 in Ring Side Clearance Compression Rings 0 040 0 085 mm 0 0016 0 0033 in Oil...

Page 1113: ... 5 J9509 97 OWERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS C O N D I T I O N IDENTIFICATION L O C A T I O N O F IDENTIFICATION 0 025 mm 0 001 inch U S Crankshaft R or M M 2 3 etc Indicating No 2 3 main bearing journal and or R l 4 etc Indicating No 1 4 connecting rod journal Milled flat on number three crankshaft counterweight 0 508 mm 0 020 inch O S Cylinder Bores A Following engine serial numb...

Page 1114: ...in Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs D E S C R I P T I O N T O R Q U E Rear Mount Support Cushion to Crossmember Nut 47 N m 35 ft lbs Rear Mount Support Cushion to Trans Support Bracket Nuts 47 N m 35 ft lbs Rear Mount Transmission Support Bracket Bolts 102 N m 75 ft lbs Rear Support Plate to Transfer Case Bolts 41 N m 30 ft lbs R...

Page 1115: ......

Page 1116: ...9 126 5 9L ENGINE S P E C I A L T O O L S Continued B R Piston Ring Compressor C 385 ...

Page 1117: ...rankshaft The V 10 uses a full flow oil filter page OIL PUMP 150 PISTON AND CONNECTING ROD ASSEMBLY 148 ROCKER ARMS AND PUSH RODS 136 TIMING CHAIN COVER OIL SEAL COVER NOT REMOVED 144 TIMING CHAIN COVER OIL SEAL COVER REMOVED 144 TIMING CHAIN COVER 141 TIMING CHAIN 143 VALVE STEM SEAL AND SPRING REPLACEMENT 136 VALVES AND VALVE SPRINGS 139 VIBRATION DAMPER 141 DISASSEMBLY AND ASSEMBLY CYLINDER BLO...

Page 1118: ...lacement is necessary use the engine type and serial number for reference Fig 8 Engine identification LUBiiCATiOl SYSTEi The lubrication system is a full flow filtration pres sure feed type Oil stored in the oil pan is taken in and discharged by an internal gear pump directly coupled to the crankshaft Its pressure is regulated by the relief valve located in the chain case cover The oil is pump thr...

Page 1119: ...OIL GALLERY FOR TAPPETS CAMSHAFT HYDRAULIC TAPPET CAM BEARINGS GALLERIES FRTOF BLOCK OIL PICKUP J9505H44 Fig 4 Engine Lubrication System ...

Page 1120: ...nkshaft until the No 6 exhaust valve is closing and No 6 intake valve is opening 2 Insert a 6 350 mm 1 4 inch spacer between rocker arm pad and stem tip of No l intake valve Allow spring load to bleed tappet down giving in effect a solid tappet 3 Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular as pos sible Zero the indicator 4 Rotate the crankshaft clockw...

Page 1121: ... the rings down to ensure positioning rings squarely in the cylinder bore before measur ing b Insert feeler stock in the gap Gap for com pression rings should be between 0 254 0 508 mm 0 010 0 020 inch The oil ring gap should be 0 381 1 397 mm 0 015 0 055 inch c Rings with insufficient end gap may be prop erly filed to the correct dimension Ends should be stoned smooth after filing with Arkansas W...

Page 1122: ...01 inch 0 051 mm 0 002 inch 0 076 mm 0 003 inch 0 254 mm 0 010 inch and 0 305 mm 0 012 inch under size Install the bearings in pairs DO NOT use a new bearing half with an old bearing half DO NOT file the rods or bearing caps FITTING CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly Upper and lower bearing halves are NOT inter c...

Page 1123: ...th support lifting fixture while guiding the engine bracket cushion and thru bolt into support cushion brackets Fig 13 4 Install thru bolt nuts and tighten the nuts to 68 N m 50 ft lbs torque 5 Lower the vehicle 8 0L ENGINE I 133 C U S H I O N B R A C K E T J 9 4 0 9 5 4 Fig 13 Positioning Engine Mounts Front 6 Remove lifting fixture ENGINE MOUNT REAR REMOVAL 1 Raise the vehicle on a hoist 2 Posit...

Page 1124: ...ing System 16 Remove the generator with the wire connec tions refer to Group 8B Battery Starter Generator Service 17 Remove the air cleaner 18 Disconnect the throttle linkage 19 Remove throttle body 20 Remove the upper intake manifold refer to Group 11 Exhaust System and Intake Manifold 21 Remove the coil assemblies with the ignition cables 22 Disconnect the heater hoses 23 Disconnect the power st...

Page 1125: ...ift lever refer to Group 21 Transmissions 15 Connect the fuel lines 16 Connect the heater hoses 17 Install the upper intake manifold refer to Group 11 Exhaust System and Intake Manifold 18 Install the coil assemblies with the ignition cables 19 Using a new gasket install throttle body Tighten the throttle body nuts to 23 N m 200 in lbs torque 20 Connect the throttle linkage 21 Install the air clea...

Page 1126: ... NOT switch the systems 8 Connect the negative cable to the battery ROCKER ARMS AND PUSH RODS REMOVAL 1 Disconnect spark plug wires by pulling the boot straight out in line with plug 2 Remove cylinder head cover and gasket 3 Remove the rocker arm bolts and the rocker arm assembly Fig 17 Place rocker arm assemblies on a bench in the same order as removed 4 Remove the push rods and place them on a b...

Page 1127: ...ud bolts and the bolts to 16 N m 144 in lbs torque 15 Install closed crankcase ventilation system 16 Connect the evaporation control system 17 Install air cleaner 18 Connect the negative cable to the battery 19 Road test vehicle and check for leaks CYLINDER HEADS REMOVAL 1 Disconnect the negative cable from the battery 2 Drain cooling system refer to Group 7 Cooling System for the proper procedure...

Page 1128: ...ead bolts in sequence to 58 N m 43 ft lbs torque Step 2 Tighten all cylinder head bolts in sequence to 143 N m 105 ft lbs torque CAUTION When tightening the rocker arm bolts make sure the piston in that cylinder is NOT at TDC Contact between the valves and piston could occur 4 Install push rods and rocker arm assemblies in their original position Tighten the bolts to 28 N m 21 ft lbs torque J 9 4 ...

Page 1129: ...uel line 23 Install the generator and drive belt Tighten generator mounting bolt to 41 N m 30 ft lbs torque Tighten the adjusting strap bolt to 23 N m 200 in lbs torque Refer to Group 7 Cooling Sys tem for adjusting the belt tension 24 Install the intake manifold to generator bracket support rod Tighten the bolts to 41 N m 30 ft lbs torque 25 The cylinder head cover gasket can be used again Instal...

Page 1130: ...ol 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 measure the installed height of springs Make sure the mea surement Is taken from bottom of spring seat in cyl inder head to the bottom surface of spring retainer If spacers are installed measure from the top of sp...

Page 1131: ... valve mechanism engine must not be r u n above fast idle until all hydraulic tappets have filled with oil and have become quiet 10 Connect the negative cable to the battery 11 Road test vehicle and check for leaks fiBFtATION i A i P E i REMOVAL 1 Disconnect the negative cable from the battery 2 Remove fan shroud retainer bolts and set shroud back over engine 3 Remove the cooling system fan 4 Remo...

Page 1132: ...ount of Mopar Silicone Rubber Adhe sive Sealant or equivalent at the joint between tim ing chain cover gasket and the oil pan gasket Finger tighten the timing chain cover bolts at this time 4 Tighten timing chain cover bolts to 47 N m 35 ft lbs torque Tighten oil pan bolts to 24 N m 215 in lbs torque 5 Install pulley vibration damper use tool C 3688 Fig 32 6 Prime oil pump by squirt oil in the oil...

Page 1133: ...ools C 3688 C 3718 and MB 990799 seat sprocket against crankshaft shoulder Fig 34 2 Turn crankshaft to line up the timing mark with the crankshaft and camshaft centerline 3 Put chain on camshaft sprocket 4 Take chain and camshaft sprocket align timing marks and install chain and cam sprocket onto crankshaft sprocket Check to see that timing marks are on the centerline of the crankshaft and camshaf...

Page 1134: ... damper using tool C 3688 SPECIAL TOOL C 3688 SPECIAL TOOL 6806 J9409 136 Fig 37 Timing Chain Cover and Oil Seal 3 Install serpentine belt refer to Group 7 Cool ing System 4 Install cooling fan and shroud 5 Connect negative cable to the battery TIMING CHAIN COVER OIL SEAL COVER REMOVED REMOVAL 1 With timing cover removed from engine place a suitable tool behind the lips of the oil seal to pry the ...

Page 1135: ... camshaft into the cylinder block NOTE Whenever an engine has been rebuilt a new camshaft and or new tappets installed add 1 pint of Mopar Crankcase Conditioner or equivalent The oil mixture should be left in engine for a minimum of 8 0 5 km 500 miles Drain at the next normal oil change 2 Install camshaft thrust plate Tighten the torx bolts to 22 N m 16 ft lbs torque 3 Check camshaft end play The ...

Page 1136: ... 16 Position the cylinder head cover onto the gas ket install the stud bolts and hex head bolts in the proper positions Fig 43 Tighten the stud bolts and the bolts to 16 N m 144 In lbs torque 17 Install the intake manifolds refer to Group 11 Intake and Exhaust Systems Fig 43 Cylinder Head Cower CAMSHAFT BEARING R E M O V A L This procedure requires that the engine is removed from the vehicle 1 Wit...

Page 1137: ...ent Dowels 2 Install the dowels in the cylinder block at the four corners 3 Apply small amount of Mopar Silicone Rubber Adhesive Sealant or equivalent at the split lines The split lines are between the cylinder block the timing chain cover and the rear crankshaft seal assembly Fig 45 After the sealant is applied you have 3 minutes to install the gasket and oil pan 4 Slide the one piece gasket over...

Page 1138: ...rail gap 4 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located properly Fig 48 5 Immerse the piston head and rings in clean engine oil Slide Piston Ring Compressor Tool C 385 over the piston and tighten with the special wrench part of Tool C 385 Be sure position of rings does not change during this operation 6 Install connecting rod bolt ...

Page 1139: ...59 3 Lubricate the main journals with clean engine oil Install main bearing caps and bolts Follow the 2 step tightening sequence Step 1 Starting with bearing cap No l tighten the bolts to 27 N m 20 ft lbs torque Step 2 Starting with bearing cap No l tighten the bolts to 115 N m 85 ft lbs torque 4 Apply a rearward axial load of 667 N 150 Ibs f on crankshaft centerline driving No 3 main cap and thru...

Page 1140: ...lign rear flange of thrust bearings in a common plane Front face of No l main cap must not extend forward in front of face of No l bulkhead 9 Install the oil pickup tube Tighten the bolts to 16 N m 144 in lbs torque 10 Install the oil pan OIL PUMP REMOVAL 1 Remove the timing chain cover 2 Remove the relief valve plug gasket spring and valve Fig 52 Discard the gasket 3 Remove oil pump cover Fig 53 ...

Page 1141: ...es behind the camshaft thrust plate This will reduce internal leakage and help maintain higher oil pressure at idle REMOVAL 1 Using a blunt tool such as a drift or a screw driver and a hammer strike the bottom edge of the cup plug Fig 56 2 With the cup plug rotated grasp firmly with pliers or other suitable tool and remove plug Fig 56 CYLINDER Fig 56 Core Hole Plug Removal INSTALLATION 1 Thoroughl...

Page 1142: ...he stems are scuffed or scored Service valves with oversize stems are available Fig 59 Reamer O S Valve Guide Size 0 076 mm 8 026 8 052 mm 0 003 in 0 316 0 317 in 0 381 mm 8 331 8 357 mm 0 015 in 0 328 0 329 in J9309 30 Fig 59 Reamer Sizes 5 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Ream the valve guides from standard to 0 381 mm 0 015 inch Use a 2 step proc...

Page 1143: ...g 62 Place spring over stud on the table and lift compressing lever to set tone device Pull on torque wrench until ping is heard Take reading on torque wrench at this instant Multiply this reading by 2 This will give the spring load at test length Fractional measurements are indicated on the table for finer adjustments Refer to specifications to obtain specified height and allowable tensions Disca...

Page 1144: ...scratched or grooved Lay a straightedge across the pump cover surface Fig 63 If a 0 076 mm 0 003 inch feeler gauge can be inserted between cover and straightedge cover should be replaced 68 Fig 68 Checking Oii Pump Cower Flatness Measure thickness Fig 64 Fig 65 and diameter of rotors If either rotor thickness measures 14 956 mm 0 5876 Inch or less or if the diameter is 82 45 mm 3 246 inches or les...

Page 1145: ...ance Ower Rotors If oil pressure was low and pump is within specifi cations inspect for worn engine bearings or other reasons for oil pressure loss CYLINDER BLOCK GLEAMING Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking INSPECTION Examine block for cracks or fractures The cylinder walls should be checked for out of round and taper with Cylinder Bore Indicator ...

Page 1146: ... mm 2 124 2 125 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm V 0 001 in Crankshaft Cont Main Bearing Diametrical Clearance No l No 6 0 0051 0 058 mm 0 0002 0 0023 in Max Allowable 0 071 mm 0 0028 in End Play 0 076 0 305 mm 0 003 0 012 in Max Allowable 0 381 mm 0 015 in Main Bearing Journals Diameter 76 187 76 213 mm 2 9995 3 0005 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 025...

Page 1147: ...8 in In Rod Interference 0 018 0 061 mm 0 0007 0 0024 in Diameter 24 996 25 001 mm 0 9841 0 9843 in End Play NONE Length 67 818 68 326 mm 2 670 2 690 in Piston Rings Ring Gap Compression Rings 0 254 0 508 mm 0 010 0 020 in Oil Control Steel Rails 0 381 1 397 mm 0 015 0 055 in Ring Side Clearance Compression Rings 0 074 0 097 mm 0 0029 0 0038 in Oil Ring Steel Rails 0 185 0 246 mm 0 0073 0 0097 in ...

Page 1148: ...ONDITION IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R o r M M 2 3 etc indicating no 2 and 3 main bearing journal and or R 1 4 etc indicating no 1 and 4 connecting rod journal Milled flat on no 8 crankshaft counterweight CYLINDER BORES OVERSIZE 0 508 mm 0 020 in A Following engine serial number HYDRAULIC TAPPETS OVERSIZE 0 2032 mm 0 008 in Diamond sha...

Page 1149: ...ft lbs 144 in lbs 55 ft lbs 55 ft lbs 25 ft lbs 174 in lbs 50 ft lbs 35 ft lbs 16 ft lbs 55 ft lbs 30 ft lbs 30 ft lbs 175 in lbs 16ft lbs 40 ft lbs Intake Manifold Bolts Upper 22 N m 16ft lbs Oil Filter 9 N m 80 in lbs 45 Oil Filter Connector 46 N m 34 ft lbs Oil Pan Bolts 1 4 20 11 N m 96 in lbs Oil Pan Stud Bolts 16 N m 144 in lbs Oil Pan Bolts 5 16 18 16 N m 144 in lbs Oil Pan Drain Plug 34 N ...

Page 1150: ...ool 6715 Valve Spring Compressor Adapter Tool 6716A Valve Spring Compressor Tool MD 998772A Valve Spring Compressor Screw Tool 6756 Black Valve Guide Sleeve Tool C6819 Silver Vaive Guide Sleeve Tool C6818 8 0 1 1 d 4 2 b Dial Indicator Tool C3389 Crankshaft Pulley Damper Installer Tool C8688 ...

Page 1151: ...procket Puller Jaws Tool 6820 Crankshaft Sprocket Installer Tool 3718 Crankshaft Sprocket Installer Tool MD990799 8 0L ENGINE 9 Front Oil Seal Installer Tool 6806 Front Oil Seal Installer Toot 6761 8011d423 Camshaft Bearing Installer Tool C3132A Compression Ring Installer Tool C4184 ...

Page 1152: ...9 162 8 0L ENGINE S P E C I A L T O O L S Continued B R Seal Installer Tool 6687 Seal Installer Tool 6687 ...

Page 1153: ... are the same grade as the original pis ton If a new cylinder block or crankshaft is used the piston grading procedure MUST be performed to determine the proper piston grade for each cylinder page ENGINE REAR MOUNT 179 FLYWHEEL RING GEAR 197 GEAR HOUSING COVER 184 GEAR HOUSING 185 OIL FILTER BYPASS VALVE 198 OIL PAN AND SUCTION TUBE 191 OIL PRESSURE REGULATOR VALVE AND SPRING 199 OIL PUMP 198 PIST...

Page 1154: ...ating oil pressure gauge This allows unfiltered oil into the engine This condition should be avoided by changing the filter at each oil change The turbocharger receives filtered cooled and pressur ized lubricating oil through a supply line from the filter head A drain line connected to the bottom of the turbo charger housing returns the lubricating oil to the lubri cating oil pan through a fitting...

Page 1155: ......

Page 1156: ...re from the oil pump exceeds 448 kPa 65 psi the regulator valve opens to allow oil to drain back into the pan TIMING PIN The timing pin is used for three different proce dures Valve adjustment Top Dead Center TDC location Fuel injector pump timing procedure SERVICE PROCEDURES OIL FILTER When replacing the oil filter use replacement filter specified in your Operator s Manual CAUTION The internal fi...

Page 1157: ...h the correct grade of new oil The engine capacity is 9 46 liters 10 quarts in the crankcase and 0 95 liters 1 quart in the lubri cating oil filter 8 Start the engine and operate it at idle for sev eral minutes Check for leaks at the filter and drain plug 9 Stop the engine Wait approximately 15 min utes to let the oil in the upper parts of the engine to drain back to the oil pan Check the oil leve...

Page 1158: ...ntegral seats only is 0 254 mm 0 010 inch Service valve seats are available for over limit integral valve seats Identify ground valve seats by stamping the cylin der head Install the valves in their designated locations and measure the depth of each The valve depth limit Integral and Inserted Seats is 0 99 mm to 1 52 mm 0 039 inch to 0 060 inch Replace the valve if the depth is over this limit App...

Page 1159: ...eir designated location and measure the valve depth The valve depth is the dis tance from the valve face to the head deck Record the depth of each valve Fig 11 The depth is 0 99 1 52 mm 0 039 0 060 inch Grind the valve seats to remove scores scratches and burns The valve seat angle is 30 Intake and 45 Exhaust Install the valves in their respective bores and measure the depth again Fig 11 The valve...

Page 1160: ...function of drill speed and how fast the hone is moved vertically Fig 14 7 Vertical strokes MUST be smooth continuous passes along the full length of the bore Fig 14 1 STROKE f P E R S E C O N D Fig 14 De Glazing Drill Speed and Wertical Speed 8 Inspect the bore after 10 strokes 9 Use a strong solution of hot water and laundry detergent to clean the bores Clean the cylinder bores immediately after...

Page 1161: ...ble in two sizes 0 50 mm 0 0197 inch and 1 00 mm 0 0393 inch Any combination of standard 0 50 mm 0 0197 inch or 1 00 mm 0 0393 inch overbore may be used in the same engine If more than 1 00 mm 0 0393 inch overbore is needed a repair sleeve can be installed refer to Method 2 Repair Sleeve Cylinder block bores may be bored twice before use of a repair sleeve is required Fig 17 The first bore is 0 50...

Page 1162: ...e is required the block must be bored and a repair sleeve installed Bore the block cylinder bore to 104 500 104 515 mm 4 1142 4 1148 inch Fig 19 Repair sleeves can be replaced by using a boring bar to bore out the old sleeve DO NOT cut the cyl inder bore beyond the oversize limit After machining the block for the new repair sleeve thoroughly clean the bore of all metal chips debris and oil residue...

Page 1163: ...ately 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 sure there is no grit residue present Apply a rust preventing compound if the block will not be used immediately A standard diameter piston and a piston ring set must be used with a sleeved cylind...

Page 1164: ...he connect ing rod with the tang of the bearing in the slot of the connecting rod The connecting rod bearing shell must be installed in the original connecting rod and MIN 68 962 mm 2 715 inch MAX 69 013 mm 2 717 inch Out of Round Max 0 050 mm 0 002 inch Taper Max 0 013 mm 0 0005 inch Bearing Clearance Max 0 089 mm 0 0035 inch J9109 91 Fig 25 Connecting Rod Journal Diameter Limits cap Use clean lu...

Page 1165: ...n A Rel N u m b e r G r a d e 51 554 to 51 607mm 2 029 to 2 031 in 2571 A 51 654 to 51 707mm 2 033 to 2 035in 2572 3 51 754 to 51 807mm 2 037 to 2 039in 2573 C J9509 1 Fig 28 Piston Grading Measurement CRANKSHAFT REWORK Crankshaft main and rod journals may be ground in increments of 0 25 mm 0 0098 inch up to a total of 1 00 mm 0 0394 inch The only exception is the main journal thrust width surface...

Page 1166: ...en the main bearing thrust width surface is ground When the thrust surface width requires grinding the main journal must be ground to the same undersize dimension Fig 30 THRUST JOURNAL WIDTH 37 500 0 025 mm 1 4764 0 001 inch UNDERSIZES REGRIND WIDTH TO 0 50 mm 38 000 0 025 mm 0 0197 inch 1 4961 0 001 inch 1 00 mm 38 500 0 025 mm 0 0394 inch 1 5158 0 001 inch J9109 127 Fig 30 Crankshaft Thrust Jour...

Page 1167: ... bearing grinding specifications are shown in Fig 34 PREFERRED PROCEDURE Smoothly blend a 4 00 0 020 0 1575 0 0008 inch radius to the ground diameters and side faces Fig 35 STANDARD ROD JOURNAL DIAMETER 69 000 0 013 mm 2 7165 0 0005 inch WORN ROD JOURNAL DIAMETER LIMIT 68 962 2 7150 inch UNDERSIZES REGRIND TO 0 25 mm 0 0098 inch 68 750 0 013 mm 2 7067 0 0005 inch 0 50 mm 0 0197 inch 68 500 0 013 m...

Page 1168: ... main bearing journal to bearing clearance the clearance specifications are 0 119 mm 0 00475 inch If the crankshaft journal is within limits replace the main bearings If not within spec ifications grind the crankshaft to next size and use oversize bearings REMOVAL A N D I N S T A L L A T I O N ENGINE FRONT MOUNTS REMOVAL 1 Disconnect the negative cable from the battery mm M A X 83 106 mm 3 2719 in...

Page 1169: ...ighten the nuts to 68 N m 50 ft lbs torque 5 Lower the vehicle 6 Remove lifting fixture 5 9L DIESEL ENGINE 9 179 ENGINE SUPPORT BRACKET CUSHION BRACKET J9409 122 Fig 40 Positioning Engine Front Mounts ENGINE REAR MOUNT WM0VAI 1 Raise the vehicle on a hoist 2 Position a transmission jack in place 3 Remove support cushion stud nuts Fig 41 4 Raise rear of transmission and engine SLIGHTLY Fig 41 Engin...

Page 1170: ...8 If equipped remove the condenser 9 Remove the washer bottle 10 Remove the radiator overflow bottle 11 Disconnect the top radiator hose 12 Remove the fan 13 Remove the fan shroud 14 Disconnect the lower radiator hose 15 Remove radiator refer to Group 7 Cooling System 16 Remove the generator Fig 42 with the wire connections refer to Group 8B Battery Starter Gen erator Service 17 Disconnect the hea...

Page 1171: ...mission cooler line brackets to oil pan 12 Install and tighten engine front mount thru bolt nuts 13 Install the oil pan Install the drain plug 14 Lower the vehicle 15 On Manual Transmission vehicles install the shift lever refer to Group 21 Transmissions 16 Connect the fuel lines to the lift pump and fuel return Use tags to identify the lines 17 Connect all electrical connections to the engine Use...

Page 1172: ...dowel bores in the cylinder head 2 If the push rod is holding pedestal off head bar the engine until the pedestal will set on the head surface without interference 3 Use clean engine oil to lubricate the cylinder head bolt threads and under the bolt heads 4 Install the long bolts 12 mm into the rocker lever pedestals Tighten the bolts as follows Step 1 Tighten the bolts in sequence Fig 46 to 90 N ...

Page 1173: ... must be clean and dry 2 Position the gasket onto the dowels Fig 50 Make sure the gasket is correctly aligned with the holes in the cylinder block 3 Carefully put the cylinder head onto the gasket and cylinder block Make sure the cylinder head Is installed onto the dowels in the cylinder block Fig 50 CYLINDER HEAD Fig 50 Cylinder Head Gasket Alignment 4 Install the push rods and rocker levers 5 Us...

Page 1174: ...to identify their position 3 Compress the valve spring and remove the valve stem collets Fig 52 4 Release valve spring and remove the retainer and spring Fig 52 5 Remove the remaining collets retainers springs and valves Keep the valves in a labeled rack 6 Remove the valve stem seals Fig 52 Fig 52 Valve Removal INSTALLATION 1 Clean all cylinder head components before assembling 2 Install the valve...

Page 1175: ...he gear housing cover bolts to 24 N m 18 ft lbs torque 7 Remove the alignment installation tool Always use a seal pilot when you install a seal 8 Apply a bead of Loctite 277 to the outside diameter of the seal Install the pilot from the seal kit onto the crankshaft Install the seal onto the pilot and start into the gear housing cover Remove the pilot 9 Use the alignment installation tool and a pla...

Page 1176: ...r driven accessories 5 Install the gear housing cover refer to Gear Housing Cover Installation for the proper proce dures 6 Install the front end components 7 Install the engine assembly into the vehicle TIMING PIN The timing pin can be replaced without removing the assembly from the gear housing REMOVAL 1 Remove the timing pin by prying the retaining ring out with a small screwdriver Replace the ...

Page 1177: ...rew for the No l intake valve to zero lash plus 5 turns CAUTION Use extreme care when rotating the crankshaft Use of too much force could damage the valve or push rod Fig 63 7 Rotate the crankshaft slowly in the opposite direction of normal engine rotation until the piston touches the intake valve Fig 63 8 Mark the vibration damper at the wire pointer Fig 63 9 Rotate the crankshaft in the directio...

Page 1178: ...1 Temporarily install the vibration damper and a fabricated wire pointer Fig 66 Put a flat washer between the pointer and gear housing to prevent damage to the gear housing Fig 68 Fabricated Wire Pointer 2 Fabricate a steel plate Fig 67 3 Use two flywheel housing bolts to assemble the plate over No l cylinder Fig 68 50 8 mm Fig 67 Fabricated Steel Plate Fig 68 Fabricated Plate Location on NoJ Cyli...

Page 1179: ...No l bore is the same as for the other bores without bushings The limit of the inside diameter is 54 133 mm 2 1312 inch If the camshaft bore for the first cam bushing is worn beyond the limit install a new service bushing Inspect the rest of the camshaft bores for damage or excessive wear 2 If the bores without a bushing are worn beyond the limit the engine must be removed for machining and instal...

Page 1180: ...mbly Drive belt Push rods Rocker lever assemblies Valve covers 7 Install the engine in the vehicle 8 Operate the engine at idle for five to ten min utes and check for leaks and loose parts BACKLASH 0 080 0 330 mm 0 003 0 013 inch CLEARANCE C U 5 2 0 2 5 4 mm 0 006 0 010 inch Fig 73 Camshaft Backiash and End Clearance TAPPET REMOVAL 1 Remove the camshaft 2 Insert a trough the full length of the cam...

Page 1181: ...urs pull the trough out enough to allow the tap pet to drop down and align itself Now pull the tap pet up Into the bore carefully 9 After the tappet has been pulled up into posi tion slide the trough back into the cam bore and rotate it 1 2 turn This will position the round side of the trough up which will hold the tappet in place J 9 1 0 9 1 5 5 Fig 76 insert installation Tool into Tappet TAPPET ...

Page 1182: ... does not make a deep cut into the bore DO NOT remove more metal than is necessary to remove the ridge 5 If cylinders have ridges the cylinders are over size and will need boring 6 Use a hammer and a steel stamp to mark the cylinder number onto each connecting rod cap Mark the cylinder number onto the top of each piston 7 Remove the connecting rod bolts and rod caps Use care so the cylinder bores ...

Page 1183: ...e caps are installed If the crankshaft does not rotate freely check the installa tion of the rod bearing and the bearing size 12 Measure the side clearance between the con necting rod and the crankshaft Fig 82 DO NOT measure the clearance between the cap and crank shaft J9109 86 SIDE CLEARANCE LIMITS MIN 0 100 mm 0 004 inch MAX 0 300 mm 0 012 inch Fig 82 Side Ciearance between Connecting Rod Crank...

Page 1184: ... Make sure the saddle surface is clean and dry Install the upper main bearings Fig 86 Piston Cooling Nozzles 3 Install the combination thrust main bearing in the number six main bearing location 4 Lubricate the bearings with Lubriplate 105 or equivalent WARNING TO AVOID INJURY USE A HOIST TO INSTALL THE CRANKSHAFT 5 Install the crankshaft CAUTION Crankshaft must be lowered onto the bearings straig...

Page 1185: ... seal face 180 apart 4 Use a slide hammer tool with a 10 metal screw Pull alternating from side to side until the seal is free INSTALLATION 1 The sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks 2 If the gear cover was replaced use the align ment tool from the seal kit to make sure the cover is aligned with the crankshaft 3 Apply a bead of Loctite 277 to th...

Page 1186: ... the 12 3 6 and 9 o clock posi tions to drive the seal evenly and prevent bending the seal housing CRANKSHAFT REAR SEAL HOUSING REMOWAL 1 Remove the rear seal housing and gasket Fig 93 2 Support the seal area of the rear seal housing and press drive out the seal using a hammer and a pin pinch 3 Clean the rear seal housing Fig 92 Seal Installation using Alignment Tool Fig 93 Crankshaft Rear Seal Ho...

Page 1187: ...m the flywheel Fig 19 Strike the gear at several points around the wheel until it Is off 6 Heat the new ring for 20 minutes in an oven preheated to 1 2 7 C 250 F 5JL DIESEL ENGINE 9 197 Fig 96 Crankshaft Rear Seal Alignment installation Tool 7 Install the gear The gear must be installed so the bevel on the teeth is towards the crankshaft side of the flywheel Fig 97 Fig 97 Flywheel Ring Gear Positi...

Page 1188: ...Fig 99 INSTALLATION 1 Lubricate the pump with clean engine oil Fill ing the pump with clean engine oil during installa tion will help to prime the pump at engine start up Make sure the idler gear pin is installed in the locating bore in the cylinder block 2 Install the pump Tighten the oil pump mount ing bolts in two steps and in the sequence shown Fig 99 Fig 99 Oil Pump Removal Step 1 Tighten to ...

Page 1189: ...or Spring Check INSTALLATION 1 Clean and inspect the plunger bore and seat before assembly The plunger must move freely in the valve bore 2 Install the valve spring gasket and plug Tighten the plug to 80 N m 60 ft lbs torque DISASSEMBLY A N D ASSEMBLY ROCKER LEVERS DISASSEMBLE 1 Remove the retaining rings and thrust washers Fig 105 2 Remove the rocker levers Fig 105 DO NOT disassemble the rocker l...

Page 1190: ...push rod sockets with clean engine oil 8 Make sure the rocker lever adjusting screws are completely backed out PISTON AND CONNECTING ROD ASSE1BLY DISASSEMBLE 1 Remove the retainer rings from the piston Fig 106 2 Remove the piston pin Heating the piston is not required 3 Remove the piston rings Fig 106 ASSEMBLE 1 Be sure the FRONT marking on the piston and the numbers on the rod and cap are oriente...

Page 1191: ...ol ring groove bottom groove 9 Install the oil control ring with the end gap OPPOSITE the ends on the expander Fig 111 10 Install the intermediate piston ring in the sec ond groove Fig 109 11 Install the top piston ring in the top groove Fig 112 12 Position the rings as shown in Fig 113 O I L C O N T R O L Fig 111 Oil Control Ring Expander Location in Groove Fig 112 Piston Ring installation Tool F...

Page 1192: ...ylinder Block Check the top surface for damage caused by the cylinder head gasket leaking between cylinders Inspect the block and head surface for nicks ero sion etc Check the head distortion Fig 116 The distortion of the combustion deck face is not to exceed 0 010 mm 0 0004 inch in any 50 8 mm 2 00 inch diame ter Overall variation end to end or side to side 0 30 mm 0 012 inch DO NOT proceed with ...

Page 1193: ...wire wheel Mark the valve with the number noted above Polish the valve stems with crocus cloth Inspect for abnormal wear on the valve heads and stems Replace badly worn valves Check for bent valves Replace bent valves Measure the valve stem diameter Fig 118 The valve stem diameter should be 7 935 7 960 mm 0 3126 0 3134 inch If out of limits replace the valve Mark the new valves with the replacemen...

Page 1194: ...the spring VALVE SEATS INSPECTION Cylinder head with Integral valve seats can be ground only once Previously ground integral seats must be replaced with service seats One X stamped into the head casting identify seats that have been ground previously Fig 122 Two X s stamped on the head indicate service seats have been installed Fig 122 Service seats can be ground Fig 122 Reworked Cylinder Head Sea...

Page 1195: ...alve lobes Fig 125 OIL PUMP CLEAN AND INSPECT Visually inspect the lube pump gears for chips cracks or excessive wear Remove the back plate Fig 126 Mark T O P on the gerotor planetary using a felt tip pen Fig 126 Remove the gerotor planetary Fig 126 Inspect for excessive wear or damage Clean all parts in solvent and dry with compressed air Inspect the pump housing and gerotor drive for damaged and...

Page 1196: ... 0 015 inch If the backlash is out of limits replace the oil pump OIL PUMP J9109 24 Fig 130 Measure Gear Backlash Install the back plate CYLINDER BLOCK 1 Remove the engine assembly from the vehicle 2 Remove the cylinder head from the block 3 Remove the camshaft 4 Remove the piston connecting rod assemblies INSPECTION Measure the combustion deck face using a straight edge and a feeler gauge Fig 131...

Page 1197: ...CAUTION DO NOT use bead blast to clean the pistons DO NOT clean the pistons and rods in an acid tank Soak the pistons in cold parts cleaner Soaking the pistons overnight will usually loosen the carbon deposits Wash the pistons and rods in a strong solution of laundry detergent and hot water Clean the remaining deposits from the ring grooves with the square end of a broken ring DO NOT use a ring gr...

Page 1198: ...re Fig 137 The maximum diameter is 40 025 mm 1 5758 inch If the bore is over limits replace the piston Inspect the piston pin for nicks gouges and exces sive wear Measure the pin diameter Fig 138 The mini mum diameter is 39 990 mm 1 5744 inch If the diameter is out of limits replace the pin Inspect the rod for damage and wear The I Beam section of the connecting rod cannot have dents or other dama...

Page 1199: ...ming pin after locating top dead center Refer to TIMING PIN for more information Fig 140 Locating TDC using Timing Pin Adjust the valves when the engine is cold below 60 C 140 F STEP 1 Adjust the clearance for the valves shown in Fig 141 The valve lash adjustment is 0 254 mm 0 010 inch for the intake valve The valve lash adjustment is 0 508 mm 0 020 inch for the exhaust valve Tighten the valve adj...

Page 1200: ...in 2 6855 in Machined 1 00 mm 67 962 mm 0 0394 in 2 6757 in Out of Round Max 0 050 mm 0 002 in Taper Max 0 013 mm 0 0005 in Oil Clearance 0 089 mm 0 0035 in End Clearance 0 100 0 430 mm 0 004 0 017 in BR Crankshaft Cont Gear Backlash 0 080 0 330 mm 0 003 0 03 in Cylinder Block Cylinder Bore Diameter 102 116 mm 4 0203 in Out of Round Max 0 038 mm 0 0015 in Taper Max 0 076 mm 0 003 in Tappet Bore Di...

Page 1201: ...101 880 101 823 mm 4 0110 4 0088 in Ring Groove Depth Intermediate 0 150 mm 0 006 in Oil Control 0 130 mm 0 005 in 5 9L DIESEL ENGINt Piston Pins Diameter Min 39 990 mm 1 5744 in Bore Diameter Max 40 025 mm 1 5758 in Piston Rings Ring End Gap Top Ring 0 400 0 700 mm 0 016 0 0275 in Intermediate Ring 0 250 0 550 mm 0 010 0 0215 in Oil Control Ring 0 250 0 550 mm 0 010 0 0215 in Valves Clearance Int...

Page 1202: ... 15 ft lbs 45 ft lbs 88 ft lbs 129 ft lbs 66 ft lbs 89 ft lbs 32 ft lbs 42 ft lbs 18 ft lbs 57ft lbs 7 ft lbs 95 in lbs 101 ft lbs 57ft lbs 50 ft lbs 140ft lbs 30 ft lbs 59 ft lbs 18ft lbs 18ft lbs 18ft lbs DESCRIPTION TORQUE Intercooler Attaching Bolts Intercooler Duct Clamp Nuts 2N m 8 N m Lifting Bracket Rear 77 N m I Cooler Assembly I Fill Tube Bracket Bolt I Filter I Pan Drain Plug I Pan Bolt...

Page 1203: ...m must be properly aligned to prevent stress leakage and body contact If the sys tem contacts any body panel it may amplify objec tionable noises from the engine or body When inspecting an exhaust system critically inspect for cracked or loose joints stripped screw or page EXHAUST PIPE DIESEL 12 EXHAUST TAILPIPE 6 EXHAUST TAILPIPE DIESEL 13 HEAT SHIELDS DIESEL 13 INTAKE MANIFOLD COVER AIR INTAKE H...

Page 1204: ...eded to protect both the vehicle and the environment from the high tem peratures developed by the catalytic converter The combustion reaction facilitated by the catalyst soiine Engines Typical releases additional heat in the exhaust system Under severe operating conditions the temperature increases in the area of the reactor Such conditions can exist when the engine misfires or otherwise does not ...

Page 1205: ...ir flows back into the intake man ifold The charge air cooler Intercooler is a heat exchanger that uses air flow to dissipate heat from the intake air As the turbocharger increases air pressure the air temperature increases Lowering the intake air temperature increases engine effi ciency and power Diesel Engines Typical INTAKE MANIFOLD V 6 and V 8 ENGINES The aluminum intake manifold is a single p...

Page 1206: ...e intake manifold J9211 3 INTAKE MANIFOLD DIAGNOSIS An intake manifold leak is characterized by lower than normal manifold vacuum Also one or more cyl inder may not be fuctioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine allowing it to warm up 2 Inspect for disconected vacuum hoses ...

Page 1207: ...d 8 0L 4 Disconnect the catalytic converter from the support hanger on the 3 9L 5 2L and 5 9L Light Duty engines Fig 3 5 Remove the catalytic converter INSTALLATION 1 Connect the support hanger on the 3 9L 5 2L and 5 9L Light Duty engines Fig 3 2 Assemble converter and clamps loosely to per mit proper clearance with exhaust heat shields and underbody parts 3 Tighten all clamp nuts to 43 N m 32 ft ...

Page 1208: ...ig 9 Extension Pipe INSTALLATION 1 Loosely assemble exhaust tailpipe and exten sion pipe if used to permit proper alignment of all parts 2 Connect the support hangers Fig 8 Fig 9 3 Position the exhaust tailpipe and extension pipe if used for proper clearance with the underbody parts 4 Tighten all clamp nuts to 43 N m 32 ft lbs torque 5 Lower the vehicle 6 Start the engine and inspect for exhaust l...

Page 1209: ...manifold upside down Sup port the manifold b Remove the bolts and lift the pan off the manifold Discard the gasket INSTALLATION 1 Install the plenum pan if removed as follows a Turn the intake manifold upside down Sup port the manifold b Place a new plenum pan gasket onto the seal rail of the intake manifold Position the pan over the gasket Align all the gasket and pan holes with the intake manifo...

Page 1210: ... manifold bolts and tighten as follows a V 6 ENGINE Fig 14 Step 1 Tighten bolts 1 and 2 to 8 N m 72 in lbs torque Tighten in alternating steps 1 4 N m 12 in lbs torque at a time Step 2 Tighten bolts 3 through 12 in sequence to 8 N m 72 in lbs torque Step 3 Check that all bolts are tighten to 8 N m 72 in lbs torque Step 4 Tighten all bolts in sequence to 16 N m 12 ft lbs torque Step 5 Check that al...

Page 1211: ... Group 7 Cooling System for the proper procedures 3 Remove the accessory drive belt refer to Group 7 Cooling System for the proper procedures 4 Remove the generator brace and generator Fig 16 5 Remove the A C compressor brace Fig 16 Remove the compressor and set aside 6 Remove the air cleaner cover and filter Remove the air cleaner housing Fig 17 Discard the gasket 7 Perform the Fuel System Pressu...

Page 1212: ...s in place inspect to make sure seals and gaskets are in place Finger start all the lower intake bolts 5 Tighten the lower intake manifold bolts in sequence to 54 N m 40 ft lbs torque Fig 19 INTAKE MANIFOLD GASKET SEALANT J9409 65 Fig 20 Lower Intake Manifold Gaskets LOCATOR DOWELS INTAKE MANIFOLD GASKETS LOCATOR DOWELS J9409 64 Fig 21 Intake Manifold Flange Gasket Alignment 6 Using a new gasket p...

Page 1213: ... precau tion is not taken 1 Position the engine exhaust manifolds on the two studs located on the cylinder head Install coni cal washers and nuts on these studs Fig 22 Fig 23 2 Install two bolts and conical washers at the inner ends of the engine exhaust manifold outboard arms Install two bolts WITHOUT washers on the center arm of engine exhaust manifold Fig 22 Fig 23 Starting at the center arm an...

Page 1214: ...the exhaust pipe to turbocharger exhaust pipe Fig 25 4 Remove the clamp nuts 5 Disconnect the exhaust pipe support hanger INSTALLATION 1 Connect the exhaust pipe support hangers 2 Align the exhaust pipe with the turbocharger exhaust pipe and the catalytic converter Install the bolts and nuts Tighten the nuts to 34 N m 25 ft lbs torque HEATED OXYGEN SENSOR WIRE SPRINGS 9411 18 Fig 25 Exhaust Pipe M...

Page 1215: ... assemble exhaust tailpipe and exten sion pipe if used to permit proper alignment of all parts HANGER Fig 28 Exhaust Tailpipe HD 2 Connect the support hangers 3 Position the exhaust tailpipe and extension pipe if used for proper clearance with the underbody parts 4 Tighten all clamp nuts to 43 N m 32 ft lbs torque 5 Lower the vehicle 6 Start the engine and inspect for exhaust leaks and exhaust sys...

Page 1216: ...er Apply anti seize to the studs and then tighten the turbocharger mounting nuts to 32 N m 24 ft lbs torque 3 Position the charge air cooler intercooler inlet duct to the turbocharger With the clamp in position tighten the clamp nut to 8 N m 72 in lbs torque 4 Position the air intake pipe and the exhaust pipe onto the turbocharger Tighten the clamps to 8 N m 74 in lbs torque 5 Install the oil drai...

Page 1217: ... a new gasket install the intake manifold cover 2 Connect the air temperature switch to the intake manifold cover 3 Connect the charge air temperature sensor to the intake manifold cover 4 Some of the intake manifold bolt holes are drilled through and must be sealed Apply liquid teflon sealant to the bolts Install the intake manifold cover bolts Tighten the bolts to 24 N m 18 ft lbs torque 5 Insta...

Page 1218: ...ing studs Fig 37 Air Cooler Intercooler inlet Duct 2 Install the turbocharger Tighten the turbo charger mounting nuts to 32 N m 24 ft lbs torque 3 Use a new gasket and connect the drain line Tighten the drain line connection bolts to 24 N m 18 ft lbs torque 4 New turbocharger must be pre lubricated with clean engine lubricating oil before start up Pour 50 60 cc 2 3 ounces of oil into supply fittin...

Page 1219: ...age apply air pres sure to the actuator to release the spring tension on the lever Remove the control rod from the wastegate lever Fig 40 Pull the wastegate lever toward the actuator closed position 4 Adjust the length of the clevis end of the con trol rod to align the clevis pin hole to the wastegate lever Install the adjusting link and retaining clip Fig 40 CAUTION DO NOT pull push or force the ...

Page 1220: ...em refer to Group 24 Heating and Air Conditioning for the proper procedures 4 Install the front support bracket Install and tighten the bolts 5 Install the grille refer to Group 23 Body for the proper procedure C L E A N I N G A N D I N S P E C T I O N EXHAUST PIPE INSPECTION Discard rusted clamps broken or worn supports and attaching parts Replace a component with orig inal equipment parts or equ...

Page 1221: ...ed CATALYTIC CONVERTOR INSPECTION Look at the stainless steel body of the catalytic inspect for bulging or other distortion that could be a result of overheating If the catalytic has a heat shield attached make sure it is not bent or loose WARNING UNLEADED FUEL MUST BE USED TO PREVENT BLOCKAGE OR CONTAMINATION TO THE CATALYST CORE If you suspect internal damage to the catalyst tap ping the bottom ...

Page 1222: ... Fig 45 Pull the wastegate lever toward the actuator closed position 4 Adjust the length of the clevis end of the con trol rod to align the clevis pin hole to the wastegate lever Install the adjusting link and retaining clip Fig 45 CAUTION DO NOT pull push or force the align ment of the clevis pin 5 After the adjustment is complete tighten the actuator rod j a m nut 6 Recheck the travel on the was...

Page 1223: ...alytic Converter Clamp Nuts Exhaust Pipe to Exnaust Manifold Bolts Nuts Fuel Heater Ground Bolt Fuel Line Nuts 23 N m 200 in lbs 14N m 10ft lbs 24N m 18ft lbs 43 N m 32 ft lbs 43 N m 32 ft lbs 43 N m 32 ft lbs 26 N m 19 ft lbs 12 N m 110 in lbs 24 N m 18 ft lbs Intake Manifold Capbolts Intake Manifold Cover Bolts Intercooler Attaching Bolts Intercooler Duct Clamp Nuts Refer to Procedure in Service...

Page 1224: ......

Page 1225: ... fastener is designed for the specific frame coating Refer to the Torque Specifications Chart at the end of each group to determine the correct torque value page FRONT BUMPER LOWER FASCIA 2 FRONT BUMPER UPPER FASCIA 1 FRONT BUMPER 1 REAR BUMPER 3 R E M O V A L AMD I N S T A L L A T I O N FRONT BUMPER REMOVAL 1 Support front bumper on a suitable lifting device 2 Remove bolt holding front bumper bra...

Page 1226: ...s holding end of upper fascia to bumper face bar Fig 3 3 Disengage clips holding lower fascia to bumper face bar 4 Separate lower fascia from bumper B R INSTALLATION Reverse the preceding operation J9413 2 Fig 3 Front Bumper Lower Fascia FRONT BUMPER AIR 0AM REMOVAL 1 Remove Pin type fasteners holding air dam to bottom of front bumper Fig 4 2 Remove screws holding air dam to bottom of front bumper...

Page 1227: ...Front Bumper Air Dam REAR BUMPER REMOVAL 1 Support rear bumper on a suitable lifting device 2 Remove bolts holding rear bumper braces to frame rails Fig 5 3 Disengage license plate lamp wire connector from body wire harness if equipped 4 Separate rear bumper from vehicle INSTALLATION Reverse the preceding operation Fig 5 Rear Bumper ...

Page 1228: ...orrect torque value GENERAL INFORMATION BR trucks have a ladder type frame Fig 1 with Box section front rails dropped center section and open channel side rails in the rear Cross members attached to the frame side rails with rivets welds or bolts form a ladder type con struction Fig 1 The cab is isolated from the frame with rubber load cushions Fig 2 with through bolts The cargo box or bed is atta...

Page 1229: ...round riveted cross members and frame side rails is not recommended A straightening repair process should be limited to frame members that are not severely damaged The replacement bolts nuts and rivets that are used to join the frame members should conform to the same specifications as the original bolts nuts and rivets FRAME REPAIRS DRILLING HOLES Do not drill holes in frame side rail top and bot...

Page 1230: ...SE SKID PLATE REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove bolts holding skid plate to frame rails Fig 6 Fig 5 Cab Chassis Adapter Bracket Rear 3 Separate skid plate from vehicle INSTALLATION 1 Position skid plate on vehicle 2 Install bolts holding skid plate to frame rails 3 Remove safety stands and lower vehicle Fig 6 Skid Plate SPARE TIRE WINCH REMOVAL 1 Remove spare tire from ...

Page 1231: ...ler hitch from vehicle INSTALLATION 1 Position trailer hitch on vehicle 2 Install the bolts holding trailer hitch to frame rails and remove lifting device 3 Install fasteners holding trailer wiring connec tor to trailer hitch if equipped S P E C I F I C A T I O N S VEHICLE DIMENSIONS Frame dimensions are listed in inch scale All dimensions are from center to center of Principal Locating Point PLP ...

Page 1232: ...801834a6 Fig 9 Frame Dimensions m 39 ...

Page 1233: ...NER OF OPENING 8031586c Fig 10 Body Dimensions Front View LH SIDE VIEW A Centerline of A P i l l a rgaging holetocenterline of seat belt retractor hole at B P i l l a r B Centerline of radius at rear lower door opening flange inner edge to center of radius at cowl flange edge C Centerline of radius at front lower door opening flange inner edge to center of radius at upper opening rear flage inner ...

Page 1234: ...5 8 6 e Fig 12 Body Dimensions Ciub Cab REAR VIEW A B Center of radius at top corner to center of radius at lower corner of glass mounting flange C Lower edge of upper back glass mounting flange to upper edge of lower back glass mounting flange measurement taken at centerline of rear glass opening TORQUE SPECIFICATIONS WAX COATED FRAME DESCRIPTION TORQUE Cab Chassis adapter nut 108 N m 80 ft lbs F...

Page 1235: ...ion pump The 3 9L 5 2L 5 9L LDC gas engines or the diesel engine will not use an air injection pump The Fuel System consists of the fuel tank an electric fuel tank mounted fuel pump gas powered engines a fuel injection pump diesel engine a mechanical fuel transfer lift pump diesel and a fuel filter It also consists of fuel tubes lines hoses and fittings vacuum hoses throttle body and fuel injector...

Page 1236: ...TBE Gaso line and ETBE Ethyl Tertiary Butly Ether are blends of gasoline and up to 17 percent ETBE Gas oline blended with MTBE or ETBE may be used in your vehicle Many gasolines are now being blended that con tribute to cleaner air especially in those areas of the country where pollution levels are high These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoli...

Page 1237: ...on control system This is designed to reduce the emission of fuel vapors into the atmo sphere The description and function of the Evapora tive Control System is found in Group 25 Emission Control Systems page FUEL SYSTEM PRESSURE RELEASE PROCEDURE WITH PRESSURE TEST PORT 8 FUEL TUBES LINES HOSES AND CLAMPS 10 QUICK CONNECT FITTINGS 10 REMOVAL AND INSTALLATION ACCELERATOR PEDAL 21 FUEL FILTER FUEL ...

Page 1238: ...monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity This switch is mounted in the fuel reservoir within the fuel pump module FUEL FILTER FUEL PRESSURE REGULATOR A combination fuel filter and fuel pressure regula tor is used on all engines It is pressed into a rubber grommet located on the top of the fuel pump module Fig 3 A separate frame mounted fuel ...

Page 1239: ...lly in a sequential order by the powertrain control module PCM The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off Injector pulse width is the period of time that the injector is energized The PCM will adjust injector pulse width based on various inputs it receives FUEL INJECTORS 8 0L ENGINE The fuel injectors are attached to the fuel rail F...

Page 1240: ...se are a single tab type a two tab type or a plastic retainer ring type Some are equipped with safety latch clips Refer to the Removal Installation section for more information CAUTION The interior components o rings spac ers of quick connect fitting are not serviced sepa rately but new pull tabs are available for some types Do not attempt to repair damaged fittings or fuel lines tubes If repair i...

Page 1241: ...DISCONNECTING FUEL LINE AT FUEL RAIL THIS PRESSURE MUST BE RELEASED REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1 Release fuel pressure Refer to the Fuel System Pressure Release Procedure Without Pressure Test Port 2 Disconnect latch clip and fuel line at fuel rail Refer to Quick Connect Fittings for procedures This can be found in this section of the group 3 Connect adapter tool number 69...

Page 1242: ...tain engines only If equipped the test port will be located on the fuel rail near the throttle position SPACER J9414 58 Fig 10 Fuel Injector Internal Components Typical sensor Fig 7 A sealing cap is screwed onto the test port The fuel system is under constant fuel pressure even with the engine off WARNING BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE THE PRES SURE MUST BE RELEASED BEFORE...

Page 1243: ...CE FUEL RAIL IF VISUALLY PLUGGED OR RESTRICTED AT INJECTOR DELIVERY COUPLING REPLACE INJECTOR N O TEST THE INJECTOR RESISTANCE USING A N OHMMETER ACROSS THE INJECTOR TERMINALS WITH THE INJECTOR CONNECTOR REMOVED PLACE A 12 VOLT TEST LAMP ACROSS THE INJECTOR ELECTRICAL CONNECTOR TERMINALS OBSERVE THE TEST LAMP WHILE CRANKING THE ENGINE CIRCUIT IS OK CHECK FOR FUEL DELIVERY AT SUSPECT INJECTOR BY RE...

Page 1244: ... CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSES FIT TINGS OR LINES THE FUEL SYSTEM PRESSURE MUST BE RELEASED REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP leaks are not present The component should be replaced immediately if there is any evidence of deg radation that could result in failure Never attempt to repair a plastic fuel line tube Rep...

Page 1245: ...PONENT QUICK CONNECT FITTING QUICK CONNECT FITTING J 9 4 1 4 2 5 Fig 12 Disconnecting Single Tab Type Fitting 6 Raise the pull tab until it separates from the quick connect fitting Fig 13 Discard the old pull tab 7 Disconnect the quick connect fitting from the fuel system component being serviced 8 Inspect the quick connect fitting body and fuel system component for damage Replace as necessary FUE...

Page 1246: ...er will remain on the component being serviced If this retainer must be removed very carefully release the retainer from the component with two small screwdrivers After removal inspect the retainer for cracks or any dam age 6 Prior to connecting the quick connect fitting to component being serviced check condition of fitting and component Clean the parts with a lint free cloth Lubricate them with ...

Page 1247: ... rail on certain engines Fig 16 A special tool will be necessary to separate the fuel line from the fuel rail after the latch clip is removed DISCONNECTION CONNECTION AT FUEL RAIL 1 Disconnect the negative battery cable from bat tery 2 Perform the fuel pressure release procedure Refer to the Fuel Pressure Release Procedure in this section 3 Clean the fitting of any foreign material before disassem...

Page 1248: ...nto the fuel rail 10 Install latch clip with fingers down snaps into position The fingers should protrude below the fuel rail if properly installed Fig 20 If the latch clip will not fit this indicates the fuel line is not properly installed to the fuel rail Recheck the fuel line connection 8031e888 Fig 20 Latch Clip Installation 11 Verify a locked condition by firmly pulling on fuel line and fitti...

Page 1249: ... the fuel pump module is ser viced the locknut and gasket must be replaced 1 Drain the fuel tank Refer to Draining Fuel Tank in the Fuel Tank section of this group 2 Remove fuel tank Refer to the Fuel Tank sec tion of this group 3 The plastic fuel pump module locknut is threaded onto the fuel tank Fig 22 Install Special Tool 6856 to the fuel pump module locknut and remove locknut Fig 24 The fuel p...

Page 1250: ... connecting hose Fig 25 Due to the design of this connecting hose it does use any clamps Never attempt to install a clamping device of any kind to the hose When removing the fuel rail assembly for any reason be careful not to bend or kink the connecting hose REMOVAL 1 Remove negative battery cable at battery 2 Remove air cleaner 3 Perform the fuel pressure release procedure 4 Remove throttle body ...

Page 1251: ... Mounting Typical PLIERS J9414 156 Fig 30 Injector Retaining Clips Typical Injector 2 Install injector s and injector clip s to fuel rail 3 Position the fuel rail fuel injector assembly to the injector openings on the intake manifold 4 Guide each injector into the intake manifold Be careful not to tear the injector o ring 5 Push the right fuel rail down until fuel injec tors have bottomed on injec...

Page 1252: ...et 8 0L V 10 Engine 6 Remove upper half of intake manifold Refer to Group 11 Exhaust System and Intake Manifold for procedures 7 Disconnect electrical connectors at all fuel injectors The factory fuel injection wiring harness is numerically tagged INJ 1 INJ 2 etc for injector position identification 8 Disconnect main fuel line at fuel rail On the 8 0L V 10 engine the fuel line to fuel rail connect...

Page 1253: ... To release fuel pressure refer to the Fuel System Pressure Release Procedure To remove one or more fuel injectors the fuel rail assembly must be removed from engine REMOVAL 1 Remove air cleaner assembly 2 Remove fuel injector rail assembly Refer to Fuel Injector Rail removal in this section 3 Remove the clip s retaining the injector s to fuel rail Fig 29 or Fig 30 4 Remove injector s from fuel ra...

Page 1254: ...er to Quick Connect Fittings for procedures 7 Place a transmission jack under the center of the fuel tank Apply a slight amount of pressure to fuel tank with transmission jack WARNING WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE 8 Remove the fuel tank mounting strap nuts at the mounting straps Fig 36 I f equipped remove the fuel tank heat shield bolts Fig 36 F U E L R E T U R N A N...

Page 1255: ...accelerator pedal or cables 1 From inside the vehicle hold up the accelerator pedal Remove the plastic cable retainer and throttle cable core wire from upper end of pedal arm Fig 37 The plastic cable retainer snaps into pedal the arm 2 Insert a small screwdriver into the square holes located on the pivots bushings Fig 38 Twist the screwdriver to disengage the pivot locks from the pivot pin Pivots ...

Page 1256: ...ne Remove the throttle cable socket at throttle lever ball Fig 40 snaps off 8 3 9L 5 2L 5 9L Engines Slip the cable end rearward from pin on throttle body Fig 39 Fig 39 Throttle Cable at Throttle Body 3 9U5 2U 5 9L Engines Typical 9 Remove cable housing at throttle body mount ing bracket by pressing on release tab with a small screwdriver Fig 41 or Fig 40 To prevent cable housing breakage press on...

Page 1257: ...index slot on the plastic cable retainer to this Index tab S P E C I F I C A T I O N S VECI LABEL SPECIFICATIONS If anything differs between the specifications found on the Vehicle Emission Control Information VECI label and the following specifications use specifica tions on VECI label The VECI label is located in the engine compartment FUEL TANK CAPACITY Models Liters U S Gallons 118 Wheelbase 9...

Page 1258: ...ENSOR 02S 8 0L MDC ENGINES PCM INPUT 33 HEATED OXYGEN SENSOR 02S HDC ENGINES PCM INPUT 33 IDLE AIR CONTROL IAC MOTOR 3 9L 5 2L 5 9L ENGINES PCM OUTPUT 39 IDLE AIR CONTROL IAC MOTOR 8 0L ENGINE PCM OUTPUT 39 IGNITION CIRCUIT SENSE PCM INPUT 34 IGNITION COILS 8 0L ENGINE PCM OUTPUTS 40 IGNITION COIL 3 9L 5 2L 5 9L ENGINES PCM OUTPUT 40 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 3 9L 5 2L 5 9L ENGINES PC...

Page 1259: ...mission control devices charging system speed con trol air conditioning compressor clutch engagement AIR CLEANER HOUSING AIR CLEANER ELEMENT FILTER 8 0L V 10 ENGINE 64 AUTOMATIC SHUTDOWN ASD RELAY 57 CAMSHAFT POSITION SENSOR 62 CRANKSHAFT POSITION SENSOR 62 DUTY CYCLE EVAP CANISTER PURGE SOLENOID 3 9L 5 2L 5 9L ENGINES 61 DUTY CYCLE EVAP CANISTER PURGE SOLENOID 8 0L ENGINE 61 ENGINE COOLANT TEMPER...

Page 1260: ... width This is done to achieve optimum fuel economy combined with low emission engine performance BR The fuel injection system has the following modes of operation Ignition switch 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 deceleration and wide open...

Page 1261: ...ignal if equipped Air conditioning request signal if equipped Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Camshaft position sensor signal in the distribu tor Battery voltage Park neutral switch gear indicator signal auto trans only Oxygen sensors Based on these...

Page 1262: ...applied to the fuel injectors with the powertrain control module PCM The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individ ual injector on and off The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel This is done by adjusting injector pulse width The PCM adjusts ignition timing by tur...

Page 1263: ...ol module PCM contains a voltage convertor This converts battery voltage to a regulated 5 0 volts It Is used to power the crankshaft position sensor camshaft position sensor and vehicle speed sensor The PCM also provides a five 5 volt supply for the manifold absolute pressure MAP sen sor and throttle position sensor TPS AIR CONDITIONING A C CONTROLS PCM INPUT The A C control system information app...

Page 1264: ... ertrain control module PCM receives an input indi cating that the brakes are being applied After receiving this input the PCM maintains idle speed to a scheduled rpm through control of the idle air con trol IAC motor The brake switch input is also used to operate the speed control system CAMSHAFT POSITION SENSOR 3 9L 5 2L 5 9L ENGINES PCM INPUT A sync signal is provide by the camshaft position se...

Page 1265: ...ders The sensor is bolted to the side of the cylinder block Fig 6 Fig Crankshaft Position Sensor 8 0L Engine Typical Refer to Group 8D Ignition System for more crankshaft position sensor Information The engine will not operate if the PCM does not receive a crankshaft position sensor input ENGINE COOLANT TEMPERATURE SENSOR 3 9L 5 2L 5 9L ENGINES PCM INPUT The engine coolant temperature sensor is in...

Page 1266: ... other inputs and adjusts the injector pulse width accordingly During Open Loop operation the PCM ignores the 02 sensor input The PCM adjusts injector pulse width based on preprogrammed fixed values and inputs from other sensors The Automatic Shutdown ASD relay supplies bat tery voltage to both the upstream and downstream heated oxygen sensors The oxygen sensors are equipped with a heating element...

Page 1267: ...n sensors The oxygen sen sors are equipped with a heating elements The heating elements reduce the time required for the sensors to reach operating temperature Pig 10 Left Right Heated Oxygen Sensors HDC Engines HEATED OXYGEN SENSOR 02S 8 0L I D C ENGINES PCM INPUT The 8 0L V 10 engine when equipped with a Medium Duty Emission Cycle MDC package will use four heated 02S sensors They are Left right ...

Page 1268: ...en the catalytic converter efficiency drops below emission standards the PCM stores a diagnostic trouble code and illuminates the Malfunction Indica tor Lamp MIL For more information refer to Group 25 Emission Control Systems IGNITION CIRCUIT SENSE PCM INPUT The ignition circuit sense input tells the Power train Control Module PCM the ignition switch has energized the ignition circuit Refer to the...

Page 1269: ...xture The MAP sensor is mounted on the side of the engine throttle body Fig 15 The sensor is con nected to the throttle body with a rubber L shaped fitting MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 8 0L ENGINE PCM INPUT The MAP sensor reacts to absolute pressure in the intake manifold It provides an input voltage to the powertrain control module PCM As engine load changes manifold pressure varies The ...

Page 1270: ...ortional to the transmission governor pressure It provides feedback for control of the variable force solenoid which regulates transmis sion governor pressure This input is used with 4 speed electronic transmissions only TRANSMISSION TEMPERATURE SENSOR PCM INPUT This input is used in the shift operation for 4 speed electronic transmissions only The tempera ture data is used for torque converter cl...

Page 1271: ...is received by the PCM but a speed sensor signal is not received Under deceleration conditions the PCM adjusts the idle air control IAC motor to maintain a desired MAP value Under idle conditions the PCM adjusts the IAC motor to maintain a desired engine speed POWER GROUND The power ground is used to control ground cir cuits for the following powertrain control module PCM loads Generator field win...

Page 1272: ...data link connector Fig 20 is located at lower edge of instrument panel near steering column For operation of the DRB scan tool refer to the appropri ate Powertrain Diagnostic Procedures service man ual 18 WAY DATA LINK CONNECTOR 805dd852 Fig 20 16 Way Data Link Connector DUTY CYCLE EVAP PURGE SOLENOID VALVE PCM OUTPUT Refer to Group 25 Emission Control System for information FUEL INJECTORS 3 9L 5...

Page 1273: ...rtrain control module PCM regulates the charging system voltage within a range of 12 9 to 15 0 volts Refer to Groups 8A and 8C for charging system information GENERATOR LAMP PCM OUTPUT If the powertrain control module PCM senses a low charging condition in the charging system it will illuminate the generator lamp if equipped on the instrument panel For example during low idle with all accessories ...

Page 1274: ...nitial ignition timing is not adjustable The PCM adjusts ignition timing to meet changing engine operating conditions The ignition coil is located near the front of the right cylinder head Fig 26 Refer to Group 8D Ignition System for additional information VACUUM FITTING PASSAGE CONTROL IAC MOTOR VIEW FROM BOTTOM l Q A A A Q Fig 25 Idle Air Control Passage 8 0L Engine Fig 26 Ignition Coil 3 9U5 2U...

Page 1275: ...Emission Control System for more information OVERDRIVE LAMP PCM OUTPUT This circuit controls a signal for the operation of the instrument panel mounted push button overdrive lamp switch When the lamp is illuminated the over drive is disengaged SPEED CONTROL SOLENOIDS PCM OUTPUT Speed control operation is regulated by the power train control module PCM The PCM controls the vacuum to the throttle ac...

Page 1276: ...e ignition switch is turned on and it is turned off when the engine is started up With the engine run ning the lamp is turned ON OFF depending upon engine speed and load TRANSMISSION R E L A Y P C I OUTPUT The output to this relay provides battery voltage to the overdrive OD torque converter clutch TCC and variable force VSS solenoids Once battery volt age Is applied to the solenoids they are Indi...

Page 1277: ... 82 Throttie Body 8 0L Engine The throttle position sensor TPS and idle air con trol IAC motor are attached to the throttle body The accelerator pedal cable speed control cable and transmission control cable when equipped are con nected to the throttle arm A factory adjusted set screw is used to mechani cally limit the position of the throttle body throttle plate Never attempt to adjust the engine...

Page 1278: ...irmly connected to the generator 7 Inspect the system body grounds for loose or dirty connections Refer to Group 8 Wiring for ground locations 8 Verify positive crankcase ventilation PCV valve operation Refer to Group 25 Emission Control System for additional information Verify PCV valve hose is firmly connected to PCV valve and manifold Fig 37 Fig 37 PCV Valve Hose Connections 3 9U5 2U 5 9L Engin...

Page 1279: ...Injector number INJ 1 INJ 2 etc of its corresponding fuel injector and cylinder number 18 Verify harness connectors are firmly con nected to idle air control IAC motor throttle posi tion sensor TPS and manifold absolute pressure MAP sensor Fig 40 19 Verify that wire harness connector is firmly connected to the engine coolant temperature sensor Fig 42 Fig 42 Engine Coolant Temperature Sensor 3 9U 5...

Page 1280: ...t fuel pump gauge sender unit wire connector is firmly connected to harness connector 28 Inspect fuel hoses at fuel pump gauge sender unit for cracks or leaks 29 Inspect transmission torque convertor housing automatic transmission or clutch housing manual SENSOR ELECTRICAL CONNECTOR J9414 60 Fig 45 Vehicle Speed Sensor Typical transmission for damage to timing ring on drive plate flywheel 30 Verif...

Page 1281: ...se control cable con nections if equipped Check their connections to the throttle arm of throttle body for any binding or restrictions 12 If equipped with vacuum brake booster verify that vacuum booster hose is firmly connected to fit ting on intake manifold Also check connection to brake vacuum booster 13 Inspect the air cleaner inlet and air cleaner element for dirt or restrictions 14 Inspect ra...

Page 1282: ...ytic convertor 25 If equipped with automatic transmission ver ify that electrical harness is firmly connected to park Fig 52 Left Right Oxygen Sensors POST CATALYST PRE CATALYST OXYGEN OXYGEN SENSOR K SENSOR 805dd850 Fig 53 Pre Catalyst Post Catalyst Oxygen Sensors neutral switch Refer to Automatic Transmission section of Group 21 26 Verify that the electrical harness connector is firmly connected...

Page 1283: ...Fig 55 Power Distribution Center Terminal number 30 is connected to battery volt age and can be switched or B hot at all times The center terminal number 87A is connected a circuit is formed to terminal 30 in the de energized normally OFF position Terminal number 87 is connected a circuit is formed to terminal 30 in the energized ON posi tion Terminal number 87 then supplies battery volt age to th...

Page 1284: ...e relay If tests passed refer to Group 8W Wir ing Diagrams for fuel system relay wiring schemat ics and for additional circuit information MANIFOLD ABSOLUTE PRESSURE MAP SENSOR TEST 3JL I 2L 5JL ENGINES To perform a complete test of MAP sensor Fig 57 and its circuitry refer to DRB scan tool and appro priate Powertrain Diagnostics Procedures manual To test the MAP sensor only refer to the following...

Page 1285: ...e speed condition CAVITY FUNCTION 1 5 Volt Supply 2 Sensor Ground 3 Map Sensor Signal 805dd851 Fig 61 MAP Sensor Connector Terminals 8 0L Engine 2 Test powertrain control module PCM cavity A 27 for the same voltage described above to verify the wire harness condition Repair as necessary 3 Test MAP sensor supply voltage at sensor con nector between terminals 1 and 2 Fig 61 with the ignition ON The ...

Page 1286: ...ading HEATED OXYGEN 02S SENSORS 8 OL HDC MDC ENGINES To perform a complete test of the 02S sensors and their circuitry refer to the DRB scan tool and appro priate Powertrain Diagnostics Procedures manual To test the 02S sensors only refer to the following A total of 4 oxygen sensors left right pre catalyst and post catalyst are used with the 8 0L engine when equipped with the Medium Duty Emission ...

Page 1287: ...EMPERATURE RESISTANCE OHMS C F mm MAR 40 291 490 381 710 20 4 85 850 108 390 10 14 49 250 61 430 0 32 29 330 35 990 10 50 17 990 21 810 20 68 11 370 13 610 25 77 9 120 10 880 30 86 7 370 8 750 40 104 4 900 5 750 50 122 3 330 3 880 60 140 2 310 2 670 70 158 1 630 1 870 80 176 1 170 1 340 90 194 860 970 100 212 640 720 110 230 480 540 120 248 370 410 J928D 4 SENSOR RESISTANCE OHMS COOLANT TEMPERATUR...

Page 1288: ...nostics Proce dures manual To test the sensor only refer to the following 1 Disconnect the wire harness connector from the intake manifold air temperature sensor Fig 68 or Fig 69 2 Test the resistance of the sensor with an input impedance digital volt ohmmeter The resistance as measured across the sensor terminals should be less than 1340 ohms with the engine warm Refer to the Coolant Temperature ...

Page 1289: ...cedures manual To test the TPS only refer to the following The TPS can be tested with a digital voltmeter The center terminal of the TPS is the output termi nal Fig 71 With the ignition key in the ON position check the TPS output voltage at the center terminal wire of the connector Check this at idle throttle plate closed and at wide open throttle WOT At idle TPS output voltage should must be grea...

Page 1290: ...ol number 6714 into the disconnected vacuum line in place of the PCV valve Fig 74 5 Disconnect the idle purge vacuum line from fit ting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor Fig 75 Cap the fitting at throttle body after vac uum line has been removed FRONT OF ENGINE THROTTLE BODY J9414 6 Fig 75 Idle Purge Line 6 Connect the DRB scan tool t...

Page 1291: ...engine idle speed using this screw All idle speed functions are controlled by the powertrain control module PCM REMOVAL 1 Remove the air cleaner 2 Disconnect throttle body electrical connectors at MAP sensor IAC motor and TPS Fig 77 3 Remove vacuum line at throttle body 4 Remove all control cables from throttle body lever arm Refer to the Accelerator Pedal and Throt tle Cable section of this group...

Page 1292: ...ottle body to intake manifold 4 Install four mounting nuts Tighten nuts to 22 N m 192 in lbs torque 5 Install control cables 6 Install electrical connectors 7 Install air cleaner housing to throttle body 8 Install 4 air cleaner housing mounting nuts Tighten nuts to 11 N m 96 in lbs torque 9 Install air cleaner housing cover THROTTLE POSITION SENSOR TPS 3 9L 5 2L 5 9L ENOINES REMOVAL The TPS is loc...

Page 1293: ...he throttle shaft on the other side of the socket tangs The TPS will be under slight tension when rotated 1 Install the TPS and two retaining bolts 2 Tighten bolts to 7 N m 60 In lbs torque Fig 83 Installation Typical Mounting 3 Manually operate the throttle control lever by hand to check for any binding of the TPS 4 Connect TPS electrical connector to TPS 5 Install air cleaner housing to throttle...

Page 1294: ...o connect the MAP sensor to throttle body Fig 86 REMOVAL The throttle body must be removed from the intake manifold for MAP sensor removal 1 Remove air cleaner assembly Fig 86 MAP Sensor L Shaped Rubber Fitting 8 9U 5 2U5 9L Engines 2 Remove throttle body Refer to Throttle Body removal in this section 3 Remove two MAP sensor mounting bolts screws Fig 86 4 While removing MAP sensor slide the vacuum...

Page 1295: ...rness at solenoid Fig 88 4 Remove solenoid and its support bracket from intake manifold 5 Remove EVAP canister purge solenoid from engine INSTALLATION 1 Install EVAP canister purge solenoid and its mounting bracket to intake manifold 2 Connect vacuum harness and wiring connector 3 Install air cleaner housing DUTY CYCLE EWAP CANISTER PURGE SOLENOID 8 J L ENGINE The solenoid is located at the rear o...

Page 1296: ...r damage Repair as necessary 4 Install three 32 way connectors 5 Install battery cable CRANKSHAFT POSITION SENSOR Refer to Group 8D Ignition System for removal In stallation procedures CAMSHAFT POSITION SENSOR For removal installation procedures refer to Group 8D Ignition System See Camshaft Position Sensor OXYGEN SENSORS 3 9L 5 2L 5 9L LDC HDC ENGINES On 3 9L 5 2L 5 9L LDC engines the upstream an...

Page 1297: ...OVING OXYGEN SENSOR 1 Raise and support the vehicle 2 Disconnect the wire connector from the 02S sensor Fig 94 Left Right Oxygen Sensor Location All 8 0L Engines CAUTION When disconnecting the sensor electri cal connector do not pull directly on wire going into sensor 3 Remove the 02S sensor Snap On oxygen sen sor wrench number YA 8875 may be used for removal and installation INSTALLATION Threads ...

Page 1298: ...ile guiding the rubber grommet over the mounting stud The lower part of the screw clamp should be below the top lip of the throttle body 12 Push down on air cleaner housing at rubber grommet to seat housing at intake manifold 13 Tighten throttle body to air cleaner housing clamp to 4 N m 35 In lbs torque 14 Install the air inlet tube at air cleaner hous ing inlet AIR CLEANER HOUSINI AIR CLEANER EL...

Page 1299: ...bricate an L shaped hook tool from a coat hanger approximately eight inches long Place the hook part of tool under the connector for removal The connector is snapped onto the sensor It is not equipped with a lock type tab 5 Remove sensor from intake manifold Fig 99 Engine Coolant Temperature Sensor 3 9U 5 2U5 9L Engines Typical INSTALLATION 1 Install sensor 2 Tighten to 11 N m 8 ft lbs torque 3 Co...

Page 1300: ...lectrical connector at sensor Fig 101 or Fig 102 3 Remove sensor from intake manifold Fig 101 Air Temperature Sensor 3 9L V 6 Engine Fig 102 Air Temperature Sensor 5 2L 5 9L V 8 Engines INSTALLATION 1 Install sensor to intake manifold Tighten to 28 N m 20 ft lbs torque 2 Install electrical connector 3 Install air cleaner INTAKE MANIFOLD AIR TEMPERATURE SENSOR 8 0L ENGINE The intake manifold air te...

Page 1301: ...A T I O N S VECi LABEL SPECIFICATIONS If anything differs between the specifications found on the Vehicle Emission Control Information VECI label and the following specifications use specifica tions on VECI label The VECI label Is located in the engine compartment TORQUE SPECIFICATIONS DESCRIPTION TORQUE Air Cleaner Housing Mount Nuts 8 0L Engine 11 N m 96 in lbs Air Cleaner Housing Metal Clamp 3 ...

Page 1302: ...Spanner Wrench 6856 Test Kit Fuel Pressure 5069 Adapters Fuel Pressure Test 654 6539 6631 or Fuel Line Removal Tool 6782 6923 02S Oxygen Sensor Remover Installer G 4907 ...

Page 1303: ...iesel fuel delivery except for operation of the intake manifold air heater and manifold air heater relays is not directly regulated by the PCM The fuel delivery system of the 5 9L turbo diesel engine consists of the page FUEL TRANSFER PUMP PRESSURE CAPACITY TEST 77 HIGH PRESSURE FUEL LINE LEAK TEST 84 IDLE SPEED ADJUSTMENT 85 SERVICE PROCEDURES AIR BLEED PROCEDURE 85 FUEL INJECTION PUMP TIMING 86 ...

Page 1304: ...JECTION PUMP HIGH PRESSURE FUEL LINES INTAKE AIR TEMP SENSOR INTAKE MANIFOLD HIGH PRESSURE FUEL INJECTION PUMP WATER TEMPERATURE SENSOR FOR I P GAUGE FUEL FILTER WATER SEPARATOR THROTTLE POSITION SENSOR AUTO TRANS ONLY FUEL SHUTDOWN SOLENOID OIL PRESSURE SENSOR LEFT SIDE OF ENGINE DRAIN TUBE FUEL WATER SEPARATOR AND DRAIN VALVE RUBBER PRIMER BUTTON FUEL TRANSFER PUMP FUEL LIFT PUMP STARTER MOTOR J...

Page 1305: ...ck is used to send an electrical signal used for fuel gauge operation As the fuel level increases the float and arm move up This decreases the sending unit resistance caus ing the fuel gauge on the instrument panel to read full As the fuel level decreases the float and arm move down This increases the sending unit resis tance causing the fuel gauge on the instrument panel to read empty FUEL HEATER...

Page 1306: ...nt fuel bleed back during engine shut down The fuel transfer pump should never be operated without the pre filter installed The fuel volume of the transfer pump will vary with engine rpm but will always provide more fuel than the fuel injection pump requires Excess fuel is returned to the fuel tank through an overflow valve The valve is located on the side of the injection pump Fig 7 and is used t...

Page 1307: ... from doing so Moisture collects at the bottom of the separator filter The fuel filter water separator is located on the left side of the engine above the starter motor Fig 1 Refer to the maintenance schedules in Group 0 in this manual for the recommended fuel filter water separator replacement intervals For draining of water refer to the Removal Instal lation section of this group See Fuel Filter...

Page 1308: ... high pressure fuel of approximately 120 000 kPa 17 400 psi to each injector in precise metered amounts at the correct time P7100 INLINE FUEL INJECTION PUMP RQV K GOVERNOR J9414 104 Fig 10 Injection Pump Governor and AFC Excess fuel is returned to the fuel tank by an over flow valve Fig 7 on the injection pump This vent opens at approximately 152 kPa 22 psi and returns fuel to the fuel tank throug...

Page 1309: ...h is turned to the CRANK starter engaged position high amperage current approximately 40 amps at 12 volts is supplied to one of the coils in the shutdown solenoid from the fuel shutdown solenoid relay This high amperage current allows the solenoid shaft to pull up on the injection pump lever The injection pump shutdown lever is then positioned to the run position Fig 13 When the ignition key is re...

Page 1310: ...ions Leaking fuel is an indicator of loose connections or defective Fig 15 Fuel Drain Manifold Typical seals Air can also enter the fuel system between the fuel tank and the transfer pump Inspect the fuel tank and fuel lines for damage that might allow air into the system For air bleeding refer to the Air Bleed Procedure FUEL SUPPLY RESTRICTIONS LOW PRESSURE LINES Fuel supply line restrictions or ...

Page 1311: ...he fuel filter water separator is 35 kPa 5 psi As the filter removes contaminants in the fuel the pressure drop across the fuel filter water separator will increase Fre quent replacement of the filter may indicate a worn transfer pump The filter separator can be checked with a fuel pressure gauge For test procedures refer to Fuel Filter Water Separator Tests in this section of the group Refer to G...

Page 1312: ...fuel filter can also cause excess vacuum Repair as necessary 9 Remove vacuum gauge and adapter hose tool FUEL TRANSFER PUMP FUEL HEATER SPECIAL HOSE ADAPTER TOOL 6837 J9514 73 Fig 20 Installing Hose Adapter T FITTING J9514 74 Fig 21 Installing Vacuum Gauge 10 Install rubber fuel hose and clamps between heater and pump FUEL VOLUME TEST Fuel volume versus engme cranking rpm are used for the test WAR...

Page 1313: ...cation To use the chart in Fig 24 refer to the following procedure Draw a straight vertical line at the measured rpm Draw a straight horizontal line at the measured fuel volume If these two lines intersect below the flow line Fig 24 this indicates a defective transfer pump or a line restriction If these two lines intersect above the flow line Fig 24 this indicates acceptable fuel flow ml FLOW UNE ...

Page 1314: ...ne Fig 25 10 Install and tighten special adapter tool 6829 into the top of the fuel outlet line Fig 27 11 Install fuel pressure gauge to adapter tool 6829 Fig 27 12 Start engine and record fuel pressure 13 Compare the 2 pressures It must not exceed 35 kPa 5 psi 14 If pressure specification has been exceeded replace fuel filter and check for line restrictions Fig 26 Installing Special Tools Fig 27 ...

Page 1315: ...llows current to flow to the built in heater element to warm the fuel When the fuel temperature is above 80 degrees F the sensor stops current flow to the heater element circuit is open Voltage to operate the fuel heater element is sup plied from the ignition switch through the fuel heater relay Fig 3 0 also refer to Fuel Heater Relay to the fuel temperature sensor and on to the fuel heater elemen...

Page 1316: ...APPROXIMATELY 120 000 KPA 17 400 PSI TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH PRESSURE LINES FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE THE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH PRESSURE FUEL LINES WARNING DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE DO NOT ALLOW FUEL TO SPRAY ONTO THE...

Page 1317: ...hut off solenoid Fig 33 and fuel shutdown solenoid relay Fig 35 are not controlled by the powertrain control module PCM 1 With the ignition switch off the solenoid shaft should be down and the injection pump lever should be in the shutdown position no fuel supply to injec tion pump Fig 34 2 Turn the ignition switch to the CRANK starter engage position and observe the solenoid shaft and injection p...

Page 1318: ... solenoid is supplied from the ignition switch and through the fuel shutdown solenoid relay The fuel shutdown sole noid relay is located in the engine compartment near the brake master cylinder Fig 35 To test the relay refer to Relays Operation Test ing in this section of the group HIGH PRESSURE FUEL LINE LEAK TEST High pressure fuel line leaks can cause starting problems and poor engine performan...

Page 1319: ...djust high idle speed High idle speed adjustment screw is factory sealed Breaking seal will void injection pump warranty With engine at normal operating temperature Refer to text for idle adjustment procedures r J9414 66 Fig 38 Idle Speeds Diesel Engine SERVICE PROCEDURES AIR BLEED PROCEDURE A certain amount of air becomes trapped in the fuel system when fuel system components are ser viced or rep...

Page 1320: ... FUEL OF AS HIGH AS 120 000 KPA 17 405 PSI TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH PRESSURE LINES FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE TRATE THE SKIN AND CAUSE PERSONAL INJURY WARNING DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE DO NOT ALLOW FUEL TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN BLEEDING AIR FROM THE FUEL SYSTEM Bleed air from one injector at time 1 Loosen the high pres...

Page 1321: ...n the back of the camshaft gear When the barring tool is rotated counterclockwise the vibration damper should be rotating clockwise as viewed from front When the pin aligns to the gear Fig 43 and the intake and exhaust valves are closed at the 1 cylinder the engine is at the TDC position compres sion stroke at cylinder number 1 Place a paint mark on the dampener to indicate TDC Remove the pin This...

Page 1322: ... Fig 48 Delivery Waive Assembly 9 Using a pick remove the metal delivery valve washer Fig 4 9 from the top of the pumping ele ment Be careful not to scratch the top of the plung er barrel assembly during this process Discard the used delivery valve washer A new washer will be used during reassembly J9514 81 Fig 49 Delivery Waive Washer 10 Install the dial indicator adaptor tool 6 8 4 2 Fig 50 in p...

Page 1323: ...is located on the left side of the timing gear cover Fig 52 d Compare these specifications to the Fuel Injection Pump Plunger Lift chart Fig 53 e If specifications match a fuel timing adjust ment will not be necessary Proceed to step 27 f If the specifications do not match a fuel tim ing adjustment will be necessary Proceed to next step FUEL INJECTION PUMP PLUNGER LIFT 49 STATE AUTOMATIC TRANSMISS...

Page 1324: ... Washer Tools 17 Slowly rotate the engine clockwise until reaching the required lift setting on the dial indica tor Refer to Fuel Injection Pump Plunger Lift chart Fig 53 The injection pump should rotate with the engine since the injection pump gear is still locked to the injection pump shaft 18 With the injection pump at the correct plunger lift setting use special gear puller tool L 4407A to pul...

Page 1325: ...e removing Fig 55 24 Remove special bearing and thrust washers 6862 from pump shaft Use a magnet on the end of the shaft while removing 25 While preventing the engine from rotating with the barring tool tighten the shaft nut to 165 N m 122 lb ft torque Fig 61 26 Repeat steps 12 and 13 to verify that the final timing setting is correct If the setting is not correct repeat steps 15 through 25 27 Rem...

Page 1326: ...h pressure line at the injector Start the engine and check for leaks THROTTLE LINKAGE ADJUSTMENT DIESEL ENGINE The linkage rod Fig 65 connecting the throttle lever to the fuel injection pump lever is adjustable CAUTION Before adjusting the fuel injection pump throttle linkage verify that engine is set at correct low idle speed Refer to Idle Speed Adjustment This can be found in the Diesel Engine G...

Page 1327: ...ly the throttle lever to injection pump lever linkage rod should have stopped moving while the throttle lever continues to move towards the rear of vehicle 10 Again check and verify low idle speed Adjust if necessary 11 Diesel engines equipped with an auto matic transmission A throttle position sensor TPS is used with this driveline combination TPS voltage must now be tested Refer to Throttle Posi...

Page 1328: ... side of the engine and below the intake manifold Fig 70 REMOVAL 1 Partially drain the filter separator Refer to the following Draining Water from Filter DRAINING WATEE FROM FILTER The filter should be drained whenever the water in fuel warn ing lamp remains illuminated Note that the lamp will be illuminated for approximately two seconds when the ignition key is initially placed in the ON position...

Page 1329: ...arator If the new fuel filter water separator is not filled with clean fuel before it is installed man ual air bleeding of the fuel system may be nec Fig 73 Fuel Filter Water Separator O ring FUEL FILTER DRAIN VALVE J9414 90 Fig 74 WIF Sensor and Drain Vaive Assembly essary temporary rough engine running may occur i f necessary refer to the Air Bleed Pro cedure i n this section of the group for pr...

Page 1330: ...he fuel tank module Is ser viced the lockout and rubber gasket must be replaced 1 Using a new gasket position the fuel tank module into the opening in fuel tank The fuel line connectors the pressure relief rollover valve and the fuel gauge electrical connector should all be pointed to the drivers side of the vehicle before tightening locknut 2 Position new locknut over top of fuel tank mod ule 3 T...

Page 1331: ...nnect the electrical connector at the relay 3 Remove the relay from the mounting bracket INSTALLATION 1 Install the relay to the mounting bracket 2 Connect the electrical connector 3 Connect battery cables to both batteries FUEL INJECTION P U I P REMOVAL 1 Disconnect both negative battery cables at both batteries 2 Disconnect electrical connector at throttle posi tion sensor on side of injection p...

Page 1332: ...AFC valve at rear of injection pump Fig 83 AIR FLOW CONTROL VALVE Fig 83 Wastegate and Vacuum Lines 11 Remove the fuel supply line at both ends injection pump and fuel filter water separator Fig 84 For procedures refer to Fuel Injection Pump Supply Line in this group Place a rag beneath the fitting to catch excess fuel UPPER PART OF INTAKE MANIFOLD J9414 105 Fig 82 Intake Manifold Air Heater 8 Rem...

Page 1333: ...olders and Pressure Lines 14 Disconnect the engine oil supply line at side of pump Fig 87 Fig 87 Engine Oil Supply Line Pump Mounting Nuts 15 Remove the oil fill tube bracket mounting bolt Fig 88 16 Remove oil fill tube from tube to gear housing adapter Fig 88 Tube is removed by screwing coun terclockwise from adapter Fig 88 Oil Fill Tube Adapter and Mounting Bracket 17 Remove oil fill tube adapte...

Page 1334: ...th the barring tool Rotating the barring tool counter clockwise will rotate the crankshaft clockwise Con tinue to rotate until the timing pin drops into the machined hole in the back of the camshaft gear When the pin aligns to the gear the engine is now at the TDC position compression stroke at cylinder number 1 CAUTION When installing the fuel injection pump and to achieve proper injection pump t...

Page 1335: ...e installing the injection pump be sure that number 1 cylinder is at the Top Dead Cen ter compression stroke position Engage the tim ing pin on the rear of the gear cover Fig 89 into the rear of the camshaft gear Rotate crankshaft if necessary Before injection pump installation it must be set pump shaft rotated to a certain position to attain accurate pump timing Remove the access plug from the si...

Page 1336: ...stall and loosely tighten the J9414 77 Fig 97 injection Pump Timing Tooth access plug New pumps should have been shipped with this tool already engaged 1 If the original pump is being installed check the condition of the rubber o ring at pump mounting area 2 Apply clean engine oil to the injection pump mounting flange opening in gear cover housing to allow easier pump installation Fig 98 Also appl...

Page 1337: ...at TDC of number cylinder 1 b With the timing pin aligned into the rear of the camshaft gear the timing tooth should also be centered in the access hole on the side of the injec tion pump Fig 97 Install timing pin tool Fig 96 to verify c If the timing pin tool will not fit into the tim ing tooth in the pump the pump gear nut must be removed Loosen the pump gear from the pump shaft with the T bar p...

Page 1338: ...ries 2 Remove the high pressure fuel lines Refer to High Pressure Fuel Lines in this section 3 Remove the fuel drain manifold Refer to Fuel Drain Manifold in this section 4 Thoroughly clean the area around the injector CAUTION When rust has formed on the fuel Injec tor nut Fig 99 the injector when being removed can rotate in the cylinder head This may cause damage to the cylinder head bore Use a r...

Page 1339: ...ush the o ring into the groove on the top of the injector 5 Tighten the injector holddown nut to 60 N m 44 ft lbs torque 6 Connect the fuel drain manifold to the injec tors Refer to Fuel Drain Manifold in this section 7 Connect the high pressure fuel lines Refer to High Pressure Fuel Lines in this section Fig 106 Installing Injector 8 Connect the negative battery cables to both batteries 9 Bleed t...

Page 1340: ... 2 Pull up by hand and hold on the solenoid lever Fig 109 If the solenoid is operating cor rectly it should remain in the UP position with the key in the ON position FUEL SHUTDOWN SOLENOID HOLD SOLENOID LEVER IN UP POSITION J9414 81 Fig 109 Fuel Shutdown Solenoid Lever in Up Position 3 Take a measurement from the bottom of the solenoid mounting bracket to the top of the injection pump shutdown lev...

Page 1341: ...EL SYSTEM 14 107 FUEL SHUT OFF FUEL HEATER SOLENOID RELAY Fig 112 Fuel Shutdown Solenoid Relay Diesel The fuel transfer pump is located on the left side of the engine and above the starter motor Fig 113 The mounting bracket spacer for the fuel heater assembly is located between the engine block and the fuel transfer pump Fig 114 The fuel heater hous ing and its bracket assembly must also be remove...

Page 1342: ...hten to 24 N m 18 ft lbs torque 5 Install starter motor Refer to Group 8B for procedures 6 Connect battery cables at both batteries 7 Bleed air from fuel system Refer to the Air Bleed Procedure FUEL TANK PiESSUFtE FtELlEF ROLLOWER W A L W E Refer to Fuel Tank Module for procedures HIGH PRESSURE FUEL LINES All high pressure fuel lines are of the same length and inside diameter Correct high pressure...

Page 1343: ... Loosely install the line clamp isolator and bracket holder bolts 3 Tighten each line at the delivery valve holder to 24 N m 18 ft lbs torque 4 Tighten each line at the fuel injector to 24 N m 18 ft lbs torque CAUTION Be sure the lines are not contacting each other or any other component 5 Tighten the clamp bracket bolts to 24 N m 18 ft lbs torque 6 Bleed air from the fuel system Refer to High Pre...

Page 1344: ...ps into posi tion The two plastic pinch tabs Fig 118 should lock the cable to dash panel 4 From inside the vehicle hold up the accelera tor pedal Install the throttle cable core wire and plastic cable retainer into and through the upper end of the pedal arm the plastic retainer is snapped into the pedal arm When installing the plastic retainer to the accelerator pedal arm note the index tab on the...

Page 1345: ...t Fuel Hose Clamps 1 N m 15 in lbs Fuel Injector Retaining Nut 60 N m 44 ft lbs Fuel Pump Module Locknut 54 N m 40 ft lbs Fuel Tank Mounting Nuts 41 N m 30 ft lbs Fuel Transfer Pump Mounting Bolts 24 N m 18 ft lbs High Pressure Fuel Line F i t t i n g s 24 N m 18 ft lbs High Presure Fuel Line Fitting Clamps 6 N m 4 ft lbs injector Pump Access Plug 15 N m 11 ft lbs injection Pump to injection Pump ...

Page 1346: ...l l cover a description and operation of components controlled by the page TRANSMISSION GOVERNOR PRESSURE SENSOR PCM INPUT 118 TRANSMISSION TEMPERATURE SENSOR PCM INPUT 117 TRANSMISSION TEMPERATURE WARNING LAMP PCM OUTPUT 121 VEHICLE SPEED SENSOR AND DISTANCE PCM INPUT 118 WAIT TO START LAMP WARNING LAMP PCM OUTPUT 121 WATER IN FUEL SENSOR PCM INPUT 119 WATER IN FUEL WARNING L A M P PCM INPUT 119 ...

Page 1347: ...artment Fig 1 It is mounted to the dash panel cowl with three bolts The PCM was formerly referred to as the SBEC or engine controller Except for operation of the intake manifold air heater elements the PCM does not regulate or control fuel system operation on the diesel engine The PCM is a pre programmed dual micro proces sor digital computer Although it does not regulate or control the fuel syste...

Page 1348: ...equest signal The PCM will then remove the ground from the A C relay deactivating the A C compressor clutch AUTOMATIC SHUTDOWN ASD SENSE PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated The ASD relay is located in the power distribution center PDC The PDC is located in the engine compartment For the location of the relay within the PDC refer to PDC cove...

Page 1349: ... Intake Manifold Air Heater Relays for additional information INTAKE MANIFOLD AIR HEATER The intake manifold air heater element assembly is located in the top of the intake manifold Fig 4 The air heater is used to heat incoming air to the intake manifold to help engine starting and improve driveability with cool or cold outside temperatures Two heavy duty cables Fig 5 connect the 2 air heater elem...

Page 1350: ...he engine has yet to be started Post heat is the amount of time the relay circuits are activated after the engine is operating The wait to start warning lamp is tied to this cir cuit Lamp operation is also controlled by the PCM The wait to start warning lamp will not be illumi nated during the post heat cycle The relays are not energized during engine crank ing When initially energized they will m...

Page 1351: ... imately 56 km h to 137 km h 35 to 85 mph Inputs that effect speed control operation are Brake switch position Park neutral switch Vehicle speed sensor Engine speed sensor Throttle position sensor auto trans only Refer to Group 8H for further speed control infor mation PARK NEUTRAL POSITION SWITCH PCM INPUT The park neutral switch provides an input to the powertrain control module PCM This will in...

Page 1352: ...or control of the variable force solenoid which regulates transmis sion governor pressure This input is used with 4 speed electronic transmissions only VEHICLE SPEED SENSOR AND DISTANCE PCM INPUT The speed sensor Fig 10 is located in the exten sion housing of the transmission 2WD or on the transfer case extension housing 4WD The sensor input is used by the powertrain control module PCM to determin...

Page 1353: ...ter in fuel indicator lamp to the ON position if water is detected in the fuel The water in fuel indicator lamp is located in the instru ment panel Fig 12 The lamp will illuminate for about two seconds each time the ignition key is ini tially turned to the ON position as a bulb check Also refer to Water In Fuel Sensor PCM Input for additional information AIR CONDITIONING CLUTCH RELAY PCM OUTPUT Th...

Page 1354: ...mediate need for service The lamp can also be used to display a diagnostic trouble code DTC Cycle the ignition switch On Off Fig 15 Check Engine Lamp Typical Location On Off On within three seconds and any codes stored in the PCM memory will be displayed This is done in a series of flashes representing digits Refer to On Board Diagnostics in the General Diagnosis section of this group for more inf...

Page 1355: ...on The lamp will illuminate for about two seconds each time the ignition key is initially turned to the ON position as a bulb check This feature is used with certain heavy duty auto matic transmissions only Also refer to Transmission Temperature Sensor PCM Input for additional information INSTRUMENT Fig 17 Transmission Temperature Warning Lamp Typical Location WAIT TO START LAMP WARNING LAMP PCM O...

Page 1356: ...sion or dam aged wires The sensor is located on the top of the intake manifold Fig 20 6 Verify that the water in fuel WIF sensor elec trical connector is firmly attached to the sensor Fig AIR TEMPERATURE SENSOR SENSOR ELECTRICAL CONNECTOR INTAKE MANIFOLD p u E L UPPER HALF SHUTDOWN SOLENOID SOLENOID ELECTRICAL CONNECTOR J9414 93 Fig 20 Air Temperature Sensor and Fuel Shutdown Solenoid 21 Inspect t...

Page 1357: ...ical connection at the trans mission temperature sensor Fig 23 TEMPERATURE SENSOR J9414 46 Fig 23 Transmission Temperature Sensor Location Typical 19 Automatic Transmission Only Be sure the electrical connector is firmly connected to the plug leading to the overdrive solenoid in the transmission AUTOMATIC SHUTDOWN ASD RELAY TEST To perform a complete test of the ASD relay and its circuitry refer t...

Page 1358: ... TEST The intake manifold air heater Fig 26 is con trolled by the powertrain control module PCM through the intake manifold air heater relays Fig 27 This is done after a specified signal is sent to the PCM from the intake manifold air temperature sen sor Two heating elements are located within the air heater assembly A separate heavy duty cable is con nected to a separate terminal to supply power ...

Page 1359: ...st before replacing heater If resistance is now anything other than zero 0 proceed to next step 4 Disconnect both cables from the intake mani fold heater two nuts Fig 26 5 Measure the resistance from each of the air heater terminal threaded studs to a ground The resistance should be zero 0 If the ohmmeter is still reading anything other than zero 0 replace the intake manifold air heater elements T...

Page 1360: ...hart Fig 30 Replace the sensor if it is not within the range of resistance spec ified in the chart 3 Test the resistance of the wire harness Do this between the powertrain control module PCM wire harness connector terminal B l and the sensor con nector terminal Also check between PCM terminal A 4 to the sensor connector terminal Repair the wire harness as necessary if the resistance is greater tha...

Page 1361: ...ing nuts finger tight 2 Route sensor wiring harness behind engine pul leys Install and tighten wiring harness clip bolts Fig 33 Engine Speed Sensor Installation 3 Place the feeler gauge between the sensor and the vibration dampener 4 Gently seat push down the sensor until it con tacts the feeler gauge Be sure the sensor is not near either of the notches Fig 32 on the vibration damper If sensor is ...

Page 1362: ...osition Do not start engine 5 The voltage at the TPS center terminal should be 1 0 volt 2 volt with linkage at idle position At CENTER REAR FACE OF BALL OF BRACKET J9414 68 Fig 35 Linkage Measurement Diesel wide open throttle WOT the output voltage must be 2 2 to 2 9 volts higher than at idle speed If volt age is not correct proceed to adjusting linkage 6 The linkage rod Fig 36 connecting the thro...

Page 1363: ...negative battery cable at bat tery Fig 37 PCM Location and Mounting 2 Carefully unplug the three 32 way connectors from PCM 3 Remove three PCM mounting bolts and remove PCM from vehicle INSTALLATION 1 Install PCM and mounting bolts to vehicle 2 Tighten bolts to 4 N m 35 in lbs 3 Check pin connectors in the PCM and the three 32 way connectors for corrosion or damage Repair as necessary 4 Install th...

Page 1364: ...etest after the element has dried REMOVAL INSTALLATION 1 Loosen the air inlet tube clamp at air cleaner housing inlet Fig 38 Remove this tube at air cleaner housing cover 2 The housing cover is equipped with four 4 spring clips Fig 38 and is hinged at the front with plastic tabs Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and forward for cover removal 3 Remo...

Page 1365: ...trigger wires at both relays Fig 42 Note the position of wiring before removing 3 Lift the four rubber shields from the four cables Fig 42 4 Remove the four nuts at the cable connectors Fig 42 Note the position of wiring before removing 5 Remove the three relay mounting bracket bolts Fig 42 and remove relay assembly INSTALLATION 1 Install the relay assembly to the inner fender Tighten mounting bol...

Page 1366: ... 4 Connect electrical connector to sensor WATER IN FUEL SENSOR The water in fuel sensor is located at the bottom of the fuel filter water separator Refer to Fuel Filter Water Separator in this section of the group for removal and installation procedures S P E C I F I C A T I O N S ENGINE DATA PLATE SPECIFICATIONS If anything differs between the specifications found on the Engine Data Plate and the...

Page 1367: ...E CAUSES CORRECTION OBJECTIONAL HISS OR WHISTLE 1 Damaged steering coupler to dash panel seal 2 Noisy valve in power steering gear 1 Check and repair seal at dash panel 2 Replace steering gear RATTLE OR CLUNK 1 Gear mounting bolts loose 1 Tighten bolts to specification 2 Loose or damaged suspension components 3 Loose or damaged steering linkage 4 Internal gear noise 5 Pressure hose in contact with...

Page 1368: ...ect and lubricate steering and suspension compnents 5 Test and repair as necessary 6 Test and repair as necessary STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Tire pressure 2 Wheel alignment 3 Lack of lubrication 4 High friction in steering gear 1 Adjust tire pressure 2 Align front end 3 Inspect and lubricate steering and suspension compnents 4 Test and repair as necessary LOOSE STE...

Page 1369: ... pulley that is belt driven by the crankshaft pulley Trailer tow option vehicles are equipped with a power steering pump oil cooler The oil cooler is mounted to the radiator support NOTE Power steering pumps are not interchange able with pumps installed on other vehicles Fig 1 Saginaw Pump P Series D I A G N O S I S A N D T E S T I N G POWER STEERING PUMP FLOW RATE AND PRESSURE TEST The following ...

Page 1370: ... M 3 9L 1400 to 1500 2 4 to 2 8 5 2L 1400 to 1500 2 4 to 2 8 5 9L 1400 to 1500 2 7 to 3 1 8 0L 1450 to 1550 3 1 to 3 5 5 9L Diesel 1400 to 1500 2 7 to 3 1 PUMP LEAKAGE DIAGNOSIS S E R V I C E P R O C E D U R E S POWER STEERING PUMP INITIAL OPERATION CAUTION The fluid level should be checked with engine off to prevent injury from moving compo nents Use MOPAR Power Steering Fluid or equiva lent Do n...

Page 1371: ...REMOVAL AND INSTALLATION Continued PUMP LEAKAGE STEERING 19 5 J9419 33 ...

Page 1372: ...s to the pump 7 Install the serpentine drive belt refer to Group 7 Cooling for belt routing 8 Fill the reservoir with power steering fluid refer to Pump Initial Operation POWER STEERING PUIVSP DIESEL ENGINE REMOVAL 1 Remove and cap steering pump hoses and vac uum pump vacuum line 2 Remove the sender unit from engine block and plug hole in block Fig 5 P U M P E N G I N E B L O C K Fig 5 Oil Pressur...

Page 1373: ...spacers must mate completely with the vacuum pump bracket Fig 8 Bracket Mounting Nuts PUMP SHAFT VACUUM PUMP BRACKET SPACERS J9119 69 Fig 9 Steering Pump Vacuum Pump 3 Install the vacuum pump bracket to steering pump nuts and tighten to 24 N m 18 ft lbs 4 Position new gasket on vacuum pump assem bly Use sealer if necessary to retain the gasket 5 Align and install the pump assembly on the engine En...

Page 1374: ...aligned with the pump shaft 3 Install pump assembly 4 With Serpentine Belts Run engine until warm 5 min and note any belt chirp If chirp exists move Fig 11 Pulley Installation pulley outward approximately 0 5 mm 0 0 2 0 in If noise increases press on 1 0 mm 0 040 in Be care ful that pulley does not contact mounting bolts P SERIES PUIP RESERW01R REMOVAL NOTE Discard all O ring seals during disassem...

Page 1375: ...ON Reservoir Bolts 56 N m Flow Control Valve 75 N m Pressure Line 31 N m Oil Cooler Bolt 20 N m Pump Mounting 3 9L 5 2L 5 9L Bracket to Pump 47 N m Bracket to Engine 41 N m Pump Mounting 8 0L Rear Bracket to Pump 47 N m Rear Bracket to Front Bracket 24 N m Bracket to Engine 41 N m Pump Mounting Diesel Pump to Vacuum Pump 24 N m Pump Assembly to Engine 77 N m Pump to Support Bracket 24 N m TORQUE 4...

Page 1376: ...9 10 STEERING SPECIAL T O O L S POWER STEERING PUMP Analyzer Set Power Steering Plow Pressure 6815 Puller C 4333 Adapters Power Steering Flow Pressure Tester 6893 Installer Power Steering Pulley C 4063 B ...

Page 1377: ...n 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 the rack piston moves The rack pis ton teeth mesh with the pitman shaft Turning the worm shaft turns the pitman shaft which turns the steering linkage The steering gear can be adjusted but it is serviced as an assembly no internal parts are serviced D I A G N O ...

Page 1378: ... SEAL REPLACE THE SEAL J9219 29 STEERING J9419 20 Fig 1 Coiumn Shaft A D J U S T H E I f Y S STEERING GEAR CAUTION Steering gear m u s t be adjusted in the p r o p e r order If a d j u s t m e n t s are not performed in o r d e r gear damage a n d improper steering response may result NOTE Adjusting the s t e e r i n g gear in the vehicle is n o t recommended R e m o v e gear from the vehicle Fig ...

Page 1379: ...erclockwise 13 mm 0 50 in and mark housing Fig 5 5 Rotate adjustment cap back counterclockwise with spanner wrench until hole is aligned with the second mark Fig 6 Fig 5 Remarking The Housing FIRST MARK J9219 30 Fig 6 Aligning To The Second Mark 6 Install and tighten locknut to 108 N m 80 ft lbs Be sure adjustment cap does not turn while tightening the locknut OVER CENTER 1 Rotate the stub shaft f...

Page 1380: ...t lbs S P E C I F I C A T I O N S POWER STEERING GEAR SPECIFICATION Steering Gear Type Recirculating Ball Gear Code Ratio BN 17 5 1 HF 16 13 1 Wormshaft Bearing Preload 0 45 1 13 N m 10 15 in lbs Pitman Shaft Overcenter Drag New Gear under 400 miles 0 45 0 90 N m 6 10 in lbs Wormshaft Preload Used Gear over 400 miles 0 5 0 6 N m 4 5 in lbs Wormshaft Preload TORQUE CHART DESCRIPTION TORQUE Steering...

Page 1381: ...SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE REMOVE OR INSTALL page STEERING COLUMN 16 SPECIFICATIONS TORQUE CHART 18 THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY U...

Page 1382: ...e fit over the length of the slot If the slider binds in the slot at any point lightly file the slider until clearance is achieved WARNING WHEN A STEERING COLUMN HAS AN AIRBAG MODULE ATTACHED NEVER PLACE THE COLUMN ON THE FLOOR OR OTHER SURFACE WITH THE STEERING WHEEL OR MODULE FACE DOWN CAUTION Bumping jolting and hammering on steering column shaft and gear shift tube must be avoided during servi...

Page 1383: ...Install the ground clip on the left spacer slot 4 Install column through floor pan 5 Position the column bracket shear pins on the attaching studs Install but loose assemble the two upper bracket nuts 6 With the front wheels in the straight ahead position Align steering column shaft to the coupler Install pinch bolt and tighten to 49 N m 36 ft lbs 7 Clip the wiring harness on the steering column C...

Page 1384: ... socket 2 Using a drift of the appropriate size drive the roll pin out of the steering column and gear shift lever Remove the gear shift lever from the steering column assembly INSTALLATION 1 Support the steering column using a suitable size socket 2 Install the gear shift lever into the steering col umn assembly Align the roll pin holes in the gear shift lever and the steering column assembly 941...

Page 1385: ...INKAGE Before removing any steering component the boot seals should be closely inspected for damage If a seal is damaged it should be replaced Before installing a new seal inspect ball stud Replace ball stud if worn and lubricate the ball studs with MOPAR Multi Mile age Lubricant or an equivalent ...

Page 1386: ...orque Specifications Chart at the end of each group to determine the correct torque value IPS STEERING LINKAGE Standard and heavy duty steering linkage is used with IFS suspensions Fig 1 Heavy duty linkage is used on 8 800 and 10 500 GVW vehicles Vehicles with 10 500 GVW rating have a steering damper mounted from a frame bracket to the centerlink R E M O V A L AMD I N S T A L L A T I O N STEERING ...

Page 1387: ...g knuckles and tighten nuts to 88 N m 65 ft lbs Install new cotter pins 8 Remove the supports and lower the vehicle to the surface Center steering wheel and adjust toe refer to the Alignment Specifications chart within Group 2 Front Suspension NOTE Position the clamp on the sleeve so retain ing bolt is located on the bottom side of the sleeve 9 After adjustment tighten the tie rod adjust ment slee...

Page 1388: ...is designed for the specific frame coating Refer to the Torque Specifications Chart at the end of each group to determine the correct torque value LINK COIL STEERING LINKAGE The steering linkage is comprised of a tie rod end tie rod drag link steering damper and pitman arm Fig 1 R E M O V A L A N D I N S T A L L A T I O N STEERING LINKAGE NOTE When servicing the steering linkage use care to avoid ...

Page 1389: ... 65 ft lbs Install new cotter pins 5 Install steering damper on drag link and tighten nut to 68 N m 50 ft lbs Install new cotter pin 6 Remove the supports and lower the vehicle to the surface Center steering wheel and adjust toe refer to Group 2 Suspension 7 After adjustment tighten tie rod adjustment sleeve clamp bolts to 54 N m 40 ft lbs NOTE Position the clamp on the sleeve so retain ing bolt i...

Page 1390: ......

Page 1391: ...e transmission gears all rotate on caged type needle bearings The NV3500 has a single shaft shift mechanism The three shift forks are all mounted on a one shift shaft The shaft is supported in the front and rear housings by bushings and one bearing Internal shift components consist of the forks shaft shift lever socket and detent components Fig 2 page TRANSMISSION 4WD 6 DISASSEMBLY AND ASSEMBLY TR...

Page 1392: ......

Page 1393: ...ow available The original wide ratio version introduced last year has a 4 01 first gear and 2 318 second gear The new close ratio N V 3 5 0 0 has a 3 49 first gear and 2 16 second gear WIDE RATIO VERSION RANGE RATIO FIRST 4 016 1 SECOND 2 318 1 THIRD 1 401 1 FOURTH 1 1 FIFTH 0 729 1 REVERSE 3 55 1 DIAGNOSIS A N D TESTING NV3500 TRANSMISSION LOW LUBRICANT LEVEL A low transmission lubricant level is...

Page 1394: ...xtended period the first indi cations of a problem are usually hard shifting and noise Incorrect or contaminated lubricants can also con tribute to hard shifting The consequence of using non recommended lubricants is noise excessive wear internal bind and hard shifting Improper clutch release is a frequent cause of hard shifting Incorrect adjustment or a worn damaged pressure plate or disc can cau...

Page 1395: ...on to jack with safety chains 20 Remove nuts bolts attaching transmission front housing to engine 21 Move transmission rearward until clear of engine Then lower jack and remove transmission from under vehicle 22 Remove transmission from jack and position transmission on workbench 23 If transmission will be overhauled remove release bearing and fork from front housing 24 If shift lever extension is...

Page 1396: ...erify that all linkage components hoses and electrical wires have been connected 19 Remove any remaining support stands and lower vehicle 20 Install crankshaft position sensor 21 Connect battery negative cable 22 Apply Mopar Gasket Maker or Loctite 518 to mounting surface of shift tower isolator plate and transmission case 23 Install isolator plate on shift tower or rear case Then install shift to...

Page 1397: ...ousing Move cylinder aside for working clearance 21 Remove clutch housing dust cover 22 On some models it may be necessary to remove front axle struts and oil filter for access and removal clearance Remove these components if nec essary 23 Support transmission with transmission jack Secure transmission to jack with safety chains 24 Remove bolts attaching transmission clutch housing to engine block...

Page 1398: ...ect exhaust system compo nents Be sure exhaust components are clear of all chassis and driveline components 20 Align and install front and rear propeller shafts Tighten U joint clamp bolts to 19 N m 170 in lbs torque 21 Verify that all linkage components hoses and electrical wires have been connected 22 Check transfer case fluid level Add Mopar Dexron II or ATF Plus if necessary Correct level is t...

Page 1399: ...Fig 11 Backup Light Switch Location 4 Remove shift tower bolts and remove tower and lever assembly Fig 12 Use 8 mm socket to tower remove bolts 5 If isolator and plate assembly came off shift tower during removal remove plate assembly from rear hous ing Fig 12 Note that plate assembly is one way fit Narrow side of plate goes toward driver side of trans mission and rubber coated side faces upward F...

Page 1400: ...bearing retainer from input shaft Fig 16 Note position of retainer lube channel for instal lation reference SHAFT BEARING BEARING RETAINER 10 Remove snap ring that secures input shaft in front bearing Fig 17 INPUT SHAFT SNAP RING SE HEAVY DUTY PUER TOOL Fig 17 input Shaft Snap Ring Removal 11 Remove shift shaft detent plug Fig 18 Use crowfoot bar and hammer to lightly pry and tap plug out of housi...

Page 1401: ...ig 21 Use plastic mallet to tap front housing off alignment dowels REAR HOUSING 15 Remove input shaft bearing and countershaft front bearing from front case Fig 22 Use hammer handle to tap input shaft bearing out of case Coun tershaft bearing can be removed by hand INPUT SHAFT BEARING COUNTERSHAFT FRONT BEARING J9421 16 Fig 22 Input Shaft And Countershaft Front Bearing Location 16 Note position of...

Page 1402: ...ome completely out of shift shaft it only has to clear shift socket d If roll pin accidentally becomes jammed between gear teeth locking socket and shaft in place proceed to alternate disassembly method in next step 3 If shift socket roll pin becomes jammed alternate disassembly method is as follows a Remove rear bearing retainer bolts b Remove reverse idler segment but leave gear in case c Remove...

Page 1403: ...otate 3 4 fork around syn chro sleeve fork clears shift arms on 1 2 and fifth re verse forks Then remove 3 4 fork Fig 31 3 4 1 2 AND FORK 5TH REVERSE Fig 31 Removing 3 4 Shift Fork 10 Support geartrain and rear housing on Assem bly Fixture Tool 6747 with aid of helper as follows a Adjust height of reverse idler pedestal rod to 18 42 cm 7 1 4 in Then position Adapters 6747 1 and 6747 2 on Assembly ...

Page 1404: ...PECIAL TOOL 6747 J9421 46 Fig 33 Geartrain And Housing Mounted On Fixture Tool 11 Remove bolts attaching reverse idler shaft and shaft support segment to rear housing Fig 34 12 Remove reverse idler shaft support segment by sliding it straight out of housing Fig 35 REVERSE IDLER SHAFT BOLT LOCATIONS SPECIAL TOOL 6747 J9421 47 Fig 34 Removing Installing Reverse Idler Shaft Bolts REVERSE IDLER SHAFT ...

Page 1405: ...alling Output Shaft Bearing Retainer Bolts 2WD 2 Unseat output shaft bearing from bearing bore in rear housing Use plastic or rawhide mallet to tap rear housing upward and off output shaft bearing as shown Fig 37 3 Lift rear housing up and off geartrain Fig 38 4 Remove countershaft rear bearing from rear housing Fig 39 5 Examine condition of oil tube bearing bore and idler shaft notch in rear hous...

Page 1406: ...on slide hammer shaft Fig 40 SIDE SHAFT AfflOWif SOE NUT 5 16x1 V 2 in WBDMIAZE NUT TO J942M99 Fig 40 Rear Seal Remover Tool 4WD 3 Locate dimples in face of rear seal Fig 41 Fabricated seal remover tool will be threaded into one of these dimples 4 Thread fabricated seal remover tool into one of the dimples in the seal face Fig 42 LOCATION OF DIMPLES J942M97 Fig 41 Location Of Dimples In Seal Face ...

Page 1407: ...r surface of fifth gear retainer will drop onto gear after bolts are removed 5 Lift and remove output shaft and gears off input shaft RACE J9421 203 Fig 46 Rear Adapter Extension Housing Components 6 Lift and remove input shaft pilot bearing and fourth gear synchro ring from assembly fixture tool OUTPUT SHAFT GEARTRAIN DISASSEMBLY NOTE The synchronizer hubs and sleeves are dif ferent and must not ...

Page 1408: ...TAINING RING Fig 49 Thrust Washer Retaining Ring Removal 5 Remove two piece thrust washer Fig 50 Note position of washer locating lugs in shaft notches for installation reference SECOND GEAR THRUST WASHER 2 PIECE J9421 24 Fig 50 Two Piece Thrust Washer Removal 6 Remove second gear and needle bearing Fig 51 SECOND GEAR SECOND GEAR NEEDLE BEARING J9421 25 Fig 51 Second Gear And Needle Bearing Remova...

Page 1409: ... Hub And Sleeve Removal 1 2 Synchro 9 Remove first gear and needle bearing Fig 54 SPACER AS REQUIRED PRESS RAM SHAFT BEARING1 FIRST GEAR FIRST GEAR NEEDLE BEARING OUTPUT SHAFT SPECIAL TOOL 1130 Fig 56 Output Shaft Bearing Removal 2WD 12 Remove fifth gear Fig 57 J9421 28 Fig 54 First Gear And Needle Bearing Removal 10 Remove output shaft bearing snap ring Fig 55 OUTPUT SHAFT BEARING SNAP RING PLIER...

Page 1410: ...SPECIAL TOOL 1130 Fig 60 Fifth Reverse Synchro Hub And Sleeve Removal Fig 61 Reverse Gear And Needle Bearing Removal sealers are Mopar Gasket Maker or Loctite 518 for all flange joints and Loctite Ultra heavy body sili cone black sealer or Mopar equivalent for the input shaft bearing retainer Apply these products as indicated in the reassembly procedures NOTE It is very important that the transmis...

Page 1411: ...and hubs must also be cor rectly positioned on the shaft in order to operate properly Assemble and install each synchro accord ing to the following instructions 3 4 SY1CHR0 POSITION Some 3 4 synchro hubs may have a raised shoulder on one side of the spline bore If so this side of the hub must face the front of the output shaft after installation However if both hub sides are the same the hub can b...

Page 1412: ... synchro hubs and rear bearing must be pressed onto the output shaft it is easier and faster to assemble the entire geartrain while mounted in a shop press This method of reassembly is demonstrated in the following procedure Two ver sions of the NV3500 are used If any gears have been replaced compare them to the new parts before installation to ensure a proper match The original and new versions h...

Page 1413: ...e sure the sleeve is installed so the tapered side will be facing the front of the shaft 9 Start fifth reverse synchro assembly on output shaft splines by hand Then seat synchro onto shaft with shop press and suitable size pipe tool Fig 68 J9421 61 Fig 68 Fifth Reverse Synchro Assembly installation 10 Install new fifth reverse hub snap ring Fig 69 as follows a Snap rings are available in thickness...

Page 1414: ...be installed on shaft while it is still mounted in shop press 17 Install first gear bearing on output shaft Fig 75 Be sure bearing is seated on shaft shoulder and is properly joined 18 Install first gear on shaft and over bearing Fig 76 Make sure bearing synchro cone is facing up as shown Fig 73 Output Shaft Bearing Installation Fig 74 installing Output Shaft Bearing Snap Ring 19 Install first spe...

Page 1415: ...CAUTION Take time to align the synchro ring and sleeve as hub the is being pressed onto the shaft The synchro ring can be cracked if it becomes mis aligned 23 Install new 1 2 synchro hub snap ring Fig 80 as follows a Snap rings are available in thicknesses from 1 80 mm to 2 00 mm 0 070 to 0 078 in b Install thickest snap ring that will fit in shaft groove Fig 77 First Speed Synchro Ring Installati...

Page 1416: ...ing in 1 2 syn chro hub and sleeve Fig 81 Be sure synchro ring is properly seated in sleeve SECOND SPEED SYNCHRO RING 1 2 SYNCHRO J9421 74 Fig 81 Second Speed Synchro Ring Installation 25 Install second gear needle bearing on shaft Fig 82 SECOND G E A R BEARING J9421 75 Fig 82 Second Gear Bearing Installation 26 Install second gear onto shaft and bearing Fig 83 SECOND GEAR BEARING 1 2 SYNCHRO ASSE...

Page 1417: ...stalling Two Piece Thrust Washer 28 Start retaining ring around two piece thrust washer Fig 85 Fig 85 Starting Retaining Ring Over Two Piece Thrust Washer 29 Seat thrust washer retaining ring with plastic mallet Fig 86 Fig 86 Seating Thrust Washer Retaining Ring 30 Install third gear needle bearing on shaft Fig 87 Fig 87 Third Gear Bearing installation 31 Install third gear on shaft and bearing Fi...

Page 1418: ...this side of sleeve is also fac ing the front of the shaft 34 Start 3 4 synchro hub on output shaft splines by hand Fig 90 Fig 90 Starting 8 4 Synchro Hub On Output Shaft 35 Press 3 4 synchro assembly onto output shaft with shop press and suitable size pipe tool Fig 91 Fig 91 Pressing 3 4 Synchro Assembly On Output Shaft 38 Install 3 4 synchro hub snap ring Fig 92 as follows a Snap rings are avail...

Page 1419: ... be facing first gear Tapered side of fifth reverse sleeve should be facing forward REVERSE IDLER ASSEMBLY 1 Lubricate idler components with gear lube 2 Slide idler gear bearing on shaft Fig 94 Bearing fits either way on shaft 3 Slide gear onto shaft Side of gear with recess goes to rear Fig 94 4 Place first lock ball in dimple at rear end of idler shaft Fig 94 Petroleum jelly can be used to hold ...

Page 1420: ...P RING J9421 90 Fig 96 Idler Gear And Shaft Assembly GEARTRAIN BUILDUP ASSEMBLY FIXTURE TOOL 1 Install Adapter 6747 1 on input shaft hub of fixture tool Fig 97 Then install Adapter 6747 2 on front bearing hub of countershaft Adapter 6747 2 has a raised shoulder on one side Be sure the shoulder is seated against the countershaft SPECIAL TOOL 6747 2 INSTALL ON COUNTERSHAFT FRONT HUB SPECIAL TOOL 674...

Page 1421: ...art with a basic height of 18 4 cm 7 1 4 in Final adjustment can be made after gear is positioned on pedestal 7 Install assembled output shaft and geartrain in input shaft Fig 102 Carefully rotate output shaft until fourth speed synchro ring seats in synchro hub and sleeve 8 Install Adapter 6747 2 on front bearing hub of countershaft if not previously done The adapter has a shoulder on one side Th...

Page 1422: ...ft installed On Fixture Tool 11 Position reverse idler on pedestal of assembly fixture Fig 104 Be sure idler gear is properly meshed and aligned with shaft gear teeth and that bolt holes are facing out and not toward geartrain Adjust pedestal up or down if necessary Also be sure that short end of idler shaft is facing up as shown 12 On 2 wheel drive transmission thread one Pilot Stud C 3288 B in c...

Page 1423: ...TION 2WD 106 Arm of fifth reverse fork goes through slot in 1 Drive adapter housing alignment dowels back 1 2 fork into housing until dowels are flush with mounting surface Fig 108 INSERT ARM Fig 108 Preparing Rear Housing Dowels For Installation PETROLEUM JELLY APPLY TO BEARING AND RACE J9421 103 Fig 109 Lubricating Countershaft Rear Bearing ...

Page 1424: ...nto geartrain Fig 111 Be sure bearing retainer pilot stud is i n correct bolt hole i n housing Also be sure countershaft and output shaft bearings are aligned i n hous ing and on countershaft 8 Seat rear housing on output shaft rear bearing and countershaft Use plastic or rawhide mallet to tap housing into place 9 Install three bolts that secure rear bearing retainer to rear housing as follows a A...

Page 1425: ...lly to shift shaft bushing bearing in adapter housing Fig 110 8 Install adapter housing on geartrain 9 Install rear bearing snap ring on output shaft Fig 115 10 Lubricate lip of new rear seal Fig 116 with Mopar Door Ease or transmission fluid Fig 115 Installing Rear Bearing Snap Ring 4 WD 11 Install new rear seal in adapter housing bore with suitable size tool Be sure seal is fully seated in housi...

Page 1426: ...in Neutral position for proper reassembly Other wise the housings shift forks and gears can be damaged during installation of the two housings 3 Install 3 4 shift fork in synchro sleeve Fig 119 Verify that groove in fork arm is aligned with grooves in 1 2 and fifth reverse fork arms as shown 3 4 ALIGN T J9421 107 Fig 119 installing 3 4 Shift Fork 4 Check surface of shift shaft before proceeding Sm...

Page 1427: ...ct positioning of the shift shaft detent notch is important Both of the shaft roll pins can be installed even when the shaft is 180 off if this occurs the transmission will have to be disas sembled again to correct shaft alignment 12 Select correct new roll pin for shift shaft lever Fig 125 Shaft lever roll pin is approximately 22 mm 7 8 in long Shift socket roll pin is approxi mately 33 mm 1 1 4 ...

Page 1428: ...shift shaft Then start roll pin into shift shaft by hand Fig 128 ROLL PIN J9521 154 Fig 128 Starting Roll Pin In Shift Socket 17 Seat roll pin in shift socket with pin punch Roll pin must be flush with socket after installation Fig 129 j9521 155 Fig 129 Seating Shift Socket Roll Pin 18 Verify that notches in shift fork arms are aligned Fig 130 Realign arms if necessary 19 Rotate shaft lever and bu...

Page 1429: ... be in Neutral position during reassembly Otherwise the housings shift forks and gears can be damaged during housing installation Fig 133 Correct Seating Of Lever Detent Ball In Shift Fork Arms 2 Apply liberal quantity of petroleum jelly to countershaft front bearing Then insert bearing in front housing race Fig 134 Large diameter side of bearing cage goes toward countershaft Fig 135 Small diamete...

Page 1430: ...rtrain in upright position Then install front housing on rear housing and geartrain Fig 137 8 Work front housing downward onto geartrain until seated on rear housing CAUTION If the front housing will not seat on the rear housing either the shift components are not in Neutral or one or more components are mis J 9 4 2 M 2 4 Fig 137 Front Housing Installation aligned Do not force the front housing in...

Page 1431: ...Shaft Bushing Lock Bolt CAUTION If the lock bolt cannot be fully installed do not try to force it into place Either the shift shaft is not in Neutral or the shaft bushing or lever is misaligned Fig 141 14 Lubricate then install shift shaft detent plunger in housing bore Fig 142 Lubricate plunger with petroleum jelly or gear lubricant Be sure plunger is fully seated i n detent notch in shift shaft ...

Page 1432: ...21 42 NV3500 MANUAL TRANSMISSION BR DISASSEMBLY AND ASSEMBLY Continued J9421 140 Fig 148 Applying Sealer To Bearing Retainer And Housing J942M33 Fig 145 installing Backup Light Switch ...

Page 1433: ...hift tower apply sealer to plate and position it on tower Or position it on rear housing Fig 152 Plate assem bly is a one way fit Narrow side of plate goes Fig 151 Applying Sealer To Shift Tower Mounting Surface toward driver side of housing as shown Fig 152 3 Apply petroleum jelly to ball end of shift lever and interior of shift socket 4 Align and install shift tower and lever assem bly Fig 152 I...

Page 1434: ...ir Allow the bearings to either air dry or wipe them dry with clean shop towels SHIFT LEVER ASSEMBLY The shift lever assembly is not serviceable Replace the lever and shift tower as an assembly if the tower lever lever ball or internal components are worn or damaged SHIFT SHAFT AMD FORKS Inspect the shift fork interlock arms and synchro sleeve contact surfaces Fig 155 Replace any fork exhibiting w...

Page 1435: ...T serviceable items The front housing will have to be replaced if the shift shaft bearing and bushing detent plunger bushing or countershaft bearing race is loose worn or dam aged The rear housing will have to be replaced if the shift shaft rear bushing or the countershaft rear bearing race is loose worn or damaged Inspect the input shaft bearing retainer Be sure the release bearing slide surface ...

Page 1436: ...ocket if the ball seat is worn or cracked Do not reuse the original shift socket roll pin Install a new pin during reas sembly The socket roll pin is approximately is approximately 33 mm 1 1 4 in long Output Shaft And Geartrain Inspect all of the gears Fig 157 for worn cracked chipped or broken teeth Also check condi tion of the bearing bore in each gear The bores should be smooth and free of surf...

Page 1437: ...EED SYNCHRO RING FIFTH REVERSE SYNCHRO HUB THIRD GEAR STRUT SPRING DETENT BALL 3 SETS FIFTH REVERSE SYNCHRO THIRD GEAR NEEDLE BEARING SLEEVE FIFTH REVERSE SYNCHRO RETAINING RING SNAP RING FIFTH REVERSE SYNCHRO HUB THRUST WASHER 2 PIECE FIFTH SPEED SYNCHRO RING SECOND GEAR NEEDLE BEARING FIFTH GEAR NEEDLE BEARING SECOND GEAR FIFTH GEAR SECOND SPEED SYNCHRO RING BEARING RETAINER IN HOUSING SLEEVE 1 ...

Page 1438: ...using Bolts 3 0 3 5 N m 2 2 2 6 ft lbs f p _ x Front Bearing Retainer Bolts 7 10 N m 5 7ft lbs 1 i flu Idler Shaft Bolts 1 9 2 5 N m 14 18 ft lbs _J j Rear Bearing Retainer Bolts 3 0 3 5 N m 2 2 2 6 ft lbs Shift Tower Bolts 7 10 N m 5 7 ft lbs F i x t u r e NV3500 6747 Slave Cylinder Attaching Nuts 23 N m 200 in lbs Transfer Case Attaching Nuts 47 N m 35 ft lbs CjX UJoint Clamp Bolts 19 N m 170 in...

Page 1439: ...The different size shafts and gear do not affect service Overhaul pro cedures for the two versions are the same page REMOVAL AND INSTALLATION SHIFT COVER 59 SHIFT LEVER 57 TRANSMISSION 2WD 54 TRANSMISSION 4WD 55 DISASSEMBLY AND ASSEMBLY EXTENSION ADAPTER HOUSING 60 TRANSMISSION 62 CLEANING AND INSPECTION TRANSMISSION 93 SPECIFICATIONS TORQUE 98 SPECIAL TOOLS NV4500 MANUAL TRANSMISSION 99 The NV450...

Page 1440: ...21 50 NV4500 MANUAL TRANSMISSION G E N E R A L INFORMATION Continued Fig 1 NV4500 Manual Transmission ...

Page 1441: ...threads before install ing it during a lubricant change GEAR RATIOS SHIFT PATTERN The NV4500 shift pattern is in a modified H pat tern Fig 4 Overdrive fifth and reverse gears are in line and outboard of the first through fourth gear positions FILL PLUG DRAIN BOLT PTO COVER J9421 210 Fig 3 NV4500 Fill Plug And Drain Bolt RANGE RATIO First gear 5 61 1 Second Gear 3 04 1 Third Gear 1 67 1 Fourth Gear...

Page 1442: ...s can result in incomplete clutch release or engagement Verify that clutch components are all in good con dition before removing the transmission for repair S E R V I C E P R O C E D U R E S SHIFT COVER COMPONENTS The only serviceable shift cover components are fifth reverse shift fork pads reverse inhibitor vent components backup light switch expansion plugs shift lever components The shift cover...

Page 1443: ...ion The switch can be replaced with the transmission in or out of the vehicle A gasket may or may not be used with the switch Apply sealer to the switch threads before installa tion Tightening torque for the switch is 22 34 N m 192 300 in lbs EXPANSION PLUG REPLACEMENT The expansion plugs at the rear of the shift rail bores Fig 9 can be replaced if loose and or leaking Replacement procedure is as ...

Page 1444: ... a transmission jack Secure transmission to jack with safety chains 15 Remove rear crossmember 16 Remove bolts attaching clutch slave cylinder to clutch housing Then move cylinder aside for work ing clearance 17 Remove transmission harness wires from clips on transmission shift cover 18 Remove bolts attaching transmission to clutch housing 19 Slide transmission and jack rearward until drive gear c...

Page 1445: ...oval A 3 5 mm 0 12 0 20 in space should exist between shift lever isolator and top edge of stub shaft and tool lower jaw c Remove special tool Fig 11 installing Shift Lever Extension With Tool 6788 18 Install shift boot and bezel 19 Connect battery negative cable TRANSMISSION 4WD REMOVAL 1 Disconnect battery negative cable 2 Shift transmission into Neutral 3 Remove shift lever boot and bezel 4 Rem...

Page 1446: ... on lever and release bearing mak ing transmission removal installation easier Cylinder does not have to be removed completely 28 Remove bolts attaching transmission to clutch housing 29 Move transmission rearward until drive pin ion clears clutch disc and release bearing 30 Lower transmission and remove it from under vehicle 31 If transmission will be overhauled thoroughly clean transmission exte...

Page 1447: ...Tool 6783 as follows a Reposition upper jaw of Remover Installer Tool 6783 above flange on lever extension Fig 14 Tool will now be used to press extension back onto shift lever b Tighten tool screw to press extension back onto lever Press extension to scribe mark made during removal A 3 5 mm 0 12 0 20 in space should exist between shift lever isolator and top edge of stub shaft and tool lower jaw ...

Page 1448: ... lever is used for all applications lever is offset and must be positioned differ ently in standard and heavy duty transmis sions b On heavy duty transmissions install lever so offset is forward Fig 18 c On standard duty transmissions install lever so offset is rearward Fig 18 CAUTION Verify correct lever installation before proceeding This is important because if the shift lever offset is misposi...

Page 1449: ... insert pry tool only in slots provided in cover Fig 21 4 Raise cover enough to disengage it from align ment dowels in gear case Fig 22 5 Raise front of shift cover and lift cover up and off gear case Fig 22 6 Set cover assembly aside for inspection If cover components are damaged refer to shift cover service information SHIFT COVER INSTALLATION 1 Clean mating surfaces of shift cover and gear case...

Page 1450: ...1 Remove bolts attaching extension adapter hous ing to gear case Fig 23 Use 10 mm 12 point socket to remove housing bolts Loosen bolts 4 5 threads with socket and ratchet first An air wrench can then be used to complete removal but only after bolts are loose CAUTION Spline head bolts are used to attach the extension or adapter housing to the gear case The bolt splines are easily damaged if the wro...

Page 1451: ...sel Then pry seal out of housing with crowfoot pry bar 2 I f extension housing bushing must be replaced collapse old bushing with tapered drift Fig 28 Position drift in slot provided at end of housing Then tap drift into slot and against bushing to collapse and remove it 3 Remove any burrs from housing bushing bore with a file and emery cloth 4 Install new bushing in extension housing Fig 29 Use T...

Page 1452: ...driven out from bottom of fork and not from top 3 Remove shift fork and fifth gear components as assembly Rotate mainshaft as needed to allow coun tershaft fifth gear to clear mainshaft fifth gear REMOVING COUNTERSHAFT FIFTH GEAR COMPONENTS INDIVIDUALLY 1 Remove snap ring that secures fifth speed clutch gear on countershaft Fig 32 CLUTCH GEAR RING FIFTH SYNCHRO CLUTCH GEAR J9221 89 Fig 32 Removing...

Page 1453: ...asher for assembly reference coned side of washer faces rear SPECIAL TOOL 6443 OR 6743 STRIKE TOOL HERE TO LOOSEN NUT FIFTH GEAR NUT J9421 207 Fig 35 Installing Nut Wrench On Mainshaft Fifth Gear SPECIAL TOOL 6443 OR 6743 FIFTH GEAR NUT SPECIAL TOOL 6441 OR 6442 RATCHET WRENCH BREAKER BAR J9421 208 Fig 36 Removing Mainshaft Fifth Gear Nut From Shaft Threads FIFTH GEAR NUT WASHER CONED FIFTH GEAR N...

Page 1454: ...th standard and heavy duty trans missions Gear removal procedure is as follows a Position first puller jaw on gear Fig 42 Use Puller Jaws 6459 on standard duty mod els and Puller Jaws 6820 on heavy duty mod els b Assemble Puller Flange 6444 1 and Puller Rods 6444 3 Fig 43 c Slide assembled puller flange and rods onto output shaft Then seat flange in notch of puller jaw Fig 43 d Position second pul...

Page 1455: ... 45 g Tighten puller bolt to remove gear from shaft splines Fig 45 12 Remove bolts attaching mainshaft rear bear ing plate to gear case and remove fifth gear plate end play shims and bearing cup Fig 46 FRONT RETAINER REMOVAL AND DISASSEMBLY 1 Remove front retainer bolts Fig 47 Discard retainer bolts They should not be reused 2 Remove front retainer by lightly tapping it back and forth with plastic...

Page 1456: ...flange Fig 49 Narrow lip of puller jaws will go under bearing cup c Install assembled tools in front retainer Fig 50 Be sure puller jaws are seated under bearing cup d Place Insert Tool 6 4 5 3 2 in center of puller jaws Fig 50 Insert tool is used to hold puller jaws in place SPECIAL TOOL 6453 1 FRONT RETAINER SPECIAL TOOL 6453 2 J922M79 Fig 50 Installing Puller Tools In Front Retainer e Install P...

Page 1457: ... and Puller Rods 6444 4 Then position first Puller Jaw 6447 on gear Fig 54 c Slide assembled puller flange and rod tools onto output shaft Then seat flange in notch of puller jaw Fig 54 d Position second Puller Jaw 6447 on gear and in notch of puller flange Fig 54 e Slide Retaining Collar 6444 8 over puller jaws to hold them in place Fig 54 f Install Puller 6444 on puller rods Then secure puller t...

Page 1458: ...push reverse idler gear away from mainshaft gears 9 Remove mainshaft assembly as follows Fig 60 a Lift front end of mainshaft slightly b Grasp mainshaft rear splines Then turn spline end of mainshaft in counterclockwise direc tion to rotate shaft and geartrain out of case FOURTH SPEED CLUTCH GEAR Fig 59 Fourth Speed Clutch Gear Stop Ring Removal c Once mainshaft gears roll clear of counter shaft g...

Page 1459: ... Puller Jaw 6449 on bearing and in notch of puller flange Fig 64 e Slide Retaining Collar 6444 8 over puller jaws to hold them in place Fig 64 Note that retaining collar has small lip on one end and only fits one way over jaws f Install Puller 6444 on puller rods Then secure puller to rods with retaining nuts Fig 64 g Tighten puller bolt to remove bearing from shaft Fig 64 If bearing is exceptiona...

Page 1460: ...e bearing puller tools 10 Set countershaft and idler gear aside for cleaning and inspection J9221 159 6444 6 Fig 66 Removing Countershaft Front Bearing GEAR CASE DISASSEMBLY 1 Remove countershaft front bearing cap Use mallet or hammer to remove cap from inside case Fig 67 2 Remove countershaft front bearing cup with Remover Tool 6454 and Tool Handle C 4171 Fig 68 3 Remove roll pin that secures shi...

Page 1461: ...ar and syn chro components can be installed backwards To avoid reassembly problems mark the speed gears clutch gears synchro hubs and sleeves for refer ence during teardown Use paint or a scriber for marking purposes Then stack the geartrain parts in order of removal This practice will help avoid incorrect assembly and lost time 1 Remove drive gear thrust bearing from end of mainshaft if not previ...

Page 1462: ... snap ring that retains second gear thrust washer on mainshaft Fig 77 9 Remove second gear thrust washer Fig 78 Note that washer is notched for locating pin 10 Remove second gear Fig 79 11 Remove second gear bearing assembly Fig 80 12 Remove thrust washer locating pin Fig 81 Use needle nose pliers to grip and remove pin 13 Remove snap ring that retains second speed clutch gear Fig 82 Snap ring is ...

Page 1463: ...ASHER LOCATING PIN REMOVE WITH NEEDLE JOSE PLIERS 1 2 SLEEVE SNAP RING SECOND SPEED CLUTCH GEAR J922M27 Fig 82 Removing Second Speed Clutch Gear Snap Ring 1 2 SLEEVE AND HUB SYNCHRO STOP RING CLUTCH RING SECOND SPEED CLUTCH GEAR J922M28 Fig 83 Second Speed Clutch Gear Clutch Ring And Stop Ring Removal J922M26 Fig 81 Thrust Washer Locating Pin Removal J922M29 Fig 84 Removing 1 2 Sleeve And Hub Snap...

Page 1464: ...It is not really neces sary to remove this snap ring unless it or the main shaft is to be replaced 22 Remove mainshaft rear bearing as follows a Assemble Puller Flange 6444 1 and Puller Rods 6444 3 Fig 89 FIRST SPEED CLUTCH GEAR CLUTCH GEAR SNAP RING FRONT J9221 132 Fig 87 First Speed Clutch Gear Front Snap Ring Removal CLUTCH GEAR SNAP RING REAR FIRST SPEED CLUTCH GEAR J9221 133 Fig 88 First Spee...

Page 1465: ...BR NV4500 MANUAL TRANSMISSION 21 75 Fig 89 Assembling Mainshaft Rear Bearing Puller Tools SPECIAL REVERSE Fig 90 Removing Mainshaft Rear Bearing ...

Page 1466: ...be installed backwards causing shift problems 27 Remove reverse gear bearing assembly from mainshaft Fig 93 28 Remove reverse gear synchro stop ring and clutch gear Fig 93 FIRST GEAR REVERSE GEAR ASSEMBLY STOP RING BEARING ASSEMBLY Fig 93 Reverse Gear Bearing Removal J922M37 Stop Ring 29 Remove reverse gear bearing spacer from mainshaft Fig 94 30 Remove first gear snap ring Fig 94 Tension of this ...

Page 1467: ...ealing surfaces ADJUSTMENT SPECIFICATIONS Countershaft End Play 0 051 0 15 mm 0 002 0 006 in Mainshaft End Play 0 051 0 15 mm 0 002 0 006 in GEAR CASE ASSEMBLY 1 Install countershaft front bearing cup in case with Tool Handle C 4171 and Installer Tool 6061 1 or C 4340 Fig 98 2 Install new bushings in shift lug rail bores with Tool 6456 Fig 99 Seat bushings flush with bores NV4500 MANUAL TRANSMISSI...

Page 1468: ...ar bearing on countershaft rear at this time BR 5 Lubricate reverse idler gear bearings with petroleum jelly and install first bearing bearing spacer and second bearing Fig 103 6 Install idler gear front thrust washer on boss in gear case Fig 103 Coat thrust washer with lib eral quantity of petroleum jelly to hold it in place POSITION IDLER GEAR Fig 103 Positioning Idler Gear Front Thrust Washer I...

Page 1469: ...er Tool C 4040 or 6446 Fig 107 13 Remove wood block from under countershaft and lower countershaft front bearing into front bear ing cup 14 Install new front bearing cap in gear case Fig 108 Apply Mopar silicone adhesive sealer to NV4500 MANUAL TRANSMISSION 21 79 Fig 107 Installing Countershaft Rear Bearing flange and lip of new cap Then seat cap in case bore with wood block and mallet Fig 108 Cou...

Page 1470: ...tall end play shim that will pro vide minimum countershaft end play Position shim on rear bearing cup Fig 112 REAR END Fig 112 Installing Countershaft End Play Shim 7 Reinstall countershaft rear bearing plate Fig 110 Be sure plate is seated in reverse idler shaft notch before installing bolts Also be sure end play shims are still in position before tightening bearing plate bolts 8 Apply 1 2 drops ...

Page 1471: ... in upright vertical position and supported with wood blocks Fig 115 Reverse gear components are easier to install with shaft upright 5 Install first gear and bearing on shaft Fig 115 Clutch hub side of gear faces front of shaft 6 Install clutch gear on first gear Fig 115 Be sure clutch gear is seated on shaft splines 7 Install first gear snap ring Fig 115 Use heavy duty snap ring pliers to instal...

Page 1472: ... d Compress first spring with flat blade screw driver and slide strut into position in hub slot Then work spring into seat in strut with small hooked tool or screwdriver e Install second and third struts in same man ner as described in step d f Work sleeve upward on hub until struts are centered and seated in sleeve Sleeve should be in neutral position after seating struts REVERSE SLEEVE SPRING 3 ...

Page 1473: ...CLUTCH GEAR J922M96 Fig 123 Installing First Speed Clutch Gear 18 Install snap ring on mainshaft 1 2 synchro hub to secure clutch gear Fig 124 Be sure snap ring is fully seated in hub groove and against clutch gear Note that this is second of four snap rings used to secure synchro components on shaft hub 19 Assemble first speed clutch ring and stop ring Fig 125 FIRST SPEED CLUTCH GEAR MAINSHAFT 1 ...

Page 1474: ...e of hub Fig 129 Be sure retainer spring ends are securely engaged in weight slots as shown c Place synchro hub on bench so side of hub with square spring is facing up Fig 130 d Align and install sleeve on hub Be sure tapered side of sleeve faces upward toward front J9221 207 Fig 129 Installing Weight Retainer Springs In 1 2 Synchro Hub Rotate sleeve until it slides onto hub Sleeve only fits one w...

Page 1475: ...nchro hub and sleeve Fig 132 Be sure stop ring is fully seated and engaged in hub and sleeve FIRST SPEED STOP RING 1 2 SYNCHRO ASSEMBLY J9221 210 Fig 132 Installing First Speed Stop Ring in Synchro Huh Fig 133 1 2 Synchro installation 25 Check position of 1 2 and reverse synchro sleeves Be sure tapered side of 1 2 sleeve faces front and tapered side of reverse sleeve faces rear Fig 134 Also be sur...

Page 1476: ...aiilng Fiat Weight Spring 29 Assemble second speed clutch gear clutch ring and stop ring Fig 137 30 Install assembled second speed clutch gear and rings on mainshaft and in 1 2 synchro hub Fig 138 31 Install snap ring that secures second speed clutch gear on mainshaft Fig 139 Use narrow blade screwdriver to work snap ring into hub groove as shown Be sure snap ring is fully engaged i n mainshaft gr...

Page 1477: ...dle nose pliers to insert pin in shaft hole 35 Install second gear thrust washer Be sure washer is seated on gear and pin Fig 143 36 Install second gear thrust washer snap ring Fig 144 Be sure snap ring is fully seated in main shaft groove 37 Install third gear bearing spacer on shaft and seat it against thrust washer snap ring Fig 144 THRUST WASHER PIN SECOND GEAR J9221 223 Fig 142 Thrust Washer ...

Page 1478: ...lots machined In sleeve and hub Fig 148 c Install and seat synchro springs Fig 148 Use flat blade or phillips screwdriver to compress springs and seat them in struts and hub as shown STRUT 3 SPRING 3 3 4 3 4 Fig 148 Synchro Assembly 8 4 42 Remove mainshaft and geartrain from gear case or from workbench 43 Start 3 4 synchro assembly on mainshaft Tap assembly onto shaft splines until hub is about 3 ...

Page 1479: ...ed roll case on side and realign shaft and gears in case Fig 153 Drive Gear Thrust Bearing instaliation DRIVE GEAR AND RETAINER INSTALLATION 1 Install bearing on drive gear with Installer Tool 6448 Fig 154 SPECIAL T O O L 6448 Fig 154 Installing Front Bearing On Drive Gear 2 Lubricate pilot bearing with petroleum jelly and install it in drive gear bore 3 Install drive gear on mainshaft Work gear r...

Page 1480: ...g in position Fig 159 Do not install any end play shims at this time 3 Tighten rear bearing plate bolts securely 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 transmis sion on bench Do not leave transmission unsup ported 5 Mount dial indicator on rear of gear case and position indicator plunger against inne...

Page 1481: ...Tighten fifth gear nut as much as possible with Nut Wrench 6443 or 6743 long handle ratchet breaker bar and Socket Wrench 6441 or 6442 Fig 163 SPECIAL TOOL 6443 FIFTH GEAR NUT SPECIAL TOOL 6441 OR 6442 RATCHET WRENCH BREAKER BAR J9221 92 Fig 163 Fifth Gear Nut Installation 6 Lock mainshaft gears by shifting all synchro sleeves into engaged position 7 Position Spline Socket Wrench 6441 or 6442 on m...

Page 1482: ...g Synchro Sleeve On Countershaft Fifth Gear Hub 6 Install shift fork in synchro sleeve Fig 168 SYNCHRO SLEEVE SHIFT FORK J9221 238 Fig 168 Installing Fifth Gear Shift Fork In Synchro Sleeve 7 Install assembled fifth gear synchro sleeve and shift fork Fig 169 Align fork with shift lug rail and align gear with bearings and countershaft Start components onto shaft and rail Then tap gear and fork into...

Page 1483: ...G A N D I N S P E C T I O N TRANSMISSION Clean the gears bearings shafts extension adapter housing and gear case with solvent Dry all parts except the bearings with compressed air Allow the bearings to either air dry or wipe them dry with clean shop towels Inspect the reverse idler gear bearings shaft and thrust washers Fig 173 Replace the bearings if the rollers are worn chipped cracked flat spot...

Page 1484: ...ol ishing Replace the retainer if worn or damaged in any way Do not reuse the original retainer bolts Install new bolts during assembly BEARING CUP FRONT BEARING RETAINER Fig 176 Countershaft And Bearings Check condition of the mainshaft Inspect all the bearing surfaces splines and threads Also check con dition of the snap ring grooves in the hub area and the speedometer drive gear teeth Fig 177 M...

Page 1485: ...shings Inspect the gear and hub assembly Minor burrs can be cleaned up with an oil stone However the gear and hub assembly should be replaced if the teeth or splines are excessively worn or damaged The synchro sleeve should also be replaced If worn or damaged in any way Do not reuse synchro struts that are worn or springs that are collapsed or severely distorted Replace worn distorted synchro part...

Page 1486: ...place the weights if worn or damaged Examine the hub and sleeve for wear or damage Replace the sleeve and hub if the splines are worn chipped or damaged Replace the synchro struts if worn or chipped Also replace the springs if collapsed distorted or broken Inspect the mainshaft geartrain components Fig 181 Check the teeth on all gears hubs clutch gears stop rings and clutch rings The teeth must be...

Page 1487: ......

Page 1488: ... SPACER 16 MAINSHAFT END PLAY SHIMS 40 THIRD GEAR 17 MAINSHAFT REAR BEARING PLATE 41 THIRD GEAR BEARING ASSEMBLIES 2 18 MAINSHAFT FIFTH GEAR 42 THIRD GEAR SYNCHRO STOP RING 19 THRUST WASHER 43 3 4 SYNCHRO SLEEVE 20 FIFTH GEAR NUT 44 SYNCHRO STRUTS AND SPRINGS 3 EACH 21 MAINSHAFT SPLINE SEAL 45 3 4 SYNCHRO HUB 22 CLUTCH GEAR SNAP RING 46 FOURTH GEAR SYNCHRO STOP RING 23 FIRST SPEED CLUTCH GEAR 47 F...

Page 1489: ...Q0 MANUAL TRANSMISSION Installer Bearing Cone 6052 Wrench Splined Socket 6441 NV4500 MANUAL TRANSMISSION 21 Wrench Splined Socket 6442 Wrench 5th Gear Nut 6443 Puller Bearing and Gear 6444 Jaws Bearing Cone For Puller 6444 6445 ...

Page 1490: ...earing Cone 5th Gear 6446 Jaws Bearing Cone For Puller 6444 6451 Jaws Bearing Cone For Puller 6444 6447 Remover Countershaft Bearing Cup 6454 installer Bearing Cone 6448 Remover installer Bushing 6456 Jaws Bearing Cone For Puller 6444 6449 Jaws 5th Gear For Puller 6444 6459 ...

Page 1491: ...BR NV4500 MANUAL TRANSMISSION 2 1 1 0 1 SPECIAL TOOLS Continued Installer C 4340 ...

Page 1492: ...E PROCEDURES ALUMINUM THREAD REPAIR 131 CONVERTER DRAINBACK CHECK VALVE SERVICE 131 FLUID AND FILTER REPLACEMENT 130 FLUID LEVEL CHECK 129 FLUSHING COOLERS AND TUBES 131 TRANSMISSION FILL PROCEDURE 131 page REMOVAL AND INSTALLATION GOVERNOR SOLENOID AND PRESSURE SENSOR 136 OUTPUT SHAFT FRONT BEARING 135 OUTPUT SHAFT REAR BEARING 134 OVERDRIVE HOUSING BUSHING 134 OVERDRIVE UNIT 139 PARK LOCK 135 PA...

Page 1493: ...clutch is applied in all ranges except fourth gear The 42RE is equipped with a lock up clutch in the torque converter The torque converter clutch is controlled by the Power train Control Module PCM The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control TCC solenoid on the valve body The torque converter c...

Page 1494: ...ING CLUTCH CONVERTER CLUTCH HOUSING OUTPUT SHAFT as 2 o g 2 as 1 5 o Z z M CO O 1 2 co 3 2 B O 3 2 C j a ft as m SEAL TRANSMISSION FRONT PLANETARY GEAR FILTER OVERDRIVE CLUTCH DIRECT PISTON CLUTCH SPRING OVERDRIVE PLANETARY GEAR J9321 407 Fig 1 42RE Transmission W 50 ...

Page 1495: ...uid temperatures The converter clutch is engaged in fourth gear and in third gear when the overdrive switch is OFF The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced If a transmission failure resulted in large amounts of metal or fiber contam...

Page 1496: ...d valve to the governor circuit It is the solenoid valve that develops the necessary gover nor pressure TRANSMISSION FLUID TEMPERATURE THERMISTOR Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor Fig 5 The temperature readings are used to control engagement of the fourth gear overdrive clutch the converter clutch and governor pressure Norma...

Page 1497: ... low range SHIFT VALVE OPERATION The shift valves are moved by a combination of throttle and governor pressure The governor pres sure is generated by electrical components The conditions under which a shift to fourth will not occur when Overdrive switch is Off Transmission fluid temperature is below 10 C 50 F or above 121 C 250 F Shift to third not yet completed Vehicle speed too low for 3 4 shift...

Page 1498: ...ontrol module 3 4 SHIFT SEQUENCE The overdrive clutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear Fourth gear overdrive range is electron ically controlled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens a...

Page 1499: ... hydraulic pressure test if shift prob lems were noted during road test 7 Perform air pressure test to check clutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift trans...

Page 1500: ...LE CORRECT FLUID FLUID LEVEL LEVEL 804d8eae Fig 8 Dipstick Fluid Level Marks c If fluid is black dark brown turned to sludge contains extensive amount of metal or fric tion material particles transmission will need overhaul Main and auxiliary coolers will have to be flow tested and reverse flushed as well EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with ...

Page 1501: ...or inter nal damage to the transmission may occur 4 If flow is found to be within acceptable limits reconnect the cooler line Then fill transaxle to the proper level using the approved type of automatic transmission fluid OVERDRIVE 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 ...

Page 1502: ...ing another gear which does not use these clutches the slipping unit can be determined For example if the transmission also slips in Reverse the front clutch is slipping If the transmission does not slip in Reverse the rear clutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive clutch is slipping Simi larly if the direct clutch were to fail the transmis i A...

Page 1503: ...t 2 Connect 300 psi Gauge C 3293 SP to rear servo port Fig 9 3 Disconnect throttle and gearshift rods from manual and throttle levers 4 Start and run engine at 1000 rpm 5 Move shift lever on manual lever shaft all the way forward into manual low 6 Move transmission throttle lever from full for ward to full rearward position and note pressures on both gauges 7 Line pressure at accumulator port shou...

Page 1504: ...n the road or on a chassis dynamometer Do not perform this test on a hoist Use 300 psi Test Gauge C 3292 for this test 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug 3 Lower vehicle 4 Turn on OD switch 5 Secure test gauge so it can be viewed from driver s seat 6 Start engine and sh...

Page 1505: ...rmal indicates the converter overrunning clutch is slipping The vehicle also exhibits poor acceleration but operates normally once highway cruise speeds are reached Torque converter replacement will be necessary Stall Speed Normal But Acceleration Poor If stall speeds are normal 1800 2300 rpm but abnormal throttle opening is required for accelera tion or to maintain cruise speed the converter over...

Page 1506: ...se rear of vehicle and allow accumulated fluid to drain out of converter housing 2 Check and adjust transmission fluid level 3 Raise vehicle Remove converter housing dust cover and wipe as much fluid as possible from con verter housing 4 Fabricate test probe Fig 13 Attach probe to converter housing with a dust shield bolt 5 Have a helper run engine at 2500 rpm with transmission in Neutral for two ...

Page 1507: ...ap is needed to secure the seal cup for testing The strap can be made from 31 75 mm 1 1 4 in wide stock Fig 17 The strap attaching hole positions are approximate only Measure hole position on the converter housing before drilling The pump vent tool is made from 6 35 mm 1 4 in rod and 4 76 mm 3 16 in plate Fig 18 The fabricated tools can all be made from mild steel or aluminum stock WELD OR BRAZE B...

Page 1508: ...n front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is removed FRONT FITTING INSTALL PLUG HOSE AND TUBING CONNECTED TO REAR FITTING Fig 20 Pressurizing Transmission With Tool 7700 3 Remove oil pump and remove pump seal Inspect pump housing drainback and vent holes for obstructions Clear holes with solvent and...

Page 1509: ...proper check ball installation 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if threads are damaged 10 Remove disassemble and repair transmission as necessary 11 Replace converter and flush cooler and line before installing new converter DELAYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Fluid Level Low 2 Filter Clogged 3 Gearshift Linkage Misadjusted 4 To...

Page 1510: ...for leaks if drive is restored 2 Repair or replace linkage components 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Remove and disassemble valve body Replace assembly if any valves or bores are damaged 5 Remove and disassemble transmission Replace overrunning clutch 6 Remove and disassemble transmission Replace seal rings and any o...

Page 1511: ...l or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described Misadjusted in service section 6 Governor Valve Sticking 6 Inspect clean or repa...

Page 1512: ...ct Look for stuck 1 2 valve or governor plug 2 Remove clean and inspect Replace faulty parts 3 Test using DRB and repair as required NO LOW GEAR MOVES IN 2ND OR 3RD GEAR ONLY 1 Governor Valve Sticking 2 Governor Circuit RE Only Electrical Fault 3 Valve Body Malfunction 4 Front Servo Piston Cocked in Bore 5 Front Band Linkage Malfunction 1 Remove governor clean inspect and repair as required 2 Test...

Page 1513: ...Check for binding cable or missing return spring 2 Adjust linkage and repair linkage if worn or damaged 3 Check line and governor pressures to determine cause Correct as required 4 Check operating pressures and test with DRB scan tool repair faulty component 5 Adjust Band 6 Air pressure check operation of clutches and bands Repair faulty component CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted ...

Page 1514: ...ooier Lines 7 Rear Clutch Malfunction Leaking Seals or Worn Plates 8 Overrunning Clutch Worn Not Holding Slips in 1 Only 1 Add fluid and check for leaks 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Adjust linkage 4 Adjust linkage 5 Inspect and replace as needed 6 Perform hydraulic and air pressure tests to determine c...

Page 1515: ... Connectors Shorted 2 PCM Malfunction 3 TPS Malfunction 4 Lockup Solenoid Not Venting 5 Overdrive Solenoid Not Venting 6 Valve Body Valve Sticking 1 Test wiring and connectors with test lamp and volt ohmmeter Repair wiring as necessary Replace connectors and or harnesses as required 2 Check PCM operation with DRB scan tool Replace PCM only if faulty 3 Check TPS with DRB scan tool at PCM 4 Remove v...

Page 1516: ...or correct routing Should not touch engine or bell housing NO 3 4 UPSHIFT 1 Dash O D Switch In OFF Position 2 Overdrive Circuit Fuse Blown 3 O D Switch Wire Shorted Open Cut 4 Distance or Coolant Sensor Malfunction 5 TPS Malfunction 6 Neutral Switch to PCM Wire Shorted Cut 7 PCM Malfunction 8 Overdrive Solenoid Shorted Open 9 Solenoid Feed Orifice in Valve Body Blocked 10 Overdrive Clutch Failed 1...

Page 1517: ...le transmission remove retainer and replace orifice 4 Remove overdrive unit Replace seals if worn Replace piston if damaged If piston retainer is damaged remove and disassemble the transmission 5 Remove and overhaul valve body Replace accumulator seals Make sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are ...

Page 1518: ...oid assembly 1 Adjust linkage cable 2 Check continuity with test lamp Repair as required 3 Refer to service section for test and replacement procedure 4 Connectors spread open Repair 5 Inspect lever assembly and replace if damaged NO REVERSE OR SLIPS IN REVERSE 1 Direct Clutch Pack front clutch Worn 2 Rear Band Misadjusted 3 Front Clutch Malfunctioned Burned 4 Overdrive Thrust Bearing Failure 5 Di...

Page 1519: ...e Unit Overrunning Clutch Rollers Worn Scored 1 Remove unit and rebuild clutch pack 2 Remove and disassemble unit Replace either thrust bearing if damaged 3 Remove and disassemble unit Replace either bearing if damaged 4 Remove and overhaul overdrive unit 5 Remove and overhaul overdrive unit S E R V I C E P R O C E D U R E S FLUID LE EL CHECI Transmission fluid level should be checked monthly unde...

Page 1520: ...ve remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pan 9 Remove screws holding filter to valve body Fig 23 10 Separate filter from valve body and pour fluid in filter into drain pan 11 Dispose used trans fluid and filter properly INSPECTION AND CLEANING INSPECTION Inspect bottom of pan and magnet for ex...

Page 1521: ... Is spring loaded and has an opening pres sure of approximately 2 psi The valve is serviced as an assembly It Is not repairable Do not clean the valve if restricted or contaminated by sludge or debris I f the valve fails or if a transmission malfunction occurs that gener ates sludge and or clutch particles and metal shav ings the valve must be replaced The valve must be removed whenever the cooler...

Page 1522: ...suction line into a one quart container of Mopar type 7176 automatic transmis sion fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from coo...

Page 1523: ...g screw Tighten clamp screw to 10 12 N m 90 110 in lbs torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary PARI NEUTRAL POSITION SWITCH Switch Replacement 1 Raise vehicle and position drain pan under switch 2 Disconnect switch wires 3 Remove switch from case 4 Move shift lever to Park and Neutral positions Verify that switch operating ...

Page 1524: ...ol to bushing and remove bushing Fig 30 INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 2 Tap bushing into place with Special Tool 6951 and Special Tool C 4171 3 Install new oil seal in housing using Seal Installer C 3972 A HOUSING BUSHING 80a11095 Fig 30 Overdrive Housing Bushing Removal OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove o...

Page 1525: ...hicle 2 Remove overdrive geartrain from housing 3 Remove bolt holding park pawl in overdrive housing CAUTION Do not over stress snap ring during removal snap ring distortion can result 4 Remove snap ring holding reaction plug in overdrive housing 5 Pull park pawl shaft from housing 6 Separate park pawl park pawl spring and reaction plug from overdrive housing Fig 33 INSTALLATION 1 Place park pawl ...

Page 1526: ...e sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace gasket 1 Lubricate O ring on pressure sensor with transmission fluid 2 Align pressure sensor to bore in governor body Fig 38 3 Push pressure sensor into governor body 4 Install retainer to hold pressure sensor to gov ernor body 5 Place gasket in position on back of governor body Fig 37 6 Place gov...

Page 1527: ...nd solenoid case connector Fig 39 6 Position drain pan under transmission oil pan 7 Remove transmission oil pan and gasket 8 Remove fluid filter from valve body 9 Remove bolts attaching valve body to transmis sion case 10 Lower valve body enough to remove accumu lator piston and springs 11 Work manual lever shaft and electrical con nector out of transmission case Then lower valve body rotate it aw...

Page 1528: ...ccumulator piston and outer spring manual lever shaft and electrical connector in case Then seat valve body on case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in lbs torque 12 Install new fluid filter on valve body Tighten filter screws to 4 N m 35 in lbs torque 13 Install and connect park neutral position switch in cas...

Page 1529: ...SSION COOLER REPLACEMENT MAIN COOLER REPLACEMENT The main transmission cooler is located in the radiator The cooler is not a serviceable component If the cooler is damaged the radiator must be replaced AUXILIARY COOLER REPLACEMENT 1 Remove grille refer to Group 23 Body for proper procedures 2 Remove brackets holding cooler to radiator and radiator support Fig 45 3 Tag cooler hoses for installation...

Page 1530: ...er procedures 12 Remove and retain overdrive piston thrust bearing Bearing may remain on piston or in clutch hub during removal 13 Position drain pan on workbench Fig 47 Removing Installing Overdrive Unit Attaching Bolts 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 15 Examine fluid for clutch material or metal fragments If fluid contains these items overhaul w...

Page 1531: ...ary gear and overrunning clutch splines 11 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reaction plug at same time Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to rotate out of alignment If this occurs it will be necessary to remove and dis assemble overdrive unit to real...

Page 1532: ...NSFER TUBE V6 J9421 256 Fig 51 Fill Tube Attachment at a time Rotate crankshaft with socket wrench on dampener bolt 12 Mark propeller shaft and axle yokes for assembly alignment Then disconnect and remove propeller shaft ON 4 x 4 models remove both pro peller shafts 13 Disconnect wires from park neutral position switch transmission solenoid and vehicle speed sen sor 14 Disconnect gearshift rod and...

Page 1533: ...ump gears 6 Check converter seating with steel scale and straightedge Fig 54 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 Temporarily secure converter with wedge tool or C clamp Fig 54 Typical Method Of Checking Converter Seating 8 Position transmission on jack and secure it with chains 9 Check condition of converter driveplate Replace the pl...

Page 1534: ...e a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the tor...

Page 1535: ...or pressure sen sor and solenoid Fig 56 Fig 56 Governor Pressure Solenoid And Sensor Wire Locations 2 Remove screws attaching governor body and retainer plate to transfer plate Fig 57 3 Remove retainer plate governor body and gas ket from transfer plate Fig 58 Fig 58 Governor Body And Gasket 4 Disconnect wires from governor pressure sen sor if not done previously 5 Remove governor pressure sensor ...

Page 1536: ...onnector r e m o v a l Fig 61 Solenoid Harness Case Connector Shoulder Bolt 8 Unhook overdrive converter solenoid harness from 3 4 accumulator cover plate Fig 62 9 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 63 10 Remove solenoid and harness assembly from valve body Fig 64 BR OVERDRIVE CONVERTER Fig 62 Unhooking Solenoid Harness From A...

Page 1537: ... Secure detent ball and spring with Retainer Tool 6583 Fig 67 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING 14 Remove E clip and washer that retains throt tle lever shaft in manual lever Fig 68 M A N U A L S H A F T E C L I P A N D W A S H E R J9321 424 Fig 68 Throttle Lever E Clip And Washer 15 Remove manual lever and throttle lever Fig 69 Rotate and lift manual lever off valve body and throttle...

Page 1538: ... adjusting screw bracket to valve body and transfer plate Fig 72 Hold bracket firmly against spring tension while removing last screw REMOVE THESE SCREWS FIRST REMOVE THIS SCREW LAST BRACKET J9321 430 Fig 72 Adjusting Screw Bracket Fastener 19 Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 73 Do not remove throt tle pressure...

Page 1539: ... 75 ACCUMULATOR HOUSING 3 4 SHIFT VALVE SPRING CONVERTER CLUTCH V A L V E S P R I N G J9321 433 Fig 75 3 4 Shift And Converter Clutch Valve Springs And Plug 22 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 76 3 4 SHIFT V A L V E S P R I N G 3 4 A C C U M U L A T O R H O U S I N G C O N V E R T E R C L U T C H V A L V E S P R I N G A N D PLUG J9321 434 Fig 76 Accumu...

Page 1540: ...this position the two check balls in upper housing will remain in place and not 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 80 Note position of boost valve tube brace for assembly reference 28 Remove lower housing and overdrive separa tor plate from transfer plate Fig 80 29 Remove transfer p...

Page 1541: ...alls in valve body upper housing Fig 85 Then remove the one large diame ter and the six smaller diameter check balls 2 Remove E clip that secure shuttle valve second ary spring on valve stem Fig 86 3 Remove governor plug and shuttle valve covers Fig 87 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 87 5 Remove boost valve retainer spring and valve if not...

Page 1542: ...21 152 AUTOMATIC TRANSMISSION 42RE DISASSEMBLY AND ASSEMBLY Continued BR I 217 Fig 87 Shuttle And Boost Valve Components Fig 88 Upper Housing Control Valve Locations ...

Page 1543: ...g and plug 4 Remove 3 4 shift valve and spring 5 Remove converter clutch valve spring and plug Fig 90 6 Remove converter clutch timing valve retainer and valve spring And Pressure Plug Locations 3 4 ACCUMULATOR H0USI1G DISASSEMBLY 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston seals Fig 91 VALVE BODY ASSEMBLE CAUTION Do not force valves or plugs in...

Page 1544: ... 90 Lower Housing Shift Valves And Springs 5 Install timing valve end plate Tighten end plate screws to 4 N m 35 in lbs torque 6 Install 3 4 shift valve and spring 7 Install converter clutch valve spring and plug 8 Install converter clutch timing valve and spring 3 4 ACCUMULATOR ASSEMBLY 1 Lubricate accumulator piston seals and hous ing piston bore with clean transmission fluid Fig 91 2 Install ne...

Page 1545: ...PPER ANi LOWER HOUSINGS 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 95 Seven check balls are used The single large check ball is approximately 8 7 mm 11 32 in diameter The remaining 6 check balls are approximately 6 3 mm 1 4 in in diameter 2 Position assembled transfer plate and upper hous ing separator plate on upper...

Page 1546: ...bly in upper housing and install cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring 5 Install shift valve cover plate 6 Install shuttle valve as follows Fig 98 Installing Lower Housing On Transfer Plate And Upper Housing a Insert plastic guides in shuttle valve second ary spring and install sp...

Page 1547: ...R AUTOMATIC TRANSMISSION 42RE 21 157 DISASSEMBLY AND ASSEMBLY f Continued i I SHUTTLE r VALVE COVER J 9 4 2 1 2 1 7 F g 99 Shuttle And Boost Vaive Components Fig 100 Upper Housing Control Vaive Locations ...

Page 1548: ...lower housing is facing upward Fig 102 2 Lubricate tube ends and housing 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 102 B O O S T VALVE TUBE L O W E R H O U S I N G UPPER H O U S I N G D I S E N G A G E THIS E N D O F TUBE FIRST 4 Insert and seat each end of tube in hou...

Page 1549: ... 4 shift valve springs in housing Fig 105 2 Loosely attach accumulator housing with right side screw Fig 105 Install only one screw at this time as accumulator must be free to pivot upward for ease of installation R I G H T S I D E S C R E W 3 4 A C C U M U L A T O R Fig 105 Converter Clutch And 3 4 Shift Valve Springs 3 Position plug on end of converter clutch valve spring Then compress and hold ...

Page 1550: ... manual lever until fully seated Remove detent ball retainer tool after lever is seated 9 Then Install manual lever seal washer and E clip 10 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 11 Verify that throttle lever Is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 110 12 Install boost valv...

Page 1551: ...g 112 RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR 80a0c4fa Fig 112 Governor Pressure Sensor 5 Install governor pressure solenoid in governor body Fig 113 Push solenoid in until it snaps into place in body 6 Position governor body gasket on transfer plate Fig 114 7 Install retainer plate on governor body and around solenoid Fig 115 Be sure solenoi...

Page 1552: ...SSEMBLE 1 Remove transmission from vehicle 2 Remove overdrive unit 3 Clean transmission exterior with steam gun or with solvent Wear eye protection during cleaning operations 4 Remove shift and throttle levers from valve body manual lever shaft 5 Remove transmission speed sensor and O ring seal from overdrive unit Fig 117 6 Place transmission in upright position Fig 118 7 Remove bolts attaching ov...

Page 1553: ...E UNIT J9321 351 Fig 121 Thrust Bearing And Plate Removal screws Filter screws are longer and should be kept with filter TRANSMISSION CASE OIL FILTER Fig 119 Overdrive Unit Removal J9321 350 SPECIAL TOOL FILTER SCREWS 3 J 9 3 2 1 3 8 3 Fig 122 Oil Filter Removal lnstallation 13 Remove overdrive piston from retainer Fig 123 OVERDRIVE CLUTCH PISTON PISTON RETAINER J 9 3 2 M 3 3 Fig 120 Overdrive Spl...

Page 1554: ...hing valve body to transmission case Fig 126 A total of 10 bolts are used Note different bolt lengths for assembly refer ence 17 Remove valve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 127 Exercise care during removal as governor pressure solenoid and transducer can both be damaged by rough handling 18 Remove accumulator piston and...

Page 1555: ...E EXTENSION FRONT BAND LEVER SHAFT ACCESS PLUG J 9 3 2 1 4 6 2 Fig 129 Removing Installing Front Band Lever Shaft Access Plug J9121 120 Fig 130 Removing Oil Pump And Reaction Shaft Support Assembly 24 Loosen front band adjusting screw until band is completely loose 25 Squeeze front band together and remove band strut Fig 131 BAND LEVER BAND STRUT FRONT BAND J9121 121 Fig 131 Removing Installing Fr...

Page 1556: ...mblies 30 Lift front clutch off rear clutch Fig 135 Set clutch units aside for overhaul FRONT CLUTCH 31 Remove intermediate shaft thrust washer from front end of shaft or from rear clutch hub Fig 136 INTERMEDIATE SHAFT THRUST WASHER REAR CLUTCH RETAINER HUB INPUT SHAFT J9121 214 Fig 136 Removing Intermediate Shaft Thrust Washer 32 Remove output shaft thrust plate from inter mediate shaft hub Fig 1...

Page 1557: ...chined surfaces on interme diate shaft or overdrive piston retainer to become nicked or scratched J9121 217 Fig 139 Removing Planetary Geartrain And Intermediate Shaft Assembly 35 Loosen rear band adjusting screw 4 5 turns 36 Remove low reverse drum snap ring Fig 140 LOW REVERSE DRUM J9121 351 Fig 140 Removing Low Reverse Drum Snap Ring 37 Remove bolts attaching overdrive piston retainer to rear o...

Page 1558: ...And Rear Band Rem ova i 42 Remove overrunning clutch cam and roller clutch assembly as a unit Fig 145 Turn cam back and forth and tilt it inward to remove it from case 43 Compress front servo rod guide about 1 8 inch with Valve Spring Compressor C 3422 B Fig 146 A C clamp and Special Tool C 4470 can also be used to compress rod guide 44 Remove front servo rod guide snap ring Exercise caution when ...

Page 1559: ...lock or restrict fluid passages and inter fere with valve operation Use petroleum jelly only Do not force parts into place The transmission components and subassemblies are easily installed by hand when properly aligned If a part seems extremely difficult to install it is either misaligned or incorrectly assembled Also ver ify that thrust washers thrust plates and seal rings are correctly position...

Page 1560: ... clutch cam is properly aligned Check alignment by threading a bolt into each bolt hole Adjust clutch cam position if necessary 8 Install and tighten overrunning clutch cam bolts to 17 N m 13 ft lbs torque Note that clutch cam bolts are shorter than piston retainer bolts 9 Lubricate clutch cam rollers with transmission fluid NON THREADED HOLE OVERRUNNING CLUTCH CAM J9121 226 Fig 151 Location Of No...

Page 1561: ...nning clutch rollers d Press drum rearward and turn it in clock wise direction until drum seats In overrunning clutch Fig 156 e Turn drum b a c k a n d forth Drum should rotate freely in clockwise direction and lock in counterclockwise direction as viewed from front of case Fig 156 installing Low Reverse Drum 13 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in ...

Page 1562: ...and Lever And Pivot Pin Instaliation 17 Install planetary geartrain assembly Fig 161 J9121 217 Fig 161 Installing Planetary Geartrain 18 Install thrust plate on intermediate shaft hub Fig 162 Use petroleum jelly to hold thrust plate in place 19 Check seal ring on rear clutch retainer hub and seal rings on input shaft Fig 163 Verify that diagonal cut ends of teflon seal rings are properly joined an...

Page 1563: ...y Then install washer in rear clutch hub Fig 166 Use enough petroleum jelly to hold washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Note thickness of this washer It is a select fit part and is used to control transmission end play B A C K FORTH UNTIL REAR CLUTCH ASSEMBLY J9121 190 Fig 165 Assembling Fr...

Page 1564: ...Fig 168 Installing Front Rear Clutch Assemblies 27 Slide front band over front clutch retainer Fig 169 28 Insert front band lever pivot shaft part way into case Fig 169 29 Install front band lever strut and adjusting screw Fig 170 30 Push front band lever shaft completely into place Then tighten band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still se...

Page 1565: ...lly Lubricate pump shaft seal lip with petroleum jelly 36 Install oil pump Fig 173 Align and position pump on pilot studs Slide pump down studs and work it into front clutch hub and case by hand Then install 2 or 3 pump bolts to hold pump in place 37 Remove pilot stud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft lbs 38 Install new seals o...

Page 1566: ...ushing surfaces with transmission fluid or petro leum jelly 47 Install overdrive unit Note that intermediate shaft is snug fit in overdrive planetary gear and overrunning clutch If overdrive unit will not seat gear and clutch splines are probably misaligned 48 Apply 1 2 drops of Mopar thread adhesive or Loctite 242 to overdrive unit attaching bolts Then install and tighten bolts to 34 N m 25 ft lb...

Page 1567: ...tight ened If this occurs the rod will have to be removed and replaced 54 Install new filter on valve body Tighten filter screws to 4 N m 35 in lbs 55 Adjust front and rear bands as follows a Loosen band adjusting screw locknuts b Tighten each band adjusting screw to 5 N m 72 in lbs with torque wrench c Back off front band adjusting screw 3 5 8 turns d Back off rear band screw 4 turns e Tighten ea...

Page 1568: ...Remove the clutch roller and spring assembly from the race afterward mm Fig 183 Removing Overrunning Clutch From Low Reverse Drum OVERRUNNING CLUTCH LOW REVERSE DRUM ASSEMBLE 1 Assemble clutch rollers and springs in retainer if necessary Fig 184 Fig 184 Overrunning Clutch Rollers Springs Retainer 2 Install overrunning clutch roller spring and retainer assembly in clutch cam Fig 185 3 Temporarily a...

Page 1569: ...4 0 Fig 187 Assembled Overrunning Clutch FRONT SERVO PISTON DISASSEMBLE 1 Remove seal ring from rod guide Fig 188 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discard servo component O ring and seal rings ASSEMBLE Clean and Inspect front servo components 1 Lubricate new O ring and seal rings with petroleum jelly and install them ...

Page 1570: ...ISASSEMBLE 1 Remove seal ring from housing and reaction shaft support Fig 190 2 Mark pump housing and support assembly for alignment reference 3 Loosen bolts that attach pump body to support Fig 191 4 Remove pump to support bolts and separate support from pump housing Fig 192 5 Remove inner and outer gears from reaction shaft support Fig 193 6 If pump seal was not removed during transmis sion disa...

Page 1571: ...afterward REACTI01 SHAFT SUPPORT BUSHING iEiOWAL 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 197 Do not clamp any part of reaction shaft or support i n vise 2 Hold Cup Tool SP 3633 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench 3 Turn remover tool hex nut down a...

Page 1572: ...hamfered Be sure the chamfered side faces forward to front of pump OUTER GEAR J9321 219 Fig 198 Supporting Pump And installing Outer Gear J9321 465 Fig 199 Pump inner Gear installation 6 Install new thrust washer on hub of reaction shaft support Lubricate washer with transmission fluid or petroleum jelly 7 I f reaction shaft seal rings are being replaced install new seal rings on support hub Fig 2...

Page 1573: ...s are fac ing out and are accessible b Secure pump assembly in case with 2 or 3 bolts or with pilot studs c Tighten support to pump bolts to 20 N m 15 ft lbs d Remove pump assembly from transmission case 12 Install new oil seal in pump with Special Tool C 4193 and Tool Handle C 4171 Fig 202 Be sure seal lip faces inward 13 Install new seal ring around pump housing Be sure seal is properly seated i...

Page 1574: ... retainer Be sure lip of each seal faces interior of clutch retainer 3 Lubricate lips of piston and retainer seals with liberal quantity of Mopar Door Ease or Ru Glyde Then lubricate retainer hub bore and piston with light coat of transmission fluid 4 Install clutch piston in retainer Fig 205 Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 020 thick can be ...

Page 1575: ...f clearance is incorrect clutch discs plates pressure plates and snap ring may have to be changed REAR CLUTCH DISASSEMBLE 1 Remove fiber thrust washer from forward side of clutch retainer 2 Remove selective clutch pack snap ring Fig 209 FEELER GAUGE RH288 Fig 208 Typical Method Of Measuring Front Clutch Pack Clearance REAR CLUTCH PISTON CLUTCH PISTON SEALS OUTPUT SHAFT THRUST WASHER METAL INPUT SH...

Page 1576: ...rts 2 Install new seal rings on clutch retainer hub and input shaft if necessary Fig 212 a Be sure clutch hub seal ring is fully seated in groove and is not twisted b Note that input shaft front seal ring is teflon and rear seal ring is metal Fig 213 Be sure chamfered ends of teflon ring are properly joined and that ends of rear ring are securely hooked J9121 538 Fig 212 Rear Clutch Retainer And I...

Page 1577: ...ainer groove 10 Install bottom pressure plate Fig 209 Ridged side of plate faces downward toward piston and flat side toward clutch pack 11 Install first clutch disc in retainer on top of bottom pressure plate Then install a clutch plate fol lowed by a clutch disc until entire clutch pack is installed 4 discs and 3 plates are required Fig 209 12 Install top pressure plate 13 Install selective snap...

Page 1578: ...y gear 10 Remove snap ring that retains sun gear in driving shell Then remove sun gear spacer and thrust plates DRIVING SHELL FRONT ANNULUS AND PLANETARY n t A k i r T A m ASSEMBLY P L A C A R Y SNAP RING J9421 175 Fig 218 Front Annulus And Planetary Assembly Removal PLANETARY SNAP RING FRONT ANNULUS GEAR J9421 176 Fig 219 Front Planetary Snap Ring Removal FRONT ANNULUS THRUST WASHER FRONT PLANETA...

Page 1579: ...ft Fig 224 Verify that assembly is fully seated on shaft Fig 224 installing Rear Annulus And Planetary On Output Shaft 6 Install front thrust washer on rear planetary gear Fig 225 Use enough petroleum jelly to hold washer on gear Be sure all four washer tabs are seated in slots 7 Install spacer on sun gear Fig 226 SELECT FIT PLANETARY SNAP RING FRONT ANNULUS THRUST WASHER DRIVING SHELL REAR THRUST...

Page 1580: ...rear of shell THRUST PLATE SUN GEAR SPACER 9 Hold sun gear in place and install thrust plate over sun gear at rear of driving shell Fig 228 DRIVING SHELL SUN GEAR REAR THRUST PLATE J912M62 Fig 228 Installing Driving Shell Rear Thrust Plate 10 Position wood block on bench and support sun gear on block Fig 229 This makes it easier to align and install sun gear lock ring Keep wood block handy as it w...

Page 1581: ... all four washer tabs are seated 14 Install front planetary gear on output shaft and in driving shell Fig 233 15 Install front thrust washer on front planetary gear Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 16 Assemble front annulus gear and support if necessary Be sure support snap ring is seated 17 Install front annulus on front planetary Fig ...

Page 1582: ...ositioned under forward end of output shaft This allows geartrain compo nents to move forward for accurate end play check 23 Check planetary geartrain end play with feeler gauge Fig 238 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartrain end play should be 0 12 to 1 22 mm 0 005 to 0 048 in If end play is incorrect snap ring or thrust washers may have to be repl...

Page 1583: ...ay possibly be reused 2 Remove intermediate shaft spacer Fig 244 Retain spacer It is a select fit part and may possibly be reused 3 Remove overdrive piston from retainer Fig 245 Fig 241 Overdrive Unit Removal Installation THRUST BEARING OVERDRIVE PISTON THRUST y PLATE Fig 242 Overdrive Piston Thrust Bearing Removal Installation OWERDRIWE CLUTCH PACK REIOWAL 1 Remove overdrive clutch pack wire reta...

Page 1584: ...termediate Shaft Spacer Location OVERDRIVE PISTON PISTON RETAINER J9121 299 Fig 245 Overdrive Piston Removal J9321 352 Fig 246 Removing Overdrive Clutch Pack Retaining Ring OVERDRIVE CLUTCH PACK Fig 247 Overdrive dutch Pack Removal PRESSURE PLATE TO FRONT CLUTCH DISC 3 OVERDRIVE CLUTCH PACK CLUTCH PLATE 2 REACTION PLATE TO REAR J9321 354 Fig 248 Overdrive Clutch Component Position ...

Page 1585: ... Fig 251 A T25 size Torx head bit is required TORX SCREWDRIVER T25 ACCESS COVER SCREWS J9321 357 Fig 251 Access Cover Screw Removal Installation 4 Remove access cover and gasket Fig 252 ACCESS COVER AND GASKET J9321 358 Fig 252 Access Cover And Gasket Removal Installation 5 Expand output shaft bearing snap ring with expanding type snap ring pliers Then push output shaft forward to release shaft be...

Page 1586: ...S USE SPRING COMPRESSOR TOOL 6227 1 AND A HYDRAULIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 1 Mount geartrain assembly in shop press Fig 257 2 Position Compressor Tool 6227 1 on clutch hub Fig 257 Support output shaft flange with steel p...

Page 1587: ...0 8 Remove Special Tool 6227 1 Then remove Fig 258 Direct Clutch Pack Snap Ring Removal 6 Remove direct clutch hub retaining ring Fig 259 J9321 363 Fig 259 Direct Clutch Hub Retaining Ring Removal J9321 365 Fig 260 Direct Clutch Pack Removal Geartrain Disassembly 1 Remove direct clutch hub and spring Fig 261 DIRECT DIRECT J9121 31 Fig 261 Direct Clutch Hub And Spring Removal ...

Page 1588: ...g 263 Insert pli ers into clutch hub Expand pliers to grip hub splines and remove clutch with counterclockwise twisting motion 4 Remove thrust bearing from overrunning clutch hub Fig 264 5 Remove overrunning clutch from hub Fig 264 6 Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 265 Use small center punch or scriber to make alignment marks OVERRUNNING CL...

Page 1589: ...res annulus gear on output shaft Fig 269 Use two screwdrivers to unseat and work snap ring out of groove as shown 11 Remove annulus gear from output shaft Fig 270 Use rawhide or plastic mallet to tap gear off shaft G E A R CASE Aii PARI LOCI DISASSEMBLY 1 Remove locating ring from gear case 2 Remove park pawl shaft retaining bolt and remove shaft pawl and spring 3 Remove reaction plug snap ring an...

Page 1590: ...ed Then install annulus gear retaining snap ring Fig 272 4 Align and install clutch drum on annulus gear Fig 273 Be sure drum is engaged in annulus gear lugs 5 Install clutch drum outer retaining ring Fig 273 SNAP RING OUTPUT SHAFT FRONT BEARING ANNULUS GEAR J9021 89 Fig 272 Annulus Gear Installation 6 Slide clutch drum forward and install inner retaining ring Fig 274 ANNULUS GEAR OUTER SNAP RING ...

Page 1591: ...SEATED IN OUTPUT SHAFT Fig 276 Assembling Overrunning Clutch And Hub 9 Install thrust bearing on overrunning clutch hub Fig 277 Use generous amount of petroleum jelly to hold bearing in place for installation Bear ing fits one way only Be sure bearing is seated squarely against hub Reinstall bearing if it does not seat squarely BE SURE THRUST BEARING IS SEATED SQUARELY AGAINST CLUTCH HUB CLUTCH HU...

Page 1592: ...as shown Bearing fits one way only If it does not seat squarely against spring plate remove and reposition bearing 15 Install assembled sun gear spring plate and thrust bearing Fig 282 Be sure sun gear and thrust bearing are fully seated before proceeding J9121 326 Fig 281 Planetary Thrust Bearing Installation Fig 282 Sun Gear Installation 16 Mount assembled output shaft annulus gear and clutch dr...

Page 1593: ...e sure plate is installed with shoulder side facing upward Fig 287 20 Install clutch hub and clutch pack on direct clutch spring Fig 288 Be sure hub is started on sun gear splines before proceeding WARNING THE NEXT STEP IN GEARTRAIN ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROX...

Page 1594: ...rum 23 Position Tool C 3995 A or similar type tool on top of Tool 6227 1 Fig 290 24 Compress clutch hub and spring just enough to place tension on hub and hold it in place 25 Slide direct clutch pack upwards on hub Fig 289 Then set clutch pack on edge of clutch hub and compressor tool as shown 26 Slowly compress clutch hub and spring Fig 289 Compress spring and hub only enough to expose ring groov...

Page 1595: ...ETAINING RING Fig 292 Clutch Hub Retaining Ring Installation ACCESS PLATE AND GASKET GEAR CASE CASE GASKET REACTION PLUG AND SNAP RING PARK LOCK ROD J9321 367 Fig 293 Park Lock Components 2 Install pawl shaft retaining bolt Tighten bolt to 27 N m 20 ft lbs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 294 Be sure pin is seated in hole in case before installin...

Page 1596: ...ing Position Fig 298 Overdrive Gear Case installation 9 Expand front bearing locating ring with snap ring pliers Fig 299 Then slide case downward until locating ring locks in bearing groove and release snap ring 10 Install locating ring access cover and gasket in overdrive unit case Fig 300 0WERDRIVE CLUTCH INSTALLATION 1 Install overdrive clutch reaction ring first Reaction ring is flat with notc...

Page 1597: ...sket Installation REACTION RING CLUTCH HUB J9321 356 Fig 301 Overdrive Clutch Reaction Ring Installation WAVE SPRING J9321 355 Fig 302 Overdrive Clutch Wave Spring Installation 5 Install first clutch disc followed by first clutch plate Then install remaining clutch discs and plates in same order 6 Verify clutch pack 3 clutch discs 2 steel plates 1 reaction plate and 1 pressure plate are required R...

Page 1598: ...ugh gauge tool slot until scale contacts end of Gauge Alignment Tool 6312 Lock scale in place Remove dial caliper tool and note distance mea sured Fig 305 d Select proper thickness end play spacer from spacer chart based on distance measured Fig 306 e Remove Gauge Alignment Tool 6312 3 Determine correct thickness overdrive piston thrust plate as follows a Position Gauge Tool 6311 across face of ov...

Page 1599: ...Fig 309 Removing Snap Ring And Front Bearing WARNING THE NEXT STEP IN GEARTRAIN DIS ASSEMBLY IN OL ES COMPRESSING THE DIRECT CLUTCH SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COM PRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS USE SPRING COM PRESSOR TOOL 6227 1 AND A HYDRAULIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT...

Page 1600: ... and spring Fig 313 11 Remove sun gear and spring plate planetary thrust bearing and planetary gear Fig 314 12 Remove overrunning clutch assembly with expanding type snap ring plier Fig 315 Insert pli ers into clutch hub Expand pliers to grip hub splines and remove clutch with counterclockwise twisting motion 13 Remove thrust bearing from overrunning clutch hub Fig 316 DIRECT CLUTCH SPRING DIRECT ...

Page 1601: ...tch drum rear retaining ring Fig 318 INNER RETAINING RING DIRECT CLUTCH DRUM ANNULUS GEAR J9121 292 Fig 318 Removing Clutch Drum Inner Retaining Ring 17 Remove direct clutch drum outer retaining ring Fig 319 OUTER RETAINING RING J9121 293 Fig 319 Removing Clutch Drum Outer Retaining Ring 18 Mark annulus gear and output shaft for assembly alignment reference Fig 320 19 Remove annulus gear from outp...

Page 1602: ...on output shaft Fig 322 4 Align and install annulus gear on output shaft Fig 322 5 Install annulus snap ring Fig 322 6 Align and install clutch drum on annulus gear Fig 323 Be sure drum is engaged in annulus gear lugs 7 Install clutch drum outer retaining ring Fig 323 8 Slide clutch drum forward and install inner retaining ring Fig 324 SNAP OUTPUT SHAFT RING FRONT BEARING ANNULUS GEAR J9021 89 322...

Page 1603: ...NAP RING PLIERS OVERRUNNING CLUTCH OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT J9121 322 Fig 325 Assembling Overrunning Clutch And Hub 1 BE SURE THRUST BEARING IS SEATED SQUARELY AGAINST CLUTCH HUB CLUTCH HUB J9121 323 Fig 326 Installing Overrunning Clutch Thrust Bearing 11 Install overrunning clutch Fig 327 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assem...

Page 1604: ...0 Slide bearing onto gear and seat it against spring plate as shown Bearing fits one way only If it does not seat squarely against spring plate remove and reposition bearing J9121 326 Fig 330 Installing Planetary Thrust Bearing 16 Install assembled sun gear spring plate and thrust bearing Fig 331 Be sure sun gear and thrust bearing are fully seated before proceeding Fig 331 Sun Gear Installation 1...

Page 1605: ...BORE DIRECT CLUTCH REACTION PLATE FLUSH WITH END OF HUB Pack Components 21 Install remainder of direct clutch components as follows a Install first clutch disc on reaction plate fol lowed by a steel plate b Alternately install remaining clutch discs and steel plates until required number are installed Fig 333 The clutch requires 8 discs and 7 steel plates c Last clutch pack item installed is clutc...

Page 1606: ...INIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 24 Position Compressor Tool 6227 2 on clutch hub Fig 337 25 Slide direct clutch pack upwards on hub Fig 337 Slide pack upward and set it partially on edge of hub and compressor tool as shown in Fig 337 26 Slowly comp...

Page 1607: ...hysical damage dented deformed broken etc CAUTION Do not turn the small screw at the end of the solenoid valve for any reason Turning the screw in either direction will ruin solenoid calibra tion and result in solenoid failure In addition the filter on the solenoid valve is NOT serviceable Do not try to remove the filter as this will damage the valve housing Inspect the throttle and manual valve l...

Page 1608: ...ore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve body assembly unless it is damaged in han dling The only serviceable valve bo...

Page 1609: ...TTLE VALVE COVER VALVE AND SPRING RETAINER BOOST VALVE SPRING 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE PLUG LINE PRESSURE ADJUSTING SCREW BOOST VALVE COVER ADJUSTING SCREW BRACKET PRESSURE SWITCH REGULATOR VALVE VALVE AND AND SPRING SPRING VALVE AND PLUG COVER MANUAL LEVER DETENT BALL AND SPRING J9521 72 Fig 341 Upper Housing Waives Plug Springs And Brackets ...

Page 1610: ...air Be sure all solvent Is removed from the case and that all fluid passages are clear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and ...

Page 1611: ...Replace the pump gears if pitted worn chipped or damaged Check the pump vent The vent must be secure Replace the pump body if the vent Is cracked broken or loose 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 unless they are actually dam aged Install the gears in the pu...

Page 1612: ... burned charred the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs on the pressure and clutch plates are also in good condition The lugs must not be bent cracked or damaged in any way Replace the piston spring and wave spring if either part is distorted warped or broken Check the lug grooves in the ...

Page 1613: ...eplace the output shaft if the machined surfaces are scored pitted or damaged In any way Also replace the shaft if the splines are damaged or i Components exhibits cracks at any location especially at the gov ernor valve shaft bore The annulus gears can be removed from their sup ports if necessary Just remove the snap rings and separate the two parts when replacement Is neces sary In addition the ...

Page 1614: ...he plates or drum if binding occurs Check condition of the annulus gear direct clutch hub clutch drum and clutch spring Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or cracked Be sure the splines and lugs on the gear drum and hub are in good condition The clutch plates and discs should slide freely in these components xrtrain Components Inspect the thr...

Page 1615: ...ction b If cable end and attachment stud are mis aligned off center cable will have to be adjusted as described in following procedure 6 Reconnect cable end to attachment stud Then with aid of a helper observe movement of transmis sion throttle lever and lever on throttle body a If both levers move simultaneously from Idle to half throttle and back to idle position adjust ment is correct b If tran...

Page 1616: ...sconnect the rods with a pry tool Pry only where the grommet and rod attach and not on the rod itself Then cut away the old grommet Use pliers to snap the new grommet into the lever and to snap the rod into the grommet 1 Shift transmission into Park 2 Raise vehicle 3 Loosen lock bolt in front shift rod adjusting swivel Fig 353 4 Be sure front shift rod slides freely in swivel Lube rod and swivel i...

Page 1617: ...n locknut to 41 N m 30 ft lbs torque 6 Lower vehicle REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehicle 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Be sure adjusting screw turns freely in lever 4 Tighten adjusting screw to 8 N m 72 in lbs torque Fig 356 5 Back off adjusting scre...

Page 1618: ...ssary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between the throttle lever cam and the kickdown valve stem Fig 358 Push the...

Page 1619: ......

Page 1620: ...to a J9321 372 HYDRAULIC FLOW IN NEUTRAL ...

Page 1621: ...HYDRAULIC FLOW IN REVERSE ...

Page 1622: ... LEVER IN DRIVE FIRST GEM PART THROTTLE LINE PRESSURE 70 78 psi GOVERNOR PRESSURE 0 75 psi THROTTLE PRESSURE To 40 psi CONVERTER LUBE PRESSURE 5 75 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 374 HYDRAULIC FLOW IN DRIVE FIRST GEAR D 39 ...

Page 1623: ...ERNOR PRESSURE 0 57 psi THROTTLE PRESSURE 0 94 psi 1 2 SHUT PRESSURE 25 70 psi CONVERTER I LUBE PRESSURE 5 75 psi PUMP SUCTION SELECTOR LEVER IN DRIVE SECOND GEAR PART THROTTLE OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 375 HYDRAULIC FLOW IN DRIVE SECOND GEAR ...

Page 1624: ...E R IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED LINE PRESSURE 57 94 psi GOVERNOR PRESSURE 0 60 psi THROTTLE PRESSURE 0 94 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 376 HYDRAULIC FLOW IN DRIVE THIRD GEAR ...

Page 1625: ...OVFRORiVE 4TH GEAk CONVERTER CLUTCH NOT APFJED LINE PRESSURE 95 130 psi GOVERNOR PRESSURE 0 60 psi THROTTLE PRESSURE 0 100 psi PUMP SUCTION CONVERTER LUBE PRESSURE j 5 57 psi J9321 377 HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH MOT APPLIED ...

Page 1626: ...OVERDRIVE 4TH GEAR CONVERTER CLUTCH APPLIED LINE PRESSURE 95 130 psi GOVERNOR PRESSURE 0 60 psi THROTTLE PRESSURE 0 100 psi CONVERTER LUBE PRESSURE 5 60 psi PUMP SUCTION J9321 378 HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED m ...

Page 1627: ...E LINE PRESSURE 55 62 psi 1 2 SHIFT CONTROL 25 35 psi GOVERNOR PRESSURE 0 30 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi o so m 1 1 1 5 ft z Q S Q 39 s ft o o 3 3 C D ft o o TO J9321 379 m 2 2 o F O 3 ro HYDRAULIC PLOW IN MANUAL LOW 1 ro C O ...

Page 1628: ...VER IN MANUAL 2 SECOND GEAR CLOSED THROTTLE LINE PRESSURE 55 62 psi 1 2 SHIFT CONTROL 25 35 psi GOVERNOR PRESSURE 6 57 psi CONVERTER LUBE PRESSURE 5 5 7 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 380 HYDRAULIC FLOW IN MANUAL SECOND 2 m 33 ...

Page 1629: ...R CLUTCH NOT APPLIED LINE PRESSURE 57 94 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIFT CONTROL 25 70 psi GOVERNOR PRESSURE 0 57 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 381 HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING GEAR ...

Page 1630: ...RQUE Fitting cooler line at trans 18 N m 13 ft lbs Bolt torque convertor 31 N m 23 ft lbs Bolt nut crossmember 68 N m 50 ft lbs Bolt driveplate to crankshaft 75 N m 55 ft lbs Plug front band reaction 17 N m 13 ft lbs Locknut front band adj 34 N m 25 ft lbs Switch park neutral 34 N m 25 ft lbs Bolt fluid pan 17 N m 13 ft lbs Screws fluid filter 4 N m 35 in lbs Bolt oil pump 20 N m 15 ft lbs Bolt ov...

Page 1631: ...edures in Overdrive Unit D A procedures Intermiediate shaft spacer Thrust plate and spacer are select fit Refer to size charts and selection procedures in Overdrive Unit D A procedures PRESSURE TEST Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle Line pressure at accumulator Closed throttl...

Page 1632: ...21 242 AUTOMATIC TRANSMISSION 42RE S P E C I A L T O O L S Pressure Gauge C 3293SP ...

Page 1633: ...B R SPECIAL TOOLS Continued AUTOMATIC TRANSMISSION 42RE 21 243 Gauge Throttle Setting C 3763 Snap ring Plier C 3915 ...

Page 1634: ...21 244 AUTOMATIC TRANSMISSION 42RE SPECIAL TOOLS Continued BR Dial Caliper C 4962 ...

Page 1635: ... Front dutch Bushing SP 3629 From kit C 3887 B Cup Bushing Remover SP 3633 From kit C 3887 B installer Oii Pump Bushing SP 5118 From kit C 3887 B Remover Reaction Shaft Bushing SP 5301 From kit C 3887 B Installer Reaction Shaft Bushing SP 5302 From kit C 3887 B Installer Front Clutch Bushing SP 5511 From kit G 3887 B ...

Page 1636: ...VICE PROCEDURES ALUMINUM THREAD REPAIR 276 CONVERTER DRAINBACK CHECK VALVE SERVICE 276 FLUID AND FILTER REPLACEMENT 275 FLUID LEVEL CHECK 274 FLUSHING COOLERS AND TUBES 276 TRANSMISSION FILL PROCEDURE 276 REMOVAL AND INSTALLATION GOVERNOR SOLENOID AND PRESSURE SENSOR 281 OUTPUT SHAFT FRONT BEARING 280 OUTPUT SHAFT REAR BEARING 279 OVERDRIVE HOUSING BUSHING 279 OVERDRIVE UNIT 284 PARK LOCK 280 PARK...

Page 1637: ...The direct clutch is applied in all ranges except fourth gear The 46RE is equipped with a lock up clutch in the torque converter The torque converter clutch is controlled by the Powertrain Control Module PCM The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic cir cuit by the torque converter control TCC solenoid on the valve body The torque ...

Page 1638: ...G CLUTCH OVERDRIVE CLUTCH DIRECT CLUTCH PLANETARY GEAR OUTPUT SHAFT SEAL Si a oo r o 50 1 2 M 3 co i a 3 0 INTERMEDIATE SHAFT VALVE BODY OVERDRIVE PISTON RETAINER DIRECT CLUTCH SPRING OVERDRIVE OVERRUNNING CLUTCH 801834a2 Fig 1 46RE Transmission 09 39 ...

Page 1639: ...B R AUTOMATIC TRANSMISSION 46 47RE GENERAL INFORMATION Continued 21 249 ...

Page 1640: ...ch is engaged in fourth gear and in third gear when the overdrive switch is OFF The torque converter hub drives the transmission oil fluid pump mm The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid If the flui...

Page 1641: ... channels governor pressure from the solenoid valve to the governor circuit It is the solenoid valve that develops the necessary gover nor pressure TRANSMISSION FLUID TEMPERATURE THERMISTOR Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor Fig 6 The temperature readings are used to control engagement of the fourth gear overdrive clutch the ...

Page 1642: ...ase in low range SHIFT VALVE OPERATION The shift valves are moved by a combination of throttle and governor pressure The governor pres sure is generated by electrical components The conditions under which a shift to fourth will not occur when Overdrive switch is Off Transmission fluid temperature is below 10 C 50 F or above 121 C 250 F Shift to third not yet completed Vehicle speed too low for 3 4...

Page 1643: ...control module 3 4 SHIFT SEQUENCE The overdrive clutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear Fourth gear overdrive range is electron ically controlled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens ...

Page 1644: ...c pressure test if shift prob lems were noted during road test 7 Perform air pressure test to check clutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission i...

Page 1645: ...T A B L E C O R R E C T FLUID FLUID LEVEL LEVEL 804d8eae Fig 9 Dipstick Fluid Level Marks c If fluid is black dark brown turned to sludge contains extensive amount of metal or fric tion material particles transmission will need overhaul Main and auxiliary coolers will have to be flow tested and reverse flushed as well EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in ai...

Page 1646: ...ollection should not exceed 1 quart or inter nal damage to the transmission may occur 4 If flow is found to be within acceptable limits reconnect the cooler line Then fill transaxle to the proper level using the approved type of automatic transmission fluid OVERDRIVE ELECTRICAL CONTROLS The overdrive off switch valve body solenoid case connectors and related wiring can all be tested with a 12 volt...

Page 1647: ...e transmission slips in fourth gear but not in third gear the overdrive clutch is slipping By select ing another gear which does not use these clutches the slipping unit can be determined For example if the transmission also slips in Reverse the front clutch is slipping If the transmission does not slip in Reverse the rear clutch is slipping d Application If slippage occurs during the 3 4 shift or...

Page 1648: ...rt 2 Connect 300 psi Gauge C 3293 SP to rear servo port Fig 10 3 Disconnect throttle and gearshift rods from manual and throttle levers 4 Start and run engine at 1000 rpm 5 Move shift lever on manual lever shaft all the way forward into manual low 6 Move transmission throttle lever from full for ward to full rearward position and note pressures on both gauges 7 Line pressure at accumulator port sh...

Page 1649: ... on the road or on a chassis dynamometer Do not perform this test on a hoist Use 300 psi Test Gauge C 3292 for this test 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug 3 Lower vehicle 4 Turn on OD switch 5 Secure test gauge so it can be viewed from driver s seat 6 Start engine and ...

Page 1650: ...ll speed 250 350 rpm below normal indicates the converter overrunning clutch is slipping The vehicle also exhibits poor acceleration but operates normally once highway cruise speeds are reached Torque converter replacement will be necessary Staff Speed Normal But Acceleration Poor If stall speeds are normal 1800 2300 rpm but abnormal throttle opening is required for accelera tion or to maintain cr...

Page 1651: ...ise rear of vehicle and allow accumulated fluid to drain out of converter housing 2 Check and adjust transmission fluid level 3 Raise vehicle Remove converter housing dust cover and wipe as much fluid as possible from con verter housing 4 Fabricate test probe Fig 14 Attach probe to converter housing with a dust shield bolt 5 Have a helper run engine at 2500 rpm with transmission in Neutral for two...

Page 1652: ...k disc Fig 17 A retaining strap is needed to secure the seal cup for testing The strap can be made from 31 75 mm 1 1 4 in wide stock Fig 18 The strap attaching hole positions are approximate only Measure hole position on the converter housing before drilling The pump vent tool is made from 6 35 mm 1 4 in rod and 4 76 mm 3 16 in plate Fig 19 The fabricated tools can all be made from mild steel or a...

Page 1653: ...en front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is removed FRONT FITTING INSTALL PLUG HOSE AND TUBING CONNECTED TO REAR FITTING Fig 21 Pressurizing Transmission With Tool 7700 3 Remove oil pump and remove pump seal Inspect pump housing drainback and vent holes for obstructions Clear holes with solvent an...

Page 1654: ... proper check ball installation 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if threads are damaged 10 Remove disassemble and repair transmission as necessary 11 Replace converter and flush cooler and line before installing new converter DELAYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Fluid Level Low 2 Filter Clogged 3 Gearshift Linkage Misadjusted 4 T...

Page 1655: ...ks if drive is restored 2 Repair or replace linkage components 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Remove and disassemble valve body Replace assembly if any valves or bores are damaged 5 Remove and disassemble transmission Replace overrunning clutch 6 Remove and disassemble transmission Replace seal rings and any other wo...

Page 1656: ... or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described Misadjusted in service section 6 Governor Valve Sticking 6 Inspect clean or repai...

Page 1657: ...t Look for stuck 1 2 valve or governor plug 2 Remove clean and inspect Replace faulty parts 3 Test using DRB and repair as required NO LOW GEAR MOVES IN 2ND OR 3RD GEAR ONLY 1 Governor Valve Sticking 2 Governor Circuit RE Only Electrical Fault 3 Valve Body Malfunction 4 Front Servo Piston Cocked in Bore 5 Front Band Linkage Malfunction 1 Remove governor clean inspect and repair as required 2 Test ...

Page 1658: ... Check for binding cable or missing return spring 2 Adjust linkage and repair linkage if worn or damaged 3 Check line and governor pressures to determine cause Correct as required 4 Check operating pressures and test with DRB scan tool repair faulty component 5 Adjust Band 6 Air pressure check operation of clutches and bands Repair faulty component CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted...

Page 1659: ... Cooler Lines 7 Rear Clutch Malfunction Leaking Seals or Worn Plates 8 Overrunning Clutch Worn Not Holding Slips in 1 Only 1 Add fluid and check for leaks 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Adjust linkage 4 Adjust linkage 5 Inspect and replace as needed 6 Perform hydraulic and air pressure tests to determine...

Page 1660: ...r Connectors Shorted 2 PCM Malfunction 3 TPS Malfunction 4 Lockup Solenoid Not Venting 5 Overdrive Solenoid Not Venting 6 Valve Body Valve Sticking 1 Test wiring and connectors with test lamp and volt ohmmeter Repair wiring as necessary Replace connectors and or harnesses as required 2 Check PCM operation with DRB scan tool Replace PCM only if faulty 3 Check TPS with DRB scan tool at PCM 4 Remove ...

Page 1661: ...for correct routing Should not touch engine or bell housing NO 3 4 UPSHIFT 1 Dash O D Switch In OFF Position 2 Overdrive Circuit Fuse Blown 3 O D Switch Wire Shorted Open Cut 4 Distance or Coolant Sensor Malfunction 5 TPS Malfunction 6 Neutral Switch to PCM Wire Shorted Cut 7 PCM Malfunction 8 Overdrive Solenoid Shorted Open 9 Solenoid Feed Orifice in Valve Body Blocked 10 Overdrive Clutch Failed ...

Page 1662: ...ble transmission remove retainer and replace orifice 4 Remove overdrive unit Replace seals if worn Replace piston if damaged If piston retainer is damaged remove and disassemble the transmission 5 Remove and overhaul valve body Replace accumulator seals Make sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are...

Page 1663: ...sembly 1 Adjust linkage cable 2 Check continuity with test lamp Repair as required 3 Refer to service section for test and replacement procedure 4 Connectors spread open Repair 5 Inspect lever assembly and replace if damaged NO REVERSE OR SLIPS IN REVERSE 1 Direct Clutch Pack front clutch Worn 2 Rear Band Misadjusted 3 Front Clutch Malfunctioned Burned 4 Overdrive Thrust Bearing Failure 5 Direct C...

Page 1664: ...d 5 Overdrive Unit Overrunning Clutch Rollers Worn Scored 1 Remove unit and rebuild clutch pack 2 Remove and disassemble unit Replace either thrust bearing if damaged 3 Remove and disassemble unit Replace either bearing if damaged 4 Remove and overhaul overdrive unit 5 Remove and overhaul overdrive unit SERVICE PROCEDURES FLUID IEWEI CHEC1 Transmission fluid level should be checked monthly under n...

Page 1665: ... remove remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pan 9 Remove screws holding filter to valve body Fig 24 10 Separate filter from valve body and pour fluid in filter into drain pan 11 Dispose used trans fluid and filter properly INSPECTION AND CLEANING INSPECTION Inspect bottom of pan and magnet f...

Page 1666: ...ll is spring loaded and has an opening pres sure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do not clean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates sludge and or clutch particles and metal shav ings the valve must be replaced The valve must be removed whenever the coole...

Page 1667: ...ction line into a one quart container of Mopar type 7176 automatic transmis sion fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from coole...

Page 1668: ...wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary PARK NEUTRAL POSITION SWITCH Switch Replacement 1 Raise vehicle and position drain pan under switch 2 Disconnect switch wires 3 Remove switch from case 4 Move shift lever to Park and Neutral positions Verify that switch operating lever fingers are cen tered in switch opening in case Fig 28 SPEEDOMETER ...

Page 1669: ...hing and remove bushing Fig 31 INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 2 Tap bushing into place with Special Tool 6951 and Special Tool C 4171 3 Install new oil seal in housing using Seal Installer C 3972 A S P E C I A L T O O L C 4471 J9521 58 EXTENSION HOUSING BUSHING Fig 31 Overdrive Housing Bushing Removal OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive un...

Page 1670: ...I REMOVAL 1 Remove overdrive unit from vehicle 2 Remove overdrive geartrain from housing 3 Remove bolt holding park pawl in overdrive housing CAUTION Do not over stress snap ring during removal snap ring distortion can result 4 Remove snap ring holding reaction plug in overdrive housing 5 Pull park pawl shaft from housing 6 Separate park pawl park pawl spring and reaction plug from overdrive housi...

Page 1671: ...sure sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace gasket 1 Lubricate O ring on pressure sensor with transmission fluid 2 Align pressure sensor to bore in governor body Fig 39 3 Push pressure sensor into governor body 4 Install retainer to hold pressure sensor to gov ernor body 5 Place gasket in position on back of governor body Fig 38 6 Place ...

Page 1672: ...tch and solenoid case connector Fig 40 6 Position drain pan under transmission oil pan 7 Remove transmission oil pan and gasket 8 Remove fluid filter from valve body 9 Remove bolts attaching valve body to transmis sion case 10 Lower valve body enough to remove accumu lator piston and springs 11 Work manual lever shaft and electrical con nector out of transmission case Then lower valve body rotate ...

Page 1673: ...10 Align accumulator piston and outer spring manual lever shaft and electrical connector in case Then seat valve body on case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in lbs torque 12 Install new fluid filter on valve body Tighten filter screws to 4 N m 35 in lbs torque 13 Install and connect park neutral position swi...

Page 1674: ...N COOLER REPLACEMENT MAIN COOLER REPLACEMENT The main transmission cooler is located in the radiator The cooler is not a serviceable component If the cooler is damaged the radiator must be replaced AUXILIARY COOLER REPLACEMENT 1 Remove grille refer to Group 23 Body for proper procedures 2 Remove brackets holding cooler to radiator and radiator support Fig 46 3 Tag cooler hoses for installation ref...

Page 1675: ...efer to Disassemble and Assemble section of this group for proper procedures 12 Remove and retain overdrive piston thrust bearing Bearing may remain on piston or in clutch hub during removal 13 Position drain pan on workbench J9021 83 Fig 48 Removing Installing Overdrive Unit Attaching Bolts 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 15 Examine fluid for clu...

Page 1676: ...Alignment Tool 6227 2 out of overdrive planetary gear and overrunning clutch splines 11 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reaction plug at same time Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to rotate out of alignment I f this occurs it will be necessary to ...

Page 1677: ...TRANSFER TUBE V6 J9421 256 Fig 52 Fill Tube Attachment at a time Rotate crankshaft with socket wrench on dampener bolt 12 Mark propeller shaft and axle yokes for assembly alignment Then disconnect and remove propeller shaft ON 4 x 4 models remove both pro peller shafts 13 Disconnect wires from park neutral position switch transmission solenoid and vehicle speed sen sor 14 Disconnect gearshift rod ...

Page 1678: ...pump gears 6 Check converter seating with steel scale and straightedge Fig 55 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 Temporarily secure converter with wedge tool or C clamp Fig 55 Typical Method Of Checking Converter Seating 8 Position transmission on jack and secure it with chains 9 Check condition of converter driveplate Replace the p...

Page 1679: ...le 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 surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pul...

Page 1680: ...r pressure sen sor and solenoid Fig 57 Fig 57 Governor Pressure Soienoid And Sensor Wire Locations 2 Remove screws attaching governor body and retainer plate to transfer plate Fig 58 Fig 58 Governor Body And Retainer Plate Attaching Screw 3 Remove retainer plate governor body and gas ket from transfer plate Fig 59 Fig 59 Governor Body And Gasket 4 Disconnect wires from governor pressure sen sor if...

Page 1681: ...oid Harness Case Connector Shoulder Bolt 8 Unhook overdrive converter solenoid harness from 3 4 accumulator cover plate Fig 63 9 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 64 10 Remove solenoid and harness assembly from valve body Fig 65 O V E R D R I V E C O N V E R T E R S O L E N O I D W I R E S H A R N E S S 3 4 A C C U M U L A T ...

Page 1682: ...ost Valve Components 13 Secure detent ball and spring with Retainer Tool 6583 Fig 68 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING 14 Remove E clip and washer that retains throt tle lever shaft in manual lever Fig 69 MANUAL SHAFT E CLIP AND WASHER J9321 424 Fig 69 Throttle Lever E Clip And Washer 15 Remove manual lever and throttle lever Fig 70 Rotate and lift manual lever off valve body and thro...

Page 1683: ...ure adjusting screw bracket to valve body and transfer plate Fig 73 Hold bracket firmly against spring tension while removing last screw REMOVE THESE SCREWS FIRST REMOVE THIS SCREW LAST BRACKET J9321 430 Fig 73 Adjusting Screw Bracket Fastener 19 Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 74 Do not remove throt tle press...

Page 1684: ...and spring Fig 76 ACCUMULATOR HOUSING 3 4 SHIFT VALVE SPRING CONVERTER CLUTCH VALVE SPRING C L U T C H VALVE L D PLUG J9321 433 Fig 78 8 4 Shift And Converter Clutch Vaive Springs And Plug 22 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 77 3 4 SHIFT VALVE SPRING 3 4 ACCUMULATOR HOUSING CONVERTER CLUTCH VALVE SPRING AND PLUG J9321 434 Fig 77 Accumulator Housing Val...

Page 1685: ...ng is fac ing upward Fig 81 In this position the two check balls in upper housing will remain in place and not 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 81 Note position of boost valve tube brace for assembly reference 28 Remove lower housing and overdrive separa tor plate from transfer pl...

Page 1686: ...large diame ter and the six smaller diameter check balls 2 Remove E clip that secure shuttle valve second ary spring on valve stem Fig 87 3 Remove governor plug and shuttle valve covers Fig 88 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 88 5 Remove boost valve retainer spring and valve if not previously removed SMALL DIAMETER CHECK BALLS 6 LARGE DIAME...

Page 1687: ...B R AUTOMATIC TRANSMISSION 46 47RE 21 297 DISASSEMBLY AND ASSEMBLY Continued I SHUTTLE VALVE COVER J9421 217 Fig 88 Shuttle And Boost Valve Components Fig 89 Upper Housing Control Vaive Locations ...

Page 1688: ...g Fig 91 6 Remove converter clutch timing valve retainer and valve spring 34 ACCUMULATOR H0USIN1 DISASSEMBLY 1 Remove end plate from housing 2 Remove piston spring And Pressure Plug Locations 3 Remove piston Remove and discard piston seals Fig 92 VALVE BODY ASSEMBLE CAUTION Do not force valves or plugs Into place during reassembly If the valve body bores valves and plugs are free of distortion or ...

Page 1689: ...VER PLATE AND SCREWS Fig 91 Lower Housing Shift Vaives And Springs 7 Install converter clutch valve spring and plug 8 Install converter clutch timing valve and spring 3 4 ACCUMULATOR ASSEMBLY 1 Lubricate accumulator piston seals and hous ing piston bore with clean transmission fluid Fig 92 2 Install new seal rings on accumulator piston 3 Install piston and spring in housing 4 Install end plate on ...

Page 1690: ...lbs torque ASSEMBLING UPPER AND LOWER HOUSINGS 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 96 Seven check balls are used The single large check ball is approximately 8 7 mm 11 32 in diameter The remaining 6 check balls are approximately 6 3 mm 1 4 in in diameter 2 Position assembled transfer plate and upper hous ing s...

Page 1691: ... A L W E AND PLUG INSTALLATION Refer to Fig 100 Fig 101 and Fig 102 to per form the following steps VALVE BODY SCREWS 13 LOWER HOUSING UPPER HOUSING TRANSFER PLATE J9321 442 Fig 99 instaliing Lower Housing On Transfer Plate And Upper Housing 1 Lubricate valves plugs springs with clean transmission fluid 2 Assemble regulator valve line pressure plug sleeve throttle plug and spring Insert assembly i...

Page 1692: ... Upper Housing Control Vaive Locations 6 Install shuttle valve as follows c Compress secondary spring and install E clip a Insert plastic guides in shuttle valve second in groove at end of shuttle valve ary spring and install spring on end of valve d Verify that spring and E clip are properly b Hold shuttle valve in place seated before proceeding UPPER HOUSING PRESSURE I VALVE LIMIT PLUG RETAINER ...

Page 1693: ...port Fig 103 BOOST LOWER UPPER THIS END OF HOUSING TUBE FIRST J9321 147 Fig 108 Boost Vatwe Tube 4 Insert and seat each end of tube In housings 5 Slide tube brace under tube and into alignment with valve body screw holes Fig 104 6 Install and finger tighten three screws that secure tube brace to valve body housings Fig 104 7 Bend tube brace tabs up and against tube to hold it in position Fig 105 8...

Page 1694: ... and not be pinched between accumulator housing and cover OVERDRIVE CONVERTER Fig 109 Solenoid Harness Routing W A L W E B0i FINAL ASSEMBLY AND ADJUSTMENT 1 Insert manual lever detent spring In upper housing 2 Position line pressure adjusting screw In adjusting screw bracket 3 Install spring on end of line pressure regulator valve 4 Install switch valve spring on tang at end of adjusting screw bra...

Page 1695: ... THIS SCREW FOR ANY REASON DOING SO WILL RUIN SOLENOID VALVE CALIBRATION CAUSING FAILURE SOLENOID VALVE O RINGS SERVICEABLE SOLENOID VALVE FILTER NOT SERVICEABLE VENT PORTS J9321 455 Fig 112 Governor Pressure Solenoid 1 Turn valve body assembly over so accumulator side of transfer plate is facing down 2 Install new O rings on governor pressure sole noid and sensor Fig 112 and Fig 113 3 Lubricate s...

Page 1696: ...c tor is positioned in retainer cutout Fig 116 Pressure Solenoid Retainer 8 Align screw holes in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 in lbs torque 9 Connect harness wires to governor pressure solenoid and governor pressure sensor Fig 117 10 Perform Line Pressure and Throttle Pressure adjustments refer to adjustment section of this group for p...

Page 1697: ...ure washer 5 Remove torque converter from front of trans mission 6 Remove throttle and shift levers from valve body manual shaft and throttle lever shaft 7 Mount transmission in repair stand C 3750 B or similar type stand Fig 118 OVERDRIVE PISTON J9121 503 Fig 119 Overdrive Piston Thrust Plate f f PISTON Pig 118 Repair Stand 8 Remove overdrive unit from transmission case refer to Removal and Insta...

Page 1698: ...ectronic governor 16 Remove accumulator outer spring piston and inner spring Fig 123 Note position of piston and springs for assembly reference Remove and discard piston seals if worn or cut 17 Remove front band lever pin access plug Fig 125 Use square end of 1 4 in drive extension to remove plug as shown 18 Remove oil pump and reaction shaft support assembly as follows J9121 114 Fig 123 Park Neut...

Page 1699: ...p housing Fig 127 PUMP HOUSING SLIDE HAMMER TOOLS THREAD INTO PUMP HOUSING J9121 14 Fig 127 Oil Pump Removal Tools d Remove oil pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case Fig 128 19 Remove oil pump gasket Fig 129 Note gas ket position in case for assembly reference 20 Loosen front band adjusting screw until band is completely loose Fig 128 O...

Page 1700: ...ONT CLUTCH RETAINER J9121 19 23 Remove front and rear clutch assemblies as a unit Fig 132 Set assemblies aside for disassembly and inspection after removal FRONT AND REAR CLUTCH ASSEMBLIES J9121 20 Fig 132 Removing Front Rear Clutch Assemblies 24 Remove front band reaction pin and lever Start pin through lever and out of case bore with drift or punch Then use pencil magnet to withdraw pin complete...

Page 1701: ...mediate Shaft And Planetary Geartrain SHAFT THRUST PLATE J9521 89 Fig 137 Low Reverse Drum Snap Ring LOW REVERSE DRUM Fig 135 Intermediate Shaft Thrust Plate 27 Remove intermediate shaft planetary geartrain assembly Fig 136 Set assembly aside for disassembly and inspection later in procedure 28 Loosen rear band locknut and loosen adjust ing screw 3 4 turns 29 Remove snap ring that retains low reve...

Page 1702: ...Race Position On Low Reverse Drum 32 Remove overrunning clutch assembly Fig 140 Assembly can be removed without displacing rollers and springs if care is exercised Note position of rollers and springs for assembly reference 33 Remove rear band adjusting lever reaction lever and pin Fig 141 Fig 141 Rear Band Levers And Pins 34 Remove strut from rear band Keep strut with levers and pin for cleaning ...

Page 1703: ...se Fig 145 43 Remove gasket from rear of case after remov ing piston retainer FRONT SERVO ROD GUIDE J9121 39 Fig 143 troni Servo Retaining Snap Ring TRANSMISSION ASSEMBLY Do not allow dirt grease or foreign material to enter the case or transmission components during assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for reassembly operations...

Page 1704: ...d blocks or cut a hole in the bench large enough for the intermediate shaft and rear support Then lower the shaft and support into the hole and support the rear of the case directly on the bench FROlT REAi SERW0 IISTALLATiOl 1 Lubricate rear servo piston seal with Mopar Door Ease or ATF Plus Lubricate servo bore in case with ATF Plus 2 Install rear servo piston in case Position piston at slight an...

Page 1705: ...o spring 8 Install front servo piston rod guide as follows a Place Tool SP 5560 or similar size tool on guide and position C clamp on tool and case Fig 150 b Slowly compress rod guide while simulta neously easing seal ring into bore with suitable tool 9 Install rod guide snap ring Fig 150 OWERRUNNiNG CLUTCH REAR BAND LOW REWERSE DRUM AID OWERDRiWE PiSTOI RETAINER INSTALLATION 1 Install new gasket ...

Page 1706: ...f not yet installed Refer to Overrunning Clutch Overhaul in this section for procedures if necessary 4 Position rear band and link in case Fig 153 5 Install low reverse drum Fig 154 Slide drum through rear band onto piston retainer hub and into engagement with overrunning clutch and race Fig 154 Low Reverse Drum 6 Install thrust washer in low reverse drum spot face Fig 155 Use petroleum jelly to h...

Page 1707: ...J9121 508 Fig 158 intermediate Shaft And Planetary Geartrain 2 Lubricate intermediate shaft thrust plate with petroleum jelly and install plate on shaft pilot hub Fig 159 Fig 159 Intermediate Shaft Thrust Plate 3 Check input shaft front seal rings fiber thrust washer and rear seal ring Fig 160 Be ends of rear seal ring are hooked together and diagonal cut ends of front seal rings are firmly seated...

Page 1708: ...his makes it easier to install front rear clutch assembly 7 Align discs in rear clutch Then install and engage assembly in front planetary and driving shell BR Fig 162 intermediate Shaft Thrust Washer Fig 163 Turn clutch retainers back and forth until both clutches are seated Fig 163 Front Rear Clutch Assemblies 8 Position front band lever in case and over servo rod guide Then install front band l...

Page 1709: ...n pilot studs and seat it in case Be sure gasket is properly aligned with fluid passages in case Fig 165 Fig 165 Oil Pump Gasket And Pilot Studs 3 Coat front clutch thrust washer with petroleum jelly to hold it in place Then install washer over reaction shaft hub and seat it on pump Fig 166 Fig 166 Front Clutch Thrust Washer CAUTION The thrust washer bore I D is cham fered on one side Make sure th...

Page 1710: ...ugs on piston i n locating bores i n retainer Fig 169 Use thin plastic strip or feeler gauge to help guide piston outer seal into retainer 3 Install spacer on intermediate shaft if not pre viously installed 4 Install overdrive piston thrust plate Fig 170 Use liberal quantity of petroleum jelly to hold thrust plate in position on piston 5 Install overdrive piston thrust bearing in direct clutch hub...

Page 1711: ...ecord read ing 4 4 End play should be 0 86 2 13 mm 0 034 0 084 in 5 If end play is incorrect change intermediate shaft thrust washer The thrust washer controls end play and is available in three thicknesses for adjust ment purposes Fig 173 Checking Input Shaft End Play BAND ADJUSTMENTS AND INSTALLATION OF ACCUMULATOR WALVE BODY OIL PAN AND TORQUE C0NWERTER 1 Install accumulator inner spring piston...

Page 1712: ...ns mission failure can result 13 Install torque converter refer to Removal and Installation section of this group for proper proce dure Use C clamp or metal strap to hold converter in place for installation CAUTION If the condition of the transmission before the overhaul procedure caused excessive metallic or fiber contamination in the fluid reverse flush the cooler s and cooler lines before filli...

Page 1713: ...fully Replace assembly if the rollers springs or cage type retainer are worn or damaged If the clutch cam requires replacement install a new cam as described in the following procedure OVERRUNNING CLUTCH CAM REPLACEMENT 1 Tap old cam out of case with pin punch Insert punch through bolt holes at rear of case Fig 178 Alternate position of punch to avoid cocking cam dur ing removal Fig 178 Overrunnin...

Page 1714: ...press clutch cam into case Fig 183 Be sure cam is pressed into case evenly and does not become cocked 11 Remove clutch cam installer tools 12 Stake case in 1 2 places around clutch cam to help secure cam in case Use blunt punch or chisel to stake case 13 Remove piston retainer from case Cover retainer with plastic sheeting or paper to keep it dust free 14 Clean case and cam thoroughly Be sure any ...

Page 1715: ...ve seal ring from rod guide Fig 186 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discard servo component O ring and seal rings ASSEMBLE Clean and inspect front servo components 1 Lubricate new O ring and seal rings with petroleum jelly and install them on piston guide and rod Fig 185 Overrunning Clutch Seated In Cam 2 Install rod...

Page 1716: ... 189 Pump Gear OIL PUiP BUSHili REiOfAL 1 Position pump housing on clean smooth sur face with gear cavity facing down 2 Remove bushing with Tool Handle C 4171 and Bushing Remover SP 3550 Fig 191 OIL PUiP BUSHING INSTALLATION 1 Assemble Tool Handle C 4171 and Bushing Installer SP 5118 2 Place bushing on installer tool and start bush ing into shaft 3 Tap bushing into place until Installer Tool SP 51...

Page 1717: ...B R AUTOMATIC TRANSMISSION 46 47RE 21 327 DISASSEMBLY AND ASSEMBLY Continued Fig 190 Oii Pump And Reaction Shaft Components J9221 244 Fig 191 Oii Pump Bushing ...

Page 1718: ... securely hooked together after installation Otherwise the rings will either prevent pump installation or break during installation 4 Align and install reaction shaft support on pump body 5 Install bolts attaching reaction shaft support to pump Tighten bolts to 20 N m 175 in lbs torque 6 Install new pump seal with Installer Tool C 3860 A Fig 194 Use hammer or mallet to tap seal into place 7 Instal...

Page 1719: ...SNAP RING CLUTCH DISCS REACTION PLATE J9321 129 Fig 196 Front C 2 Slide new bushing onto installer tool and start bushing into retainer 3 Tap new bushing into place until installer tool bottoms against clutch retainer 4 Remove installer tools and clean retainer thor oughly ASSEMBLE 1 Soak clutch discs in transmission fluid ch Components 2 Install new inner and outer seals on clutch pis ton Be sure...

Page 1720: ... snap ring 2 Remove reaction plate and remove clutch plates and discs Fig 200 3 Remove pressure plate wave spring spacer ring and piston spring from clutch retainer 4 Remove clutch piston from piston retainer with a twisting motion 5 Remove input shaft thrust washer if washer remained in piston retainer hub during removal FEELER GAUGE RH288 Fig 199 Typical Method Of Measuring Front dutch Pack dear...

Page 1721: ...spacer ring Then seat wave spring in retainer groove I f wave spring will not seat properly spacer ring has probably shifted over and into wave spring groove i n retainer Use small screwdriver to realign spacer ring i f necessary 9 Install inner pressure plate in clutch retainer 10 Install first clutch disc followed by steel plate until all discs and plates are installed 4 clutch discs and steel p...

Page 1722: ... 6 Remove tabbed thrust washer from rear plane tary gear Fig 208 Note washer position on gear for assembly reference 7 Remove rear planetary gear and rear annulus gear from intermediate shaft Fig 209 Fig 204 Removing Front Planetary And Annulus Gears FRONT PLANETARY GEAR Fig 205 Disassembling Front Planetary And Annuius Gears 8 Remove thrust plate from rear annulus gear Fig 210 ASSEMBLY 1 Lubricat...

Page 1723: ... Gear And Driving Shell Removal SUN GEAR REAR PLANETARY THRUST WASHER DRIVING SHELL J9321 172 Fig 208 Rear Planetary Thrust Washer Removal INTERMEDIATE SHAFT REAR ANNULUS GEAR REAR PLANETARY GEAR J9321 173 Fig 209 Rear Planetary And Annulus Gear Removal REAR ANNULUS GEAR THRUST PLATE J932M74 Fig 210 Rear Annulus Thrust Plate Removal DRIVING SHELL THRUST PLATE SUN GEAR REAR RETAINING RING SUN GEAR ...

Page 1724: ...on front face of rear planetary gear Fig 215 Seat washer tabs in matching slots in face of gear carrier Use extra petroleum jelly to hold washer in place if desired 7 Lubricate sun gear bushings with petroleum jelly or transmission fluid 8 Install sun gear and driving shell on interme diate shaft Fig 216 Seat shell against rear plane tary gear Verify that thrust washer on planetary gear was not di...

Page 1725: ...tching slots in face of gear carrier Use extra petroleum jelly to hold washer in place if desired Fig 218 Installing Thrust Washer On Front Planetary Gear 11 Install front annulus gear over and onto front planetary gear Fig 219 Be sure gears are fully meshed and seated Fig 219 Assembling Front Planetary And Annulus Gears 12 Install front planetary and annulus gear assembly Fig 220 Hold gears toget...

Page 1726: ... is important for accurate end play check 16 Check planetary geartrain end play with feeler gauge Fig 222 Insert gauge between rear annulus gear and shoulder on intermediate shaft as shown End play should be 0 15 to 1 22 mm 0 006 to 0 048 in 17 If end play is incorrect install thinner thicker planetary snap ring as needed 01ERDR1WE UNIT NOTE Check number of plates and discs in clutch pack for asse...

Page 1727: ...lutch hub Fig 226 Fig 227 Removing lnstaiiing Overdrive dutch Pack Retaining Ring OVERDRIVE CLUTCH PACK Fig 226 Removing Overdrive Piston Thrust Bearing 5 Remove overdrive clutch pack retaining ring Fig 227 6 Remove overdrive clutch pack Fig 228 Note that thickest plate is positioned at rear of clutch pack 7 Remove overdrive clutch wave spring Fig 229 J9121 281 Fig 228 Overdrive Clutch Pack Remova...

Page 1728: ...RING EXPAND FRONT BEARING LOCATING RING WITH SNAP RING PLIERS OVERDRIVE CASE J9121 284 Fig 232 Releasing Shaft Front Bearing From Locating Ring 11 Remove geartrain assembly from housing Fig 233 Set geartrain aside 12 Remove park pawl retaining bolt and reaction plug snap ring Fig 234 Compress snap ring only enough to remove it Snap ring can be distorted if over compressed 13 Remove park pawl shaft...

Page 1729: ...R AUTOMATIC TRANSMISSION 46 47RE 21 339 DISASSEMBLY AND ASSEMBLY Continued Fig 233 Removing Overdrive Geartrain Fig 284 Park Lock Component Removal Fig 235 Output Shaft Rear Bearing And Snap Ring Location ...

Page 1730: ...k lock reaction plug Note that plug has locating pin at rear Fig 238 Be sure pin is seated in hole in case before installing snap ring 7 Install reaction plug snap ring Fig 239 Com press snap ring only enough for installation do not distort it REACTION PLUG SNAP RING DO NOT OVERCOMPRESS TO INSTALL PARK LOCK REACTION PLUG J9121 338 LOCATING PIN SNAP RING PLIERS Fig 239 Reaction Plug And Snap Ring I...

Page 1731: ...iate shaft spacer as follows CLUTCH PLATES 3 PRESSURE PLATE CLUTCH DISCS 4 J9321 227 Fig 242 Overdrive Clutch Pack Components WAVE SPRING REACTION RING RETAINING RING WIRE TYPE J9121 470 Fig 243 Overdrive Clutch Ring Identification a Insert Special 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 ...

Page 1732: ...or installation on transmission OVERDRIVE GEARTRAIN NOTE Check number of plates and discs in clutch pack for assembly reference Some models use an additional clutch disc and plate DISASSEMBLE 1 Remove output shaft front bearing snap ring Fig 248 2 Remove front bearing from output shaft Fig 248 SPECIAL TOOL C 4962 DIRECT CLUTCH HUB THRUST BEARING SEAT SPECIAL TOOL 6311 J9221 48 Fig 246 Overdrive Pi...

Page 1733: ...e slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 249 6 Remove direct clutch pack snap ring first Fig 249 Fig 249 Removing Direct Clutch Pack Snap Ring 7 Remove direct clutch hub retaining ring Fig 250 Fig 250 Removing Direct Clutch Hub Retaining Ring 8 Release press load on clutch spring slowly and completely R...

Page 1734: ...EAR J9121 312 Fig 253 Removing Sun Gear Thrust Bearing Planetary Gear OVERRUNNING UTCH CLUTCH HUB THRUST BEARING J9121 320 Fig 255 Overrunning Clutch Components 15 Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 256 Use small center punch or scriber to make alignment marks PUNCH 8921 249 8921 248 Fig 254 Removing Overrunning Clutch Assembly Fig 256 Marking...

Page 1735: ...Remove output shaft front bearing if not pre viously removed ASSEMBLE 1 Soak direct clutch and overdrive clutch discs in Mopar ATF Plus before installation Also lubricate geartrain components with ATF Plus during reassembly 2 Install new pilot bushing and clutch hub bush ing in output shaft if necessary Fig 261 Lubricate new or old bushings with petroleum jelly 3 Install front bearing and bearing ...

Page 1736: ...on bearing if it does not seat squarely 11 Install overrunning clutch Fig 266 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion CLUTCH HUB OVERRUNNING CLUTCH J9121 322 Fig 264 Assembling Overrunning Clutch And Hub BE SURE THRUST BEARING S SEATED SQUARELY AGAINST CLUTCH HUB CLUTCH HUB J9121 323 Fig 265 Installing Overrunning...

Page 1737: ...n gear and thrust bearing are fully seated before proceeding 17 Align splines in hubs of planetary gear and overrunning clutch with Alignment Tool 6227 2 Fig 271 Insert tool through sun gear and into splines of SUN RING J9121 325 Fig 268 Sun Gear And Spring Piate Assembly J9121 326 Fig 269 Installing Planetary Thrust Bearing Fig 270 Sun Gear Installation both hubs Be sure alignment tool is fully s...

Page 1738: ...remainder of direct clutch components as follows a Install first clutch disc on reaction plate fol lowed by a steel plate b Alternately install remaining clutch discs and steel plates until required number are installed Fig 272 The clutch requires 8 discs and 7 steel plates REACTION PLATE COUNTE DIRECT CLUTCH REACTION PLATE FLUSH WITH END OF HUB CLUTCH HUB J9121 329 Fig 273 Correct Position Of Dir...

Page 1739: ...LY AND COMPLETELY TO AVOID PERSONAL INJURY 24 Position Compressor Tool 6227 2 on clutch hub Fig 276 25 Slide direct clutch pack upwards on hub Fig 276 Slide pack upward and set it partially on edge of hub and compressor tool as shown in Fig 276 SPECIAL TOOL MB990891 SPECIAL TOOL 6227 2 CLUTCH HUB SPECIAL TOOL 6227 1 DIRECT CLUTCH PACK CLUTCH DRUM J9221 2 Fig 276 Mounting Geartrain Assembly In Shop...

Page 1740: ...t ports in the sole noid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB scan tool diagnosis indicates this is necessary Or if either part has sustained physical damage dented deformed broken etc CAUTION Do not turn the small screw at the end of the solenoid valve for any reason Turning the screw In either direction will ruin solenoid calibra tion and...

Page 1741: ...parator plates for distortion or damage of any kind Inspect the upper housing lower housing 3 4 accumulator housing and transfer plate carefully Be sure all fluid passages are clean and clear Check condition of the upper housing and transfer plate check balls as well The check balls and ball seats must not be worn or damaged Trial fit each valve and plug in its bore to check freedom of operation W...

Page 1742: ... PRESSURE PLUG SHUTTLE VALVE COVER VALVE AND SPRING RETAINER BOOST VALVE SPRING 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE V LVE PLUG LINE PRESSURE ADJUSTING SCREW BOOST VALVE COVER ADJUSTING SCREW BRACKET SWITCH VALVE AND SPRING VALVE AND PLUG COVER MANUAL LEVER DETENT BALL AND SPRING J9521 72 Fig 280 Upper Housing Valves Plug Springs And Brackets ...

Page 1743: ... Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will readily adhere to c...

Page 1744: ...clean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use a new ones at assembly SNAP RING PISTON SEAL PISTON PLUG SPRING RETAINER SNAP RING PISTON CUSHION SPRING PISTON SPRING J9121 64 Fig 284 Rear Servo Components OIL PUMP AND REACTION SHAFT SU...

Page 1745: ...r scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check the clutch piston check ball The ball should be securely in place Replace the piston if the ball is missing or seized in place REAR CLUTCH Clean the clutch components Fig 288 with sol vent and dry them with compressed air Check condition of the inp...

Page 1746: ...lean the intermediate shaft and planetary compo Check thrust washer condition Washer thickness nents Fig 289 in solvent and dry them with corn should be 1 55 to 1 60 mm 0 061 to 0 063 in pressed air Replace the washer if worn or damaged Inspect the planetary gear sets and annulus gears Check condition of the two seal rings on the input The planetary pinions shafts washers and retaining shaft and t...

Page 1747: ...the towels are made from a lint free material A suf ficient quantity of lint from shop towels cloths rags etc could plug the transmission filter and fluid pas sages Discard the old case gasket and seals Do not attempt to salvage these parts They are not reus able Replace any of the overdrive unit snap rings i f distorted or damaged Minor nicks or scratches on components can be smoothed with crocus...

Page 1748: ...worn or dam aged Inspect the overrunning clutch and race The race surface should be smooth and free of scores Replace the overrunning clutch assembly or the race if either assembly is worn or damaged in any way Inspect the output shaft and governor components Fig 292 Replace the shaft pilot bushing and inner bushing if damaged Replace either shaft bearing if rough or noisy Replace the bearing snap...

Page 1749: ... position Then verify that transmission throttle lever Fig 293 is also at idle full forward position 4 Slide cable off attachment stud on throttle body lever Fig 293 5 Compare position of cable end to attachment stud on throttle body lever Fig 294 a Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction b If cable end and attachment s...

Page 1750: ...lty CABLE BRACKET CABLE BUTTON THROTTLE VALVE CABLE THROTTLE BODY LEVER ALIGN CABLE AND STUD TO WITHIN 1 MM 0 039 IN OF CENTER J9521 54 Fig 294 Throttle Valve Cable Adjustment SHIFT LINKAGE ADJUSTMENT PROCEDURE Check condition of the shift linkage Fig 295 before adjustment Do not attempt adjustment if any parts are worn loose or bent Replace the linkage grommets and bushing if the linkage exhibits...

Page 1751: ...ure adjusting screw turns freely in case Apply lubricant to screw threads if necessary LOCK NUT MANUAL LEVER SHAFT FRONT BAND ADJUSTING SCREW PARK NEUTRAL POSITION SWITCH J9521 88 Fig 297 Front Band Adjustment Screw Location 3 Tighten band adjusting screw to 8 N m 72 in lbs torque with Inch Pound Torque Wrench C 3380 A a 3 in extension and 5 16 socket CAUTION If Adapter C 3705 is needed to reach t...

Page 1752: ...sures are interdependent because each affects shift quality and timing As a result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 300 Distance should be 33 4 mm 1 5 16 in If adjustment ...

Page 1753: ...OTE The kickdown valve spring must be fully S C H E M A T I C S A N D D I A G R A M S compressed and the kickdown valve completely bottomed to obtain correct adjustment HYDRAULIC SCHEMATICS SPECIAL TOOL C 3763 POSITIONED J9521 109 Fig 301 Throttle Pressure Adjustment ...

Page 1754: ......

Page 1755: ...HYDRAULIC FLOW IN NEUTRAL ...

Page 1756: ...LECTOR LEVER IN REVERSE 5 1 LINE PRESSURE 160 270 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIFT CONTROL 25 70 psi LINE PRESSURE TO THROTTLE VALVE 50 100 psi CONVERTER LUBE PRESSURE 95 130 psi PUMP SUCTION J9321 373 HYDRAULIC FLOW IN REVERSE D 30 ...

Page 1757: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR ...

Page 1758: ... GEAR PART THROTTLE LINE PRESSURE 57 94 psi GOVERNOR PRESSURE 0 57 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIFT PRESSURE 25 70 psi CONVERTER LUBE PRESSURE 5 75 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 375 HYDRAULIC FLOW IN DRIVE SECOND GEAR 09 30 ...

Page 1759: ... psi GOVERNOR PRESSURE 0 60 psi THROTTLE PRESSURE 0 94 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi SELECTOR LEVER IN DRIVE THIRD GEAR CONVERTER CLUTCH NOT APPLIED J9321 376 HYDRAULIC FLOW IN DRIVE THIRD GEAR ...

Page 1760: ...psi GOVERNOR PRESSURE 0 60 psi THROTTLE PRESSURE 0 100 psi PUMP SUCTION CONVERTER LUBE PRESSURE 5 57 psi SELECTOR LEVER IN DRIVE OVERDRIVE 4TH GEAR CONVERTER CLUTCH NOT APPLIED J9321 377 HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED ...

Page 1761: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED ...

Page 1762: ...5 62 psi 1 2 SHIFT CONTROL 25 35 psi GOVERNOR PRESSURE 0 30 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi SELECTOR LEVER IN MANUAL 1 FIRST GEAR CLOSED THROTTLE J9321 379 HYDRAULIC FLOW IN MANUAL LOW 1 m 33 ...

Page 1763: ...HIFT CONTROL 25 35 psi GOVERNOR PRESSURE 6 57 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi SELECTOR LEVER IN MANUAL 2 SECOND GEAR CLOSED THROTTLE J9321 380 HYDRAULIC FLOW IN MANUAL SECOND 2 ...

Page 1764: ...UTCH NOT APPLIED LINE PRESSURE 57 94 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIF CONTROL 25 70 psi GOVERNOR PRESSURE 0 57 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION OVERDRIVE PRE FILL PRESSURE 0 5 psi J9321 381 o x HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING GEAR m 30 ...

Page 1765: ...ack off 2 turns Recommended fluid Mopar ATF Plus type 7176 TORQUE DESCRIPTION TORQUE Bolt torque convertor 31 N m 23 ft lbs Bolt nut crossmember 68 N m 50 ft lbs Bolt driveplate to crankshaft 75 N m 55 ft lbs Plug front band reaction 17 N m 13 ft lbs Locknut front band adj 34 N m 25 ft lbs Switch park neutral 34 N m 25 ft lbs Bolt fluid pan 17 N m 13 ft lbs Bolt oil pump 20 N m 15 ft lbs Bolt over...

Page 1766: ...te Thrust plate and spacer are select fit components Refer to size charts and Intermediate shaft spacer selection procedures in Overdrive Unit disassembly and assembly section PRESSURE TEST Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle Line pressure at accumulator Closed throttle 372 414...

Page 1767: ...BR AUTOMATIC TRANSMISSION 46 47RE 21 S P E C I A L T O O L S Pressure Gauge C 3293SP ...

Page 1768: ...21 378 AUTOMATIC TRANSMISSION 46 47RE SPECIAL TOOLS Continued Gauge Throttle Setting C 3763 Snap ring Plier C 3915 ...

Page 1769: ...BR SPECIAL TOOLS Continued AUTOMATIC TRANSMISSION 46 47RE 21 379 Dial Caliper C 4962 ...

Page 1770: ...Front Clutch Bushing SP 3629 From kit C 3887 B Cup Bushing Remover SP 3633 From kit C 3887 B installer Oil Pump Bushing SP 5118 From kit C 3887 B Remover Reaction Shaft Bushing SP 5301 From kit C 3887 B Installer Reaction Shaft Bushing SP 5302 From kit C 3S87 B Installer Front Clutch Bushing SP 5511 From kit C 8887 B ...

Page 1771: ... shafts The mainshaft input gear and front output shaft are supported by ball and nee dle bearings The synchro mechanism consists of a brass stop ring synchro hub with 3 struts and 2 retaining springs and the sliding clutch Fig 1 The synchro components allow the transfer case to be shifted between 2H and 4H ranges while the vehicle is in motion However the vehicle must be stopped in order to shift...

Page 1772: ...21 382 NV231 HD NV241 NV241 HD TRANSFER CASE GENERAL INFORMATION Continued BR ROLLER BEARING Fig 1 NV231 NV241 Transfer Case NV241 HD Version Shown J9421 230 ...

Page 1773: ... G SERVICE DIAGNOSIS Before attempting to repair a suspected transfer case malfunction check all other driveline compo nents beforehand The actual cause of a problem may be related to such items as front hubs axles propeller shafts wheels and tires transmission or clutch instead If all other driveline components are in good condition and operating properly refer to the Service Diagnosis chart for ...

Page 1774: ...1 or MOPAR MERCON Automatic Transmission Fluid Check for leaks and repair if necessary Note If unit is still n o i s y after drain a n d refill d i s a s s e m b l y a n d inspection m a y be required to locate source of n o i s e NOISY IN OR JUMPS OUT OF FOUR WHEEL DRIVE LOW RANGE 1 Transfer case not completely engaged in 4L position 2 Shift linkage out of adjustment 3 Shift linkage loose or bind...

Page 1775: ...nd adapter O rings with transmission fluid 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter w Components 6 Count number of teeth on speedometer pinion Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 4 T...

Page 1776: ...th sides of transfer case to transmission gasket Then position gasket on trans mission 2 Align and seat transfer case on transmission Be sure transfer case input gear splines are aligned with transmission output shaft Align splines by rotating transfer case rear output shaft yoke if nec essary Do not install any transfer case attach ing nuts until the transfer case is completely seated against the...

Page 1777: ...t Fig 9 5 Remove input gear and planetary PTO gear as assembly Fig 10 PLANETARY AMD INPUT GEAR ASSEMBLY AND INSTALLATION 1 Lubricate planetary components with transmis sion fluid 2 Install new needle bearing in planetary carrier Fig 11 Use Handle C 4171 and Installer 5062 to install bearing 3 Install first thrust washer in carrier Fig 12 Lube washer with petroleum jelly before installation 4 Suppo...

Page 1778: ... Fig 14 Use Handle C 4171 and Installer 5065 to install bearing flush with upper edge of bear ing bore Note that bearing has built in cup plug Do not damage plug during installation 7 Install input gear in planetary carrier Fig 15 8 Install second thrust washer in planetary car rier Be sure washer tabs are seated in carrier slots 9 Install lock ring Fig 16 CASE B R Fig 14 installing Needle Bearing...

Page 1779: ... 18 Planetary input Gear Assembly Installation 14 Install retaining ring on input gear Fig 19 DISASSEMBLY AND ASSEMBLY TRANSFER CASE SNAP RING PLIERS INPUT BEARING RETAINING RING J9421 337 Fig 19 Installing Input Gear Retaining Ring 2 Shift transfer case into neutral 3 Remove companion flange nut Fig 20 A 1 1 8 in socket is required Discard nut after removal It is not reusable COMPANION FLANGE J94...

Page 1780: ...e nut and washer that retain shift lever to sector shaft Then remove shift lever from shaft Fig 24 J9421 271 Fig 24 Shift Lever Removal 8 Loosen poppet plunger screw Fig 25 9 Remove poppet plunger screw and spring Fig 26 Note that screw has O ring seal Remove and discard seal this seal 10 Remove poppet plunger with magnet Fig 27 11 Remove rear extension bolts Fig 28 A 13 or 15 mm socket is require...

Page 1781: ...ring as assembly Fig 33 OUTPUT BEARING REAR TAINER J9421 274 Fig 30 Removing Output Bearing Retaining Ring 14 Remove rear extension bolts Fig 31 A 13 or 15 mm socket is required J9421 277 Fig 33 Rear Retainer Removal 17 Remove speedometer gear rear retaining ring Fig 34 Then remove speedometer gear and front retaining ring Fig 35 and Fig 36 18 Note position of bolts that attach rear case to front ...

Page 1782: ...ining Ring SPEEDOMETER GEAR J9421 280 Fig 35 Removing Speedometer Gear SPEEDOMETER GEAR FRONT RETAINING RING J9421 281 Fig 36 Removing Speedometer Gear Rear Retaining Ring REAR CASE NUT AND J9421 278 WASHER Fig 37 Removing Case Attaching Bolts TOOL J9421 282 Fig 38 Loosening Rear Case Breaking Sealer Bead REAR CASE J9421 283 Fig 39 Removing Rear Case From Alignment Dowels ...

Page 1783: ...est fit in bearing 2 Install front output bearing retaining ring Fig 43 3 Install new front output seal in front case with Installer Tool 6888 and Tool Handle C 4171 as fol lows a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 44 Once seal is started continue tap J9421 324 Fig 42 Front Output Bearing Installation ping...

Page 1784: ...sition slot in sector so it will be aligned with shift fork pin when shift forks are installed 8 Install shift lever on sector shaft Fig 49 9 Install washer and nut on sector shaft to secure shift lever Apply 1 2 drops Mopar Lock N Seal or Loctite 242 to nut threads before installa tion Then tighten nut to 27 34 N m 20 25 ft lbs torque SECTOR SHAFT BORE J9421 326 Fig 46 Sector Shaft O Ring And Ret...

Page 1785: ...NG Fig 52 Oil Pickup Tube And Filter Position In Rear Case 5 Insert oil pickup tube in oil pump and position pump in rear case Fig 53 OIL PUMP REAR CASE J8921 235 Fig 50 Oil Pump Seal Installation 4 Position oil pickup tube and filter in rear case Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches Fig 52 Be sure hose that connects tube to filter is secur...

Page 1786: ... time CAUTION Verify that shift rail Fig 55 and case alignment dowels are seated before installing any bolts Case could be cracked if shaft rail or dowels are misaligned Fig 55 Shift Rail Seated in Rear Case Bore 9 Verify that oil pump is aligned and seated on rear case Reposition pump if necessary 10 Install oil pump retaining ring on mainshaft Fig 56 Then install speedometer gear Fig 57 and spee...

Page 1787: ...xtension on retainer Fig 62 10 Apply Mopar silicone sealer to threads of rear extension bolts Then install and tighten bolts to 27 34 N m 20 25 ft lbs torque 11 Apply Mopar silicone adhesive sealer to mat ing surface of PTO cover and to cover bolt shanks J9421 366 Fig 62 Rear Extension installation and underside of bolt heads Then install and tighten bolts to 27 34 N m 20 25 ft lbs torque INPUT RE...

Page 1788: ... bolts Be sure lock washers are used on studs bolts at case ends Tighten bolts or stud nuts as follows flange head bolts to 47 61 N m 35 45 ft lbs all other bolts nuts to 27 34 N m 20 25 ft lbs 10 Install companion flange seal on front shaft Fig 69 J9421 368 Fig 65 input Bearing Retainer installation Fig 66 Poppet Plunger And Spring installation PLUNGER SCREW J9421 372 Fig 67 O Ring Installation O...

Page 1789: ...aft drive sprocket and remove front sprocket and chain as assembly CHAIN Fig 70 installing Companion Flange On Front Shaft GEARTRAIN AND SHIFT COMPONENT DISASSEMBLY 1 Remove shift rail cup and spring Fig 71 2 Remove front sprocket retaining ring Fig 72 3 Pull mainshaft front sprocket and chain out ward about 25 4 mm 1 inch simultaneously Fig 73 DRIVE SPROCKET FRONT SPROCKET J9421 288 Fig 73 Removi...

Page 1790: ...ge Fork Retaining Ring Removal 9 Remove range fork and support sleeve as assembly Fig 78 Fig 75 Mainshaft Assembly Removal 7 Remove mode fork sliding clutch and shift rail as assembly Fig 76 Note which way clutch fits in fork long side of clutch goes to front J9421 293 Fig 78 Range Fork And Support Sleeve Removal 10 Remove shift sector Fig 79 SLIDING CLUTCH Fig 76 Mode Fork Shift Rail And Sliding ...

Page 1791: ...mounting studs on forward surface of case Be sure blocks will not interfere with input gear installation 2 Lubricate mainshaft components with Dexron II transmission fluid 3 Install drive sprocket on mainshaft Fig 81 4 Install brass stop ring on drive sprocket Fig 82 Fig 82 Synchro Stop Ring Installation 5 Install 3 synchro struts and 2 springs in hub as follows a Insert first strut in hub Fig 83 ...

Page 1792: ...properly secure them Fig 85 d Turn hub over and install remaining spring in hub Position hooked end of second spring 180 away from first spring end J9421 345 Fig 86 Synchro Hub Instaiiation SYNCHRO HUB J9421 342 Fig 85 Correct Position Of Struts And Springs 6 Install assembled synchro hub on mainshaft Fig 86 Hub has shoulder on one side which goes toward sprocket rear of shaft Flat side of hub fac...

Page 1793: ... as shown Fig 89 If the clutch is installed so a gap SLEEVE TOOTH ALIGNED WITH STRUT CORRECT ALIGNMENT J9421 450 between splines is aligned with one or more struts gear clash will result 9 Assemble range fork and synchro clutch and hub Fig 90 Then install fork and hub in case Seat hub on support sleeve and seat range fork pin in shift sector slot Fig 91 RANGE FORK J9421 346 Fig 90 Assembling Range...

Page 1794: ...ll mode fork and shift rail in sliding clutch Fig 98 Fig 93 Assembling Mode Fork And Mainshaft 12 Install mainshaft mode fork assembly Fig 94 Guide mainshaft through hub and into input gear and shift rail through range fork and into case bore Fig 94 Installing Mainshaft And Mode Fork Assembly FRONT OUTPUT SHAFT DRIVE CHAIN AND SPROCKET INSTALLATION 1 Install front output shaft in bearing Fig 95 Fi...

Page 1795: ...ing clutch were unseated during chain installation align and reseat mainshaft in input gear and hub Then reseat synchro hub in sliding clutch Press synchro struts inward to ease clutch back onto hub 6 Install front sprocket retaining ring Fig 97 7 Realign sliding clutch on synchro hub if neces sary Press synchro struts inward to ease realign ment Be sure mainshaft is fully seated before proceeding...

Page 1796: ...embly INPUT GEAR RETAINING RING J9421 301 Fig 100 Removing Lock Ring Input Gear Retaining Ring 3 Remove lock ring and front thrust washer from carrier Fig 101 Note that lock ring and thrust washer are both tabbed THRUST WASHER LOCK RING PLANETARY J9421 302 Fig 101 Planetary Lock Ring And Front Thrust Washer Removal 4 Remove input gear from planetary carrier Fig 102 Lift gear straight up and out of...

Page 1797: ...6 Puller Jaws In Retracted Position b Insert puller bolt and jaws into bearing Fig 107 Then turn puller bolt clockwise so ramp on bolt will spread jaws forcing them under bearing c Install puller bridge on puller bolt Then install flat washer and nut on puller bolt Fig 108 Fig 107 Puller Bolt And Jaws Seated Under Needle Bearing Fig 108 Installing Puller Bridge d Hold puller bridge from turning by...

Page 1798: ...e missing DRIVE SPROCKET STOP RING J fty J9421 311 Fig 110 Synchro Hub Retaining Ring Removal SYNCHRO HUB J9421 314 Fig 113 Synchro Stop Ring Removal 5 Remove drive sprocket Fig 114 Note that sprocket does not have needle bearings like prior transfer case models DRIVE SPROCKET MAINSHAFT J9421 312 Fig 111 Synchro Hub Removal 3 Inspect synchro hub struts and springs If struts appear worn remove stru...

Page 1799: ...ged remove bearing with Driver Handle C 4171 and Tool 7828 Fig 117 Fig 117 Input Bearing Removal 4 Inspect mainshaft output bearing Replace bearing only if noisy rough or damaged in any way If bearing is still in rear retainer remove bearing from retainer 5 Inspect front output shaft needle bearing in rear case Fig 118 Leave bearing in place if in good condition However if bearing is damaged in an...

Page 1800: ...lished gear cone or inside diameters of the hub Inspect the stop ring for cracks and wear Replace the ring if necessary or if doubt exists over condition Check a replacement synchro ring for proper fit on the cone with a minimum of wobble Also check the synchronizer struts for wear or damage Inspect all gear teeth and splines for wear or dam age Also check splines for burrs or nicks Remove minor n...

Page 1801: ...e inspected for wear The mode fork and shift rail are a one piece unit If either part is damaged replace the fork and rail as an assembly Replace the shift rail cup and spring if they exhibit wear Inspect the planetary thrust washers Fig 123 carefully for wear or damage Replace both washers if necessary The planetary carrier cannot be disassembled It must be serviced as an assembly if damaged Chec...

Page 1802: ...T 5 Verify that transfer case shift lever is in 2H 1 Move shift lever into 2 H position position Fig 125 2 Raise vehicle 3 Loosen shift rod lock bolt at trunnion Fig 124 J9421 231 Fig 124 Shift Rod Lock Bolt Location Fig 125 Shift Lever Range Positions 6 Tighten shift rod lock bolt to 10 N m 90 in lbs torque 7 Lower vehicle 8 Check shift linkage operation Be sure transfer case shifts into and oper...

Page 1803: ... m 12 20 ft lbs Bolt Case Half 35 46 N m 26 34 ft lbs Nut Front Yoke 122 176 N m 90 130 ft lbs Screw Oil Pump 1 2 1 8 N m 12 15 in lbs Nut Range Lever 27 34 N m 20 25 ft lbs Bolt Rear Retainer 35 46 N m 26 34 ft lbs Nuts Mounting 35 47 N m 26 35 ft lbs Bolts U Joint 19 N m 17 ft lbs Vacuum Switch 20 34 N m 15 25 ft lbs S P E C I A L T O O L S NV231HD NV241 NV241HD C 4210 Installer Seal 5061 Instal...

Page 1804: ...21 414 NV231 HD NV241 NV241 SPECIAL TOOLS Continued HD TRANSFER CASE BR 5066 Installer Bushing 7889 A Remover Rear Output Shaft Bushing ...

Page 1805: ... PTO gear shift sec tor and shift fork shift rail and sleeve The mainshaft is supported in by a needle bearing in the input gear hub and by a ball bearing in the rear extension The input gear is supported by a page SPEEDOMETER SERVICE 419 REMOVAL AND INSTALLATION ADAPTER 420 DISASSEMBLY AND ASSEMBLY ADAPTER O V E R H A U L 421 CLEANING AND INSPECTION ADAPTER 434 ADJUSTMENTS S H I F T LINKAGE 435 S...

Page 1806: ...IFT SLEEVE MAINSHAFT REAR EXTENSION COVER INPUT GEAR SHIFT LEVER SHIFT ROD 4 GROMMET LEVER NUT AND WASHER SHIFT SECTOR BEZEL NUT SHIFT K N O B BOOT Fig 1 NV 021 PTO Adapter FLOOR SHIFT ASSEMBLY J9421 219 J9421 238 Fig 3 Floor Shift Linkage I J 9 4 2 1 2 2 5 Fig 2 Adapter Shift Lever And Shift Pattern ...

Page 1807: ...ENDED LUBRICA1T AID FILL LE1EL Recommended lubricant for the NV 021 is Mopar Dexron II or ATF Plus transmission fluid Approximate fluid capacity is 2 17 liters 4 6 pints The adapter fill and drain plugs are located in the rear extension Fig 6 Fig 6 Drain And Fill Plug Locations The correct fill level is to the bottom e d g e of the fill plug hole ADAPTER IDENTIFICATION A round identification tag F...

Page 1808: ...eration The following diagnosis information provides a list ing of probable causes of an adapter malfunction Use the lists as a guideline during diagnosis Inoperative If the adapter will not drive a PTO accessory the most probable causes are PTO accessory not compatible with adapter no gear mesh PTO accessory loose or misaligned PTO accessory damaged inoperative adapter shift lever or shift rod di...

Page 1809: ... Thoroughly clean adapter flange and adapter mounting surface in housing Surfaces must be clean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer adapter if necessary 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs ...

Page 1810: ...a gasket is used between adapter and trans mission retain gasket if in good condition IMSTALLATIOW 1 If adapter was overhauled fill adapter to bot tom edge of fill plug hole with Mopar Dexron II or ATF Plus transmission fluid Tighten fill plug to 41 54 N m 30 40 ft lbs torque 2 Clean mounting surfaces of adapter and trans mission extension with solvent 3 Apply 2 3 drops of Mopar Lock N Seal or Loc...

Page 1811: ...ving input Bearing Retainer Boits PRY TOOL IN SLOT DRAIN PLUG J9421 375 Fig 12 Drain Bott Location 2 Remove mainshaft bearing retaining ring access cover and gasket Fig 13 Cover must be removed from extension for access to retaining ring A torx head bit is required to remove cover screws J 9 4 2 1 3 7 8 Fig 15 Loosening Bearing Retainer Breaking Sealer Bead Fig 13 Retaining Ring Access Cover Remov...

Page 1812: ...nput Gear Retaining Ring Removal 6 Support adapter on 3 4 small wood blocks Fig 18 Position blocks under transmission mounting surface of front case and between studs Fig 20 Loosening Shift Lever Nut SECTOR SHAFT POPPET PLUNGER SCREW J 9 4 2 1 3 8 1 Fig 21 Shift Lever Nut And Washer Removal Fig 18 Poppet Screw Removal 7 Remove poppet plunger screw 8 Remove spring and poppet plunger Fig 19 POPPET P...

Page 1813: ...aching Boits LOCATION OF BOLTS REQUIRING A WASHER WOOD BLOCKS J9421 390 Fig 23 Location Of Rear Extension Bolts Requiring Washers 11 Pry extension away from front case with flat blade screwdriver Position screwdriver in slots pro vided at each end of case and extension Fig 24 PRY TOOL IN EXTENSION SLOT J9421 386 Fig 24 Loosening Rear Extension Breaking Sealer Bead 12 Remove rear extension as follo...

Page 1814: ...p and out of input gear and shift sleeve Fig 27 MAINSHAFT INPUT GEAR AND SLEEVE J9421 389 BEARING J9421 391 Fig 28 Output Bearing Snap Ring Removal 15 Remove output bearing from mainshaft Note position of snap ring groove i n bearing for installation reference Fig BEARING MAINSHAFT NOTE POSITION OF RING GROOVE J9421 392 Fig 29 Mainshaft Output Bearing Removal 16 Remove speedometer gear rear retain...

Page 1815: ...leeve Removal J 9 4 2 1 3 9 5 Fig 32 Speedometer Gear Front Snap Ring Removal 19 Remove shift rail by pulling it up and out of fork and case Fig 33 J9421 398 Fig 35 Separating Shift Fork And Sleeve 23 Tap input gear out of bearing with plastic mallet Fig 36 INPUT GEAR Fig 33 Shift Rail Removal 20 Remove shift fork and shift sleeve as assem bly Fig 34 21 Separate shift fork and sleeve Fig 35 Note p...

Page 1816: ...ve input bearing from front case with Driver Handle C 4171 and Tool C 4210 or 7828 whichever fits best Fig 42 Bearing can only be removed from case interior because of bearing locating ring 28 Inspect condition of needle bearing in input gear If bearing is rough noisy worn or brinnelled remove bearing as follows a Turn bolt of Puller MD998346 to retract puller jaws Then position puller jaws under ...

Page 1817: ...the adapter sealing surfaces are to be coated with Mopar Gasket Maker Loctite 518 or Mopar silicone adhe sive sealer Therefore it is important that all sealing surfaces be clean and free of grease and oil before applying sealers 1 Start input bearing in front case bore Verify that locating ring Is Installed on bearing Fig 46 Note that bearing can only be installed from case exterior because of the...

Page 1818: ...Fig 48 SPECIAL TOOL C 4171 SPECIAL TOOL 5065 J9421 415 Fig 48 Installing Needle Bearing in input Gear 4 Install new sector shaft O ring Fig 49 and O ring retainer Fig 50 in sector shaft bore J9421 416 Fig 49 Sector Shaft O Ring installation O RING RETAINER J9421 417 Fig 50 Sector Shaft O Ring Retainer installation 5 Install shift sector In front case Fig 51 J9421 418 Fig 51 Shift Sector installati...

Page 1819: ...ood hammer handle until snap ring groove in input gear is accessi ble 11 Remove front case from wood blocks and posi tion case so input gear is accessible 12 Install retaining ring on input gear Fig 55 Be sure ring is fully seated in gear groove 13 Remount front case on wood blocks 14 Assemble shift fork and sleeve Fig 56 Then install fork and sleeve Fig 57 Be sure sleeve is seated in input gear N...

Page 1820: ...l through fork and into case bore Fig 59 SHIFT RAIL Fig 59 Shift Rail Installation 18 Install shift lever on sector shaft Fig 60 Then install lever washer and nut on sector shaft Fig 61 Apply Loctite 242 to nut before installation and tighten nut to 27 34 N m 20 25 ft lbs torque 19 Install magnet in case pocket 20 Install mainshaft Fig 62 Guide shaft through sleeve and into input gear bearing SHIF...

Page 1821: ...w pliers to install ring 24 Install new seal in rear extension if necessary Use suitable size installer tool and be sure seal is fully seated 25 Apply bead of Mopar Gasket Maker Loctite 518 or Mopar silicone adhesive sealer to mating sur face of front case and rear extension Sealer beads should be no more than 1 8 to 3 16 in wide 26 Align and install rear extension on front case Fig 68 S P E E D O...

Page 1822: ...ig 69 Seating Output Bearing Retaining Ring RETAINING RING J9421 434 Fig 70 Correct Seating Of Retaining Ring 30 Install access cover and gasket In rear exten sion Fig 71 Then Install and tighten torx screws to 8 11 N m 75 95 In lbs Fig 72 COVER PLATE GASKET ACCESS OPENING J9421 435 Fig 71 Access Cower And Gasket installation 31 Install new seal in input bearing retainer with Handle C 4171 and Ins...

Page 1823: ...etainer and case This could result in partial or full blockage of the bearing oil feed hole in the front case 33 Install poppet plunger and spring in front case detent bore Fig 76 Fig 76 Poppet Plunger And Spring Installation 34 Install new O ring on poppet plunger screw Then install screw in front case Fig 77 Tighten screw to 16 24 N m 12 18 ft lbs torque 35 Install indicator switch in front case...

Page 1824: ... retaining ring in the extension interior Fig 79 This ring secures the mainshaft output bearing to the extension OUTPUT BEARING RETAINING RING J9421 408 Fig 79 Bearing Retaining Ring Location in Extension The extension has a bushing at the rear If the bushing is worn remove the seal Then remove the bushing by cutting and collapsing it with a cape chisel A new bushing can be installed with any suit...

Page 1825: ... in lbs aged in any way Adapter Mounting Nuts With 5 16 s t u d 3 0 4 1 N m 2 2 3 0 ft lbs A D J U S T M E N T S With 3 8 stud 41 47 N m 30 35 ft lbs SHIFT LINKAGE Adapter Shift Lever Nut 2 7 3 4 N T T I 2 0 2 5 ft lbs 1 Place adapter floor shift lever in D position c l l m n l A e A l l n f j n r 2 Raise vehicle F D r a m P u g s 4 1 5 4 N m 3 Loosen locknut on shift rod Front Case To Rear 4 Veri...

Page 1826: ...21 436 NV021 PTO ADAPTER S P E C I A L T O O L S Driver 5062 ...

Page 1827: ...rbs and other obstacles Radial ply tires are more prone to irregular tread wear It Is important to follow the tire rotation inter val shown In the section on Tire Rotation This will help to achieve a greater tread life potential page PRESSURE GAUGES 3 TIRE NOISE OR VIBRATION 4 TIRE WEAR PATTERNS 4 TREAD WEAR INDICATORS 3 SERVICE PROCEDURES MATCH MOUNTING 4 REPAIRING LEAKS 6 ROTATION 4 CLEANING AND...

Page 1828: ...mmended that tires from different manu factures NOT be mixed The proper tire pressure should be maintained on all four tires For proper tire pressure refer to the Tire Inflation Pressure Chart provided with the vehicle SPARE TIRE TEMPORARY The temporary spare tire is designed for emer gency use only The original tire should be repaired and reinstalled at the first opportunity or a new tire purchas...

Page 1829: ...nuous speeds above 75 mph 120 km h WARNING OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING THE TIRE CAN FAIL SUDDENLY RESULTING IN LOSS OF VEHICLE CONTROL For emergency vehicles that are driven at speeds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct inflation pressure recommendations REPLACEMENT TIRES The original equipment tires provide ...

Page 1830: ...on with dual wheels MATCH MOUNTING Wheels and tires are match mounted at the factory This means that the high spot of the tire is matched to the low spot on the wheel rim Each are marked with a bright colored temporary label on the out board surface for alignment The wheel is also marked permanently on the Inside of the rim in the tire well This permanent mark may be a paint dot a permanent label ...

Page 1831: ...O RIGHT REAR RIGHT REAR TO LEFT FRONT ROAD TEST CAR LEADS OPPOSITE DIRECTION PROBABLE CAUSE ONE OR MORE TIRES IDENTIFY TIRE S AND REPLACE AS NEEDED CAR LEADS SAME DIRECTION PROBABLE CAUSE VEHICLE ALIGNMENT CHECK FRONT WHEEL ALIGNMENT J ALIGNMENT NOT OK ADJUST ALIGNMENT TO PREFERRED SETTINGS T ROAD TEST CAR STILL LEADS PROBABLE CAUSE ONE OR MORE TIRES OK IDENTIFY TIRE S AND REPLACE AS NEEDED NOTE V...

Page 1832: ...s on rim in that direction Fig 10 This procedure will normally reduce the runout to an acceptable amount REPAIRING LEAKS For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 11 The tire should be replaced if the puncture is located in the sidewall Deflate tire completely before dismounting tire from the whe...

Page 1833: ... The coating could cause deterioration of tires Remove protective coating by Applying warm water Letting it soak one minute Scrubbing the coating away with a soft bristle brush Steam cleaning may also be used for cleaning DO NOT use gasoline or wire brush for cleaning DO NOT use mineral oil or an oil based solvent Fig 10 Remount Tire 90 Degrees In Direction of Arrow REPAIRABLE AREA J8922 6 Fig 11 ...

Page 1834: ... excessive run out Are bent or dented Leak air Have damaged bolt holes Wheel repairs employing hammering heating welding or repairing leaks are not allowed Original equipment replacement wheels should be used When obtaining replacement wheels they should be equivalent in load carrying capacity The physical dimensions diameter width offset and bolt circle of the wheel should be the same as the orig...

Page 1835: ...TION The wheel studs and nuts are designed for specific applications Do not use replacement parts of lesser quality or a substitute design The 3500 use a two piece flat face nut Fig 3 NUT MAT FACE J9422 2 Fig 3 Two Piece Lug Nut All aluminum and some steel wheels have wheel stud nuts which feature an enlarged nose This enlarged nose is necessary to ensure proper retention of the aluminum wheels CA...

Page 1836: ...orque This will ensure that the wheels are thoroughly mated Check lug nut specified torque after 100 miles 160 kilometers Also after 500 miles 800 kilome ters of vehicle operation NOTE Wheel lug nuts should be tightened to spec ified torque at every maintenance interval thereafter TIRE AND WHEEL 1ALANCE It is recommended that a two plane dynamic bal ancer be used when a wheel and tire assembly req...

Page 1837: ... WHEEL SHIMMY AND VIBRATION J8922 9 Fig 6 Dynamic Unbalance Balance S P E C I F I C A T I O N S TORQUE SPECIFICATIONS DESCRIPTION TORQUE BR1500 5 Stud Wheel 130 N m 95 ft lbs BR2500 8 Stud Wheel 180 N m 185 ft lbs BR3500 8 Stud Dual Wheel 195 N m 145 ft lbs ...

Page 1838: ......

Page 1839: ...ic panel can break Chrysler Corporation uses many different types of push in fasteners to secure the interior and exterior trim to the body Most of these fasteners can be reused to assemble the trim during various repair procedures At times a push in fastener cannot be removed without damaging the fastener or the com ponent it is holding I f it is not possible to remove a fastener without damaging...

Page 1840: ...ipped Base coat paint must retain clear coat for durability page WET SANDING BUFFING AND POLISHING 2 SPECIFICATIONS AFTERMARKET REPAIR PRODUCTS 3 PAINTED SURFACE TOUCH UP When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use Mopar Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Introduction ...

Page 1841: ...52175 CHA96 SPS Spruce Pearl Coat SPM 47550 26087 B9633 51531 CHA96 SPM Aqua Pearl Coat LQE 4446 22115 B9233 45859 CHA92 LQE Aqua Pearl Coat PQK 4786 24076 B9458 48783 CHA94 PQK Moss Green Pearl Coat RJN 47383 25036 B9533 50277 CHA95 RJN Moss Green Pearl Coat SJG 47492 26080 B9619 51527 CHA96 SJG Light Kiwi Pearl Coat SF4 47491 26076 B9628 51528 CHA96 SF4 Light Kiwi Pearl Coat SF5 47450 26077 B962...

Page 1842: ...RIOR PAINT CODES AND SUPPLIER STOCK NUMBERS INTERIOR COLOR CHRY C O D i PPG BASF DuPONT s w ACME M S Medium Quartz D5 34618 2 1346 19133 SEMI C8904 40075 Blue Spruce P8 18888 2 1578 25067 C9508 50511 Medium Driftwood F6 27468 21502 23061 C9301 47481 ...

Page 1843: ...face If the moldings are set in urethane it would also be unlikely they could be salvaged Before removing the windshield check page BACKLITE CONVENTIONAL CAB 7 WINDSHIELD 5 the availability of the windshield and moldings from the parts supplier REMOVAL AND INSTALLATION WINDSHIELD REMOVAL It is difficult to salvage a windshield during the removal operation The windshield is part of the structural s...

Page 1844: ...s onto the windshield 6 Apply black out primer onto the glass using the windshield molding as a guide The primer should be 15 mm 5 8 in wide on the top and sides of the glass and 25 mm 1 in on the bottom of windshield Allow at least three minutes drying time 7 Position one 5 mm 3 16 in soft spacer p n 55028214 at the bottom of the windshield fence Fig 6 8 Apply a 13mm 1 2 in high and 10mm 3 8 in w...

Page 1845: ... it is unlikely it would be salvaged Before removing the backlite check the availability from the parts supplier The backlite is attached to the window frame with urethane adhesive The urethane adhesive is applied cold and seals the surface area between the window opening and the glass The primer adheres the ure thane adhesive to the backlite 1 Roll down door glass 2 Remove quarter trim panels Fig...

Page 1846: ...acklite Installation or plastic pry tool Carefully push the window glass out of the windowing opening 3 Remove the weatherstrip seal from the glass INSTALLATION 1 Install the weatherstrip seal on the backlite Fig 11 2 Apply mastic or equivalent to window opening at roof joint upper corners 3 Install the backlite or frame and the weather strip seal in the window opening with a length of cord Fig 11...

Page 1847: ...BR BODY 23 REMOVAL AND INSTALLATION Continued Fig 11 Backlite Installation Fig 12 Installation Cord ...

Page 1848: ...nstall bolts Tighten slider bar bolts to 8 5 N m 6 ft lbs torque 8 Install seat page SPLIT BENCH SEAT BACK COVER 12 SPLIT BENCH SEAT BACK 12 SPLIT BENCH SEAT CUSHION COVER 12 SPLIT BENCH SEAT TRACK 11 BENCH SEAT BACK REMOVAL 1 Move seat to the full forward position 2 Release J Strap and peel back side of cover corner flap Fig 3 3 Remove bolts attaching seat back to seat cush ion and separate seat ...

Page 1849: ...t and right side J Straps 6 Remove rear J Strap 7 Remove front J Strap 8 Roll trim cover off of front and rear corners and separate from foam cushion INSTALLATION 1 Position cushion cover on cushion and roll cover over front and rear corners 2 Secure front J Strap Fig 4 8 Secure rear J Strap 4 Secure left and right side J Straps 5 Verify stitching lines are straight correct as necessary 6 Install ...

Page 1850: ...k or equivalent tool pry off lumbar handle if equipped Fig 8 Damage to lum bar handle may occur during removal verify avail ability of replacement handle before removing 2 Remove Latch release knob Fig 8 3 Disengage J Straps from base of seat back 4 Remove hogrings if equipped 5 With seat back in a normal vertical position roll cover upwards and remove Fig 8 Lumbar Handle Removal INSTALLATION 1 Wi...

Page 1851: ...AL AND INSTALLATION Continued 3 Pull the left J Strap up and secure to frame Verify cover is straight 4 Pull the right side J Strap up and secure to frame 5 Install seatback 6 Install seat tracks Fig 9 J Strap instaiiation ...

Page 1852: ...29 FRONT DOOR 25 FRONT WHEELHOUSE LINER 20 FUEL FILL DOOR 35 GRILLE FRAME 17 GRILLE SEALS 17 GRILLE 17 HEADLINER 47 HOOD HINGE 18 HOOD LATCH STRIKER 19 HOOD LATCH 19 HOOD RELEASE CABLE 19 HOOD SAFETY CATCH 18 HOOD SILENCER 18 HOOD 18 LATCH AND KEEPER CONVENTIONAL CAB 33 LEFT FRONT FENDER 21 LOW MOUNTED SIDE VIEW MIRROR 24 MIRROR FLAG COVER 24 OVERHEAD ASSIST HANDLE 48 QUARTER TRIM PANEL 41 QUARTER...

Page 1853: ...URY CAN RESULT When the conditions causing a water leak have been determined simulate the conditions as closely as possible If a leak occurs with the vehicle parked in a steady light rain flood the leak area with an open ended garden hose If a leak occurs while driving at highway speeds in a steady rain test the leak area with a reasonable velocity stream or fan spray of water Direct the spray in ...

Page 1854: ...hattering noise An open cavity or protruding edge can create whistling or howling noise Inspect the exterior of the vehicle to verify that these conditions do not exist VISUAL INSPECTION BEFORE TESTS Verify that floor and body plugs are in place and body components are aligned and sealed If compo nent alignment or sealing is necessary refer to the appropriate section of this group for proper proce...

Page 1855: ...ILLE FRAME REMOVAL 1 Release primary hood latch 2 Release hood safety catch and open hood 3 Remove bolts holding guide loop for hood safety catch release rod to grille frame 4 Remove grille 5 Remove screws holding grille frame to hood Fig 2 6 Separate grille frame from vehicle INSTALLATION Reverse the preceding operation HOOD ASSEMBLY GRILLE ASSEMBLY BRACKET J9423 15 Fig 2 Grille Mounting Frame GR...

Page 1856: ...od safety catch and open hood 3 Remove push in fasteners holding silencer to hood Fig 5 4 Separate hood silencer from vehicle INSTALLATION Reverse the preceding operation HOOD Fig 5 Hood Silencer HOOD HINGE REMOVAL 1 Support hood on the side that requires hinge replacement 2 Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to pro vide reference marks for i...

Page 1857: ... cable from hood latch 5 Detach the release cable from the retainer clips in the engine compartment 6 Separate the release cable grommet from the dash panel hole 7 From the inside of the vehicle remove the screws attaching the hood release handle to the bot tom of the instrument panel 8 Pull route the hood release cable through the dash panel hole and remove it via the inside of the vehicle INSTAL...

Page 1858: ...seal from pinch flange a front of cowl 7 Separate cowl cover from vehicle INSTALLATION Reverse the preceding operation FRONT WHEELHOUSE LINER REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove front wheel 3 Remove plastic rivets holding wheelhouse liner to fender at the edge of wheel opening 4 Remove plastic rivets holding liner to the wheelhouse Fig 10 5 Remove plastic rivets holding l...

Page 1859: ... procedures 7 Remove screws holding power distribution cen ter to left wheelhouse Fig 11 8 Disengage wire harness tie downs from wheel house 9 Disconnect wiring harness to headlamp connec tor 10 Disconnect wiring harness to airbag sensor and remove airbag sensor from wheelhouse 11 Remove bolts holding anti lock brake control ler to wheelhouse Fig 11 if equipped Refer to Group 5 Brakes for procedur...

Page 1860: ...engage air conditioning tubing from inner fender clips 8 Remove bolts holding front fender to cowl rein forcement Fig 12 9 Remove bolts holding front fender to radiator closure panel Fig 15 10 Remove bolts holding bottom of front fender to rocker panel lower flange Fig 16 11 Open right door 12 Remove bolt holding front fender to hinge pil lar mounting bracket Fig 16 13 Remove bolts holding top of ...

Page 1861: ...rior Nameplates Club Cab 1 If The original emblem is to be reused peel old adhesive tape from back of emblem 2 Clean adhesive residue from emblem with Mopar Super Clean solvent or equivalent 3 Cover the back of emblem with two sided adhe sive tape Trim tape to fit emblem Tape can be acquired from automotive paint retailer 4 Remove protective cover from adhesive tape on back of emblem 5 Position em...

Page 1862: ... O R M I R R O R F L A G D O O R SEAL NUT MIRROR J9523 148 Fig 19 Mirror Flag Door Seal imSTMLLMTtOm Reverse the preceding operation MIRROR FLAG COVER REMOVAL 1 Remove door trim panel 2 Remove flag door seal 3 Remove nuts holding door flag cover to door frame Fig 21 4 Separate flag cover from vehicle INSTALLATION Reverse the preceding operation NUT D O O R J 9 4 2 3 5 5 Fig 20 Side View Mirror DOO...

Page 1863: ...ipped 9 While holding bottom of trim panel away from door simultaneously lift upward and forward 10 Separate door trim panel from Inner belt weatherstrip 11 Disengage power outside mirror wire connec tor from control switch 12 Separate door trim panel from vehicle INSTALLATION Reverse the preceding operation FRONT DOOR WATER DAM REMOVAL 1 Remove door trim panel B O D Y 2 3 2 1 DOOR HANDLE REMOVAL ...

Page 1864: ... pillar to aid installation 6 Support door on a suitable lifting device 7 Remove bolts holding lower door hinge to hinge pillar Fig 28 8 While holding the door steady on lift remove bolts holding upper door hinge to hinge pillar 9 Separate door from vehicle DOOR J9423 85 Fig 27 Door Hinge Hidden Bolt HINGE J9423 84 Fig 28 Door INSTALLATION Reverse the preceding operation Align door to achieve equa...

Page 1865: ...to door handle 3 Roll glass up 4 Remove fastener access plug from door end panel 5 Disengage clips holding latch and lock rods to door latch 6 Separate latch and lock rods from door latch 7 Remove nuts holding outside door handle retaining bracket to door handle Fig 30 8 Separate retaining bracket from door 9 Separate outside door handle from vehicle DOOR J 9 4 2 3 7 9 Fig 30 Outside Door Handle I...

Page 1866: ...h Striker FRONT DOOR INSIDE HANDLE ACTUATOR MEMOWAL 1 Raise the window to the closed position 2 Remove the door trim panel and water dam 3 Remove the screws attaching the actuator to the door INSTALLATION 1 Install the screws attaching the actuator to the door 2 Test handle for proper operation 3 Install the door water dam and trim panel FRONT DOOR INNER BELT WEATHERSTRIP REMOVAL 1 Remove door tri...

Page 1867: ...glass from lift plate J 9 5 2 3 1 4 7 Fig 36 Door Glass 8 Lift glass upward and out of opening at top of door INSTALLATION Reverse the preceding operation FRONT DOOR WINDOW REGULATOR REMOVAL 1 Remove door trim panel 2 Remove water dam 3 Remove nuts holding door glass to window reg ulator 4 Remove glass from door or move glass to full up position 5 Disengage power window motor wire connector from d...

Page 1868: ...l and sill cover 3 Remove quarter panel 4 Pull weatherstrip from pinch flange around door opening Fig 4 0 Fig 38 Door Glass Run Lower Channels FRONT POOR GLASS RUN WEATHERSTRIP REMOVAL 1 Remove door trim p a n e l 2 Remove inner door belt weatherstrip 3 Pull door glass run weatherstrip from channel around window opening Fig 39 BODY Fig 40 Door Seal I N S T A L L A T I O N Reverse the preceding ope...

Page 1869: ...o roof rail Fig 42 4 Separate retainer from vehicle INSTALLATION Reverse the preceding operation UPPER BODY SCREW SIDE SEAL 1 J 9 4 2 3 4 5 Fig 42 Roof Raii Weatherstrip and Retainer ROOF JOINT MOLDING REMOVAL 1 Warm the roof joint molding and roof panel to approximately 38 C 100 F using a suitable heat lamp or heat gun 2 Pull molding from roof joint Fig 43 INSTALLATION 1 Remove adhesive tape resi...

Page 1870: ...nge around the perimeter of the window opening Fig 45 Fig 45 Weatherstrip Seal Removal Installation 3 Clean the flange as necessary INSTALLATION 1 Center and butt the seal ends together at the bottom centerline of the opening 2 Mate the seal with the bottom flange 3 Mate the seal with the front vertical flange 4 Move upward and mate the seal with the top flange 5 Mate the seal with the rear vertic...

Page 1871: ...nel 2 Install screws Tighten the screws with 1 5 N m 15 in lbs torque 3 Engage latch and keeper to verify operation SLIDING BACKLITE CLUB CAB To remove the sliding rear window in a club cab refer to the rear window removal installation proce dures for club cab vehicles BODY VENT THIS END OF THE UPPER RUN CHANNEL SHOULD BE INSTALLED OVER THE SLIDING GLASS PIECE WHEN IT IS IN THE CLOSED POSITION RUN...

Page 1872: ...ce finish side down 2 Peel paper backing away from overlay exposing adhesive back of overlay 3 Apply soap solution liberally to adhesive back of overlay 4 Apply soap solution liberally to body panel sur face 5 Place overlay into position on body panel Smooth out wrinkles by pulling lightly on edges of overlay until it lays flat on painted surface 6 Push air pockets from under overlay to the perime...

Page 1873: ...sive tape to back of molding 3 Clean body surface with MOPAR Super Kleen solvent or equivalent Wipe surface dry with lint free cloth 4 Apply a length of masking tape on the body parallel to the top edge of the molding to use as a guide if necessary 5 Remove protective cover from tape on back of molding Apply molding to body below the masking tape guide 6 Remove masking ta pe guide and heat body an...

Page 1874: ... rear wheelhouse liner to rear wheelhouse 3 Separate rear wheelhouse liner form vehicle FENDER RiVET J9423 19 Fig 57 Rear Wheelhouse Liner INSTALLATION 1 Position rear wheelhouse liner In wheelhouse opening 2 Install plastic rivets holding rear wheelhouse liner to rear wheelhouse 3 Install plastic rivets holding rear wheelhouse liner to rear wheel opening lip REAR FENDER DUAL REAR WHEELS REMOVAL 1...

Page 1875: ...connect tailgate marker light harness if equipped 3 Close tailgate until the notch in the right hand collar aligns with the pivot pin 4 Slip tailgate hinge collar from hinge pins 5 Slide tailgate to the right and separate left hand collar from ththe pivot pin 8 Separate tailgate from vehicle fffSFALLATfOff Reverse the preceding operation TAILGATE HANDLE ESCUTCHEON REMOVAL 1 Lift and hold tailgate ...

Page 1876: ...rse the preceding operation TAILGATE LATCH STRIKER REMOVAL 1 Release tailgate latch and open tailgate 2 Mark outline of striker on cargo box jamb to aid installation 3 Using a Torx drive wrench remove striker from cargo box Fig 62 INSTALLATION Reverse the preceding operation TAILGATE SLAM BUMPER REMOVAL 1 Release tailgate latch and open tailgate BR SILENCER J9423 33 Fig 61 Tailgate Latch Fig 62 Ta...

Page 1877: ... solvent or equivalent Wipe molding dry with lint free cloth Apply new body side molding two sided adhesive tape to back of applique BODY 23 31 3 Clean tailgate surface with MOPAR Super Kleen solvent or equivalent Wipe surface dry with lint free cloth 4 Apply a length of masking tape on the body parallel to the top edge of the applique to use as a guide if necessary 5 Remove protective cover from ...

Page 1878: ...parate A pillar grab handle from vehicle INSTALLATION Reverse the preceding operation BR Fig 67 A pillar Grab Handle 4X4 A PILLAR MOLDING NOTE Damage to trim molding may occur during removal verify availability of replacement molding before removing REMOVAL 1 Remove A pillar grab handle if equipped 2 Disengage clips holding A pillar molding to A pillar Fig 68 3 Separate A pillar molding from vehic...

Page 1879: ...tick or small flat blade screw driver remove cup holder Fig 70 4 Remove lower seat belt anchor bolts Fig 71 5 Remove screws holding club cab quarter trim panel to quarter panel Fig 71 6 Separate club cab quarter trim panel from quarter panel 7 Pull seat belt webbing through opening in quarter trim panel and remove panel from vehicle BOLT BOLT J9523 138 Fig 70 Cup Holder Removal Fig 71 Quarter Trim...

Page 1880: ...bolt holding seat belt retractor to quar ter panel 7 Separate seat belt retractor from vehicle INSTALLATION Reverse the preceding operation SHOULDER ANCHOR BOLT J9423 11 Fig 73 Seat Belt Retractor SEAT BELT RETRACTORS CLUB CAB NOTE Inspect the shoulder belt retractor and buckle Replace the belt or buckle that is either cut frayed torn or damaged Replace the belt if the retractor is inoperative REM...

Page 1881: ...H SEAT REMOVAL 1 Move seat track to forward position 2 Hinge seat backs forward 3 Remove nuts holding rear of seat tracks to floor Fig 76 4 Move seat track to rearward position 5 Remove bolts holding front of seat tracks to floor 6 Separate seat from vehicle INSTALLATION Seat adjustment latch must be engaged prior to seat installation Verify inboard and outboard seat latch operation Reverse the re...

Page 1882: ...hten to 19 5 N m 14 ft lbs torque CONSOLE LID REMOVAL 1 Open console lid 2 Using a small flat blade screwdriver disengage locking tabs located under the console lid trim bezel 3 Separate bezel from lid 4 Move driver and passenger seat to full forward position 5 Using a small drift and hammer tap out con sole lid hinge pin 8 Separate lid from console INSTALLATION 1 Align console lid with console Ve...

Page 1883: ...SION REMOVAL 1 Pull edge of floor shift boot upward to expose fasteners Fig 82 2 Remove screws holding floor shift boot to floor 3 Remove gear shift knob 4 Separate gear shift boot from floor 5 Lift floor shift boot off shifter FLOOR SHIFT Fig 82 4WD Floor Shift Boot Manual Transmission INSTALLATION Reverse the preceding operation 4WD FLOOR SHIFT BOOT AUTOMATIC TRANSMISSION REMOVAL 1 Pull edge of ...

Page 1884: ... 85 Floor Carpet or Mat FLOOR CARPET OR MAT CLUB CAB REMOVAL 1 Remove front and rear seats 2 Remove door sill and cowl trim covers 3 Remove floor shift boot if equipped 4 Remove emergency jack tool kit 5 Remove rear seat belt buckles 6 Remove quarter trim panels 7 Fold carpet or mat toward center of cab 8 Remove carpet or mat through door opening INSTALLATION Reverse the preceding operation REARfl...

Page 1885: ...ss Apply an even coat of adhesive to the contact surface on the bracket Align the bracket with the marked position on the windshield glass Press and hold the bracket in place for at least one minute NOTE Verify that the mirror support bracket is cor rectly aligned because the adhesive will cure rap idly 7 Allow the adhesive to cure for 8 10 minutes Remove any excess adhesive with an alcohol damp e...

Page 1886: ...preceding operation ASSIST HANDLE J9423 74 REMOVAL 1 Pry retainer plug from center of coat hook Fig 90 and Fig 91 2 Pull coat hook out of rear header panel COAT HOOK J9523 140 Fig 90 Coat Hook Removal HEAD LINING RETAINER PLUG J9423 177 Fig 91 Coat Hook INSTALLATION Reverse the preceding operation ADJUSTMENTS HOOD 1 Loosen the hinge arm to hood panel bolts at each side of the vehicle 2 Loosen the ...

Page 1887: ...y refer to the front door hinge removal installation pro cedure for hinge fastener location Move the door to the correct fore aft position 3 Tighten the hinge to cowl screws 4 Remove the floor jack from the door FRONT DOOR IN OUT In out door adjustment is done by loosening the hinge to door fasteners Then move the door to the correct position 1 Support the door with a padded floor jack 2 Loosen th...

Page 1888: ......

Page 1889: ...e unit housing mounted under the instru ment panel On heater only systems the evaporator page HEATER A C CONTROLS 10 HIGH PRESSURE CUT OFF SWITCH 15 LOW PRESSURE CYCLING CLUTCH SWITCH 15 REFRIGERANT SYSTEM LEAKS 15 VACUUM SYSTEM 11 SERVICE PROCEDURES REFRIGERANT OIL LEVEL 16 REFRIGERANT RECOVERY 16 REFRIGERANT SYSTEM CHARGE 16 REFRIGERANT SYSTEM EVACUATE 16 REMOVAL AND INSTALLATION ACCUMULATOR 22 ...

Page 1890: ...ehicles the outside air intake can be shut off by selecting the recirculation mode with the mode control knob This will open a vacuum actuated recirculating air door and recirculate the air that is already inside the vehicle The optional air conditioner for all models is designed for the use of non CFC R 134a refrigerant The air conditioning system has an evaporator to cool and dehumidify the inco...

Page 1891: ...ve compressor head pressure and can cause noise and system failure In addition to the warnings and cautions listed above the following precautions must also be observed whenever servicing the air conditioning sys tem Recover the refrigerant before opening any fit ting or connection Open the fittings with caution even after the system has been discharged Never open or loosen a connection before rec...

Page 1892: ...e installing Using the proper wrenches when making a connec tion is very important Improper wrenches or improper use of the wrenches can damage the fit tings Always use two wrenches when loosening or tightening tube fittings Use one wrench to hold the stationary part while loosening or tightening with the other wrench The refrigerant must be recovered completely before opening any fitting or conne...

Page 1893: ... selection of four blower motor speeds and an Off position but will only operate with the ignition switch in the On posi tion and the heater A C mode control switch in any position except Off The blower motor switch is connected in series with the blower motor ground circuit through the heater A C mode control switch The blower motor switch directs this ground path to the blower motor through the ...

Page 1894: ... it leaves the evaporator The evaporator coil cannot be repaired and if faulty it must be replaced FIXED ORIFICE TUBE The fixed orifice tube is located in the outlet line of the condenser The inlet and outlet ends of the tube have a screen to filter the refrigerant O rings on the tube body prevent the refrigerant from by passing the fixed orifice The fixed orifice tube is used to meter the flow of...

Page 1895: ...ze less lines and hoses cannot be must be replaced used to carry the refrig air conditioning system design is used for the air vehicle The ends of the from lightweight alumi fittings The refrigerant repaired and if faulty REFRIGERANT OIL The oil used in the SD7H15 compressor is a poly alkylene glycol synthetic SP 20 PAG wax free refrigerant oil Use only refrigerant oil of the same type to service ...

Page 1896: ...r conditioning sys tem When humidity is high the evaporator has to perform a double duty It must lower the air temper ature and it must lower the temperature of the moisture in the air that condenses on the evapora tor s fins Condensing the moisture in the air trans fers heat energy into the evaporator fins and tubing This reduces the amount of heat the evaporator can absorb from the air High humi...

Page 1897: ...coolant return hose is much cooler than the supply hose locate and repair the engine coolant flow obstruction in the heater system OBSTRUCTED COOLANT FLOW Possible locations or causes of obstructed coolant flow Ambient Temperature 21 C 70 F 27 C 80 F 32 C 90 F 38 C 100 F 43 C 110 F Air Temperature at Center Panel Outlet 3 to 3 C 27 38 F 1 to 7 C 33 44 F 3 to 9 C 37 48 F 6 to 13 C 43 55 F 10to18 C ...

Page 1898: ... Recover refrigerant restore oil to proper level evacuate and charge system 2 Adjust blend air door cable J9524 7 Pressure AMBIENT TEMPERATURE AIR OUTLET TEMPERATURE C r C F 15 5 60 62 2 144 21 1 70 63 8 147 26 6 80 65 5 150 32 2 90 67 2 153 J9124 11 Temperature Reference Chart Pinched or kinked heater hoses Improper heater hose routing Plugged heater hoses or supply and return ports at the coolin...

Page 1899: ...sor clutch compo nents and circuits in this group 7 Check the mode control switch operation The heater and air conditioner system should respond as described in the owner s manual to each mode selected Reduce the engine speed to normal idle The vacuum will be high at low idle and the vacuum actuators should respond quickly If not OK see the Vacuum System tests in this group 8 If the vacuum tests a...

Page 1900: ... setting shortly after each selection is made If not OK a component or vacuum line in the selected mode s circuit has a vacuum leak See the procedure in Locating Vacuum Leaks CAUTION Do not use lubricant on the switch ports or in the holes in the plug as lubricant will ruin the vacuum valve in the switch A drop of clean water in the connector plug holes will help the connector slide onto the switc...

Page 1901: ... RESISTOR For circuit descriptions and diagrams refer to 8W 42 Air Conditioning Heater in Group 8W Wir ing Diagrams To test the blower motor resistor unplug the resis tor connector Each blower motor switch input termi nal on the resistor must have continuity to the resistor output terminal which is connected to the circuit going to the blower motor If the blower motor resistor continuity does not ...

Page 1902: ...age reading at the clutch coil refer to the Powertrain Diagnostic Procedures manual for testing of the compressor clutch circuit The following components must be checked and repaired as required before you can com plete testing of the clutch coil Fuses in the fuseblock module and the power distribution center Heater A C mode control switch Compressor clutch relay High pressure cut off switch Low p...

Page 1903: ...continuity between the two termi nals of the low pressure switch There should be con tinuity with a suction pressure reading of 296 kPa 43 psi or above and no continuity with a suction pressure reading of 172 kPa 25 psi or below If OK HEATING AND AIR CONDITIONING 24 15 test and repair the clutch control circuit as required If not OK replace the faulty switch REFRIGERANT SYSTEM LEAKS WARNING REVIEW...

Page 1904: ...RIGERANT SYSTEM After the system has been tested for leaks and evacuated a refrigerant charge can be injected into the system See Refrigerant Charge Capacity for the proper amount of the refrigerant charge Charge the system using a recovery recycling charging station approved for R 134a refrigerant This device must meet SAE Standard J2210 Refer to the instructions provided with the equipment for p...

Page 1905: ... other O ring may allow the con nection to leak intermittently during vehicle operation 4 Lubricate the male fitting and O ring and the inside of the female fitting with clean R 134a SP20 PAG refrigerant oil 5 Fit the female fitting to the male fitting and push together until the garter spring snaps over the flared end of the female fitting 6 Ensure the coupling is fully engaged by pulling back on...

Page 1906: ...into the holes of the clutch plate Hold the clutch plate stationary and remove the hex nut Fig 13 FRONT PLATE SPANNER J9124 27 Fig 13 Compressor Shaft Nut Remove Install 4 Remove the clutch plate On models with the diesel engine option a puller Special Tool 6461 in Kit 6460 is used to remove the clutch plate Fig 14 This compressor also uses a shaft key which must be removed 5 Remove the external f...

Page 1907: ... Special Tool 6464 in Kit 6460 into the driver Special Tool 6143 in Kit 6460 Fig 20 J8924 23 Fig 18 Clutch Coil Lead Wire Fig 19 Clutch Field Coil Snap Ring Remove 5 Place the driver tool assembly into the bearing cavity on the rotor Make certain the outer edge of the tool rests firmly on the rotor bearing inner race Fig 21 6 Tap the end of the driver while guiding the rotor to prevent binding Tap...

Page 1908: ...ubtract shims as required The specifi cation is 0 41 0 79 mm 0 016 0 031 inch If the air gap is not consistent around the circumference of the clutch lightly pry up at the minimum variations Lightly tap down at the points of maximum varia tion NOTE The air gap is determined by the spacer shims When installing an original or a new clutch assembly try the original shims first When install ing a new ...

Page 1909: ...itch 3 Connect the battery negative cable CONDENSER WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION REMOVAL 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system as described in this group 3 Disconnect the refrigerant lines from the con denser Install plugs In or tape over all of the ...

Page 1910: ...up 4 Connect the battery negative cable ACCUMULATOR WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION REMOVAL 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system as described in this group 3 Disconnect the refrigerant lines from the com pressor and the evaporator Install plugs in or t...

Page 1911: ...trol INSTALLATION 1 Connect the temperature control cable to the back of the heater A C control 2 Connect the vacuum and electrical connectors to the heater A C control 3 Install the heater A C control to the instrument panel with four screws 4 Install the instrument cluster bezel Refer to Group 8E Instrument Panel Systems for the proce dures 5 Connect the battery negative cable BLOWER MOTOR REMOV...

Page 1912: ...e wiring connector and install the wiring into the retainer 7 Connect the blower motor cooling tube 8 Connect the battery negative cable BLOWER 10T0R RESISTOR REMOVAL 1 Disconnect and isolate the battery negative cable 2 Unplug the blower motor resistor connector 3 Remove the resistor retaining screws 4 Remove the blower motor resistor Fig 34 Fig 34 Blower Motor Resistor INSTALLATION 1 Install the...

Page 1913: ...ft retainer onto the shaft 3 Connect the rod and rod clip to the door lever 4 Install the defroster duct as described in this group 5 Install the instrument panel Refer to Group 8E Instrument Panel Systems for the procedures RECIRCULATING AIR DOOR ACTUATOR REMOVAL 1 Remove the instrument panel Refer to Group 8E Instrument Panel Systems for the procedures 2 Disconnect the vacuum line from the actua...

Page 1914: ...s described in this group 3 Connect the cable to the top of the heater A C housing 4 Install the instrument panel and raise the steering column Refer to Group 8E Instrument Panel Systems for the procedures TEMPERATURE BLEND AIR DOOR CABLE J9424 7 Fig 38 Temperature Control Cable Heater A C Control End HEATER A C HOUSING REMOVAL 1 Disconnect and isolate the battery negative cable 2 Recover the refr...

Page 1915: ...ousing from the vehi cle INSTALLATION 1 Position the heater A C housing to the dash panel Be sure the drain tube is positioned in the dash panel drain hole 2 Install the mounting nuts to the studs on the passenger compartment side of the dash panel Tighten the nuts to 4 5 N m 40 in lbs 3 Install the mounting nuts to the studs on the engine compartment side of the dash panel Tighten the nuts to 7 N...

Page 1916: ...ed in this group 2 Turn the heater A C housing upside down 3 Disconnect the vacuum line from the actuator Fig 43 Fig 43 Heat Defrost Door Actuator 4 Separate the door pivot connection from the door pivot pin 5 Remove the retaining screws 6 Remove the heat defrost door actuator INSTALLATION 1 Install the heat defrost door actuator 2 Install and tighten the retaining screws 3 Press the door pivot co...

Page 1917: ...nstall the panel defrost door actuator 2 Install and tighten the retaining screws HEATING AND AIR CONDITIONING 24 29 Fig 45 Panei Defrost Door Actuator 3 Press the actuator door pivot connection onto the door pivot pin 4 Connect the vacuum line to the actuator 5 Install the heater A C housing as described in this group RECIRCULATING AIR DOOR REMOVAL 1 Remove the heater A C housing as described in ...

Page 1918: ...he temperature control door Fig 46 INSTALLATION 1 Install the temperature control door 2 Position the top half of the heater A C housing onto the bottom half Be sure the door pivot pins align with the pivot holes 3 Carefully turn the heater A C housing over Install and tighten the screws 4 Snap on the center heat duct adaptor 5 Install the heater A C housing as described in this group HEAT DEFROST...

Page 1919: ...owered engine will be referred to as either LDC Light Duty Emission Cycle or HDC Heavy Duty Emission Cycle engine The 8 0L V 10 engine will be referred to as either MDC Medium Duty Emission Cycle or HDC Heavy Duty Emission Cycle engine The diesel engine will be referred to as HDC Heavy Duty Emission Cycle engine Either of the HDC gas powered engines can be eas ily identified by the use of an engin...

Page 1920: ...ey is in the ON position After performing the part replacement or required maintenance the SRI lamp must be reset to turn the lamp off For required part replacement or maintenance schedules in time or mileage intervals refer to either Group 0 Lubrication and Maintenance in this man ual or the vehicle Owners Manual Failure to perform the part replacement or required maintenance and only reset the S...

Page 1921: ...n engine operates above 2400 RPM resulting in 0 volt input to the PCM Because the condition happens at an engine speed above the maximum threshold 2000 rpm the PCM will not store a DTC There are several operating conditions for which the PCM monitors and sets DTCs Refer to Moni tored Systems Components and Non Monitored Cir cuits in this section NOTE Various diagnostic procedures may actually caus...

Page 1922: ... operation Most of the tests provide an audible or visual indication of device operation click of relay contacts fuel spray etc Except for intermittent conditions if a device functions properly during testing assume the device its associated wiring and driver circuit work cor rectly Connect the DRB scan tool to the data link connector and access the Actuators screen DIAGNOSTIC TR0U1LE CODES A Diag...

Page 1923: ...MAP Sensor Voltage Too Low MAP Sensor Voltage Too High No 5 Volts To MAP Sensor MAP sensor input below minimum acceptable voltage MAP sensor input above maximum acceptable voltage 5 Volt output to MAP sensor open 15 P0500 or P0720 23 A6 No Vehicle Speed Sensor Signal Low Output Spd Sensr RPM Above 15 MPH No vehicle speed sensor signal detected during road load conditions Output Speed Sensor Circui...

Page 1924: ...sponse slower than minimum required switching frequency or value does not go above 65 volts 5 9L HD 8 0L only Upstream oxygen sensor heating element circuit malfunction 3 9 5 2 5 9L LD only Left Upstream oxygen sensor heating element circuit malfunction 5 9L HD 8 0L only Tested after key off and at start to run Downstream oxygen sensor input voltage maintained above the normal operating range Neit...

Page 1925: ... Engine coolant temperature sensor input below minimum acceptable voltage Engine coolant temperature sensor input above maximum acceptable voltage 23 P0112 or P0113 39 3A Intake Air Temp Sensor Voltage Low Intake Air Temp Sensor Voltage High Intake air temperature sensor input below the maximum acceptable voltage Intake air temperature sensor input above the minimum acceptable voltage 24 P0121 or ...

Page 1926: ...t 3 9L Injector 8 output driver does not respond properly to the control signal Except 3 9L Injector 9 output driver does not respond properly to the control signal 8 0L only Injector 10 output driver does not respond properly to the control signal 8 0L only 31 P0441 or P0443 71 12 Evap Purge Flow Monitor Failure EVAP Purge Solenoid Circuit Insufficient or excessive vapor flow detected during evap...

Page 1927: ... OA 2 0 95 96 97 Fuel Pump Relay Control Circuit Auto Shutdown Relay Control Circuit No ASD Relay Output Voltage at PCM Fuel Level Sending Unit Volts Too Low Fuel Level Sending Unit Volts Too High Fuel Level Unit No Change Over Miles An open or shorted condition detected in the fuel pump relay control circuit An open or shorted condition detected in the auto shutdown relay circuit An Open conditio...

Page 1928: ...e below an acceptable range 45 P0748 or P0753 or P1756 or P1763 or P1764 or P1765 or P0783 or P1757 or P1762 or AB 32 8D A8 A7 AD A5 8E A9 BC Governor Pressure Solenoid Control Circuit Trans 3 4 Solenoid Circuit Gov Press Not Equal To Target a 15 20 PSI Governor Pressure Sensr Volts Too Hi Governor Pressure Sensr Volts Too Lo Trans 12 Volt Supply Relay Cntri Circuit 3 4 Shift Sol No RPM Drop 3 4 S...

Page 1929: ...e Denied Unsuccessful attempt to write to an EEPROM location by the PCM 64 P0420 70 Catalytic Converter Efficiency Failure Catalyst efficiency below required level 71 P1496 B9 Auxiliary 5 Volt Supply Output Too Low 5 volt output from regulator does not meet minimum requirement 72 P0420 or P0432 70 B4 Catalytic Converter Efficency Failure Right Bank Catalyst Efficiency Failure Catalyst efficiency b...

Page 1930: ... verify that the heater circuit is operating correctly Effective control of exhaust emissions is achieved by an oxygen feedback system The most important element of the feedback system is the 02S The 02S is located in the exhaust path Once it reaches oper ating temperature 300 to 350 C 572 to 862 F the sensor generates a voltage that is inversely propor tional to the amount of oxygen in the exhaus...

Page 1931: ... catalyst will have fewer downstream switches than it has upstream switches i e a ratio closer to zero For a totally ineffective catalyst this ratio will be one to one indicating that no oxidation occurs in the device The system must be monitored so that when cata lyst efficiency deteriorates and exhaust emissions increase to over the legal limit the MIL check engine lamp will be illuminated TRIP ...

Page 1932: ...INJECTOR MECHANICAL MALFUNCTIONS The PCM cannot determine if a fuel injector is clogged the needle is sticking or if the wrong injector is installed However these could result in a rich or lean condition causing the PCM to store a diagnostic trouble code for either misfire an oxygen sensor or the fuel system EMCESSIWE OIL CONSUMPTION Although the PCM monitors engine exhaust oxygen content when the...

Page 1933: ...mes necessary it is important to use only fuel resistant hose PIESSURE RELlEF ROLLOfER W A L W E These vehicles are equipped with a combination pressure relief and rollover valve This dual function valve will relieve fuel tank pressure and also prevent fuel flow through the fuel tank vent hoses in the event of an accidental vehicle rollover Tank pressure is relieved through a calibrated ori fice i...

Page 1934: ...take manifold Fig 2 or Fig 3 Fig 2 EVAP Purge Solenoid 3 9L 5 2L 5 9L Engines FUEL TANK FILLER TUBE CAP The loss of any fuel or vapor out of filler neck is pre vented by the use of a pressure vacuum fuel tank filler tube cap Relief valves inside cap will release only under significant pressure of 6 58 to 8 44 kPa 1 95 to 2 5 psi The vacuum release for all fuel filler tube caps is between 97 and 2 ...

Page 1935: ...ve J8925 14 Fig 7 High Intake Manifold Vacuum Minimal Vapor Flow During periods of moderate manifold vacuum the plunger is only pulled part way back from inlet This results in maximum vapor flow through the valve Fig 8 J8925 15 Fig 8 Moderate Intake Manifold Vacuum Maximum Vapor Flow CRANKCASE VENTILATION SYSTEM 8J L 11 ENGINE The 8 0L V 10 engine is equipped with a Crankcase Ventilation CCV syste...

Page 1936: ... specifications if adjustable Idle speeds if adjustable Spark plug and gap VEHICLE EMISSION CONTROL INFORMATION VECI LABEL VECI LABEL 5 9L HDC ONLY INCLUDES CANADA J9425 8 Fig 11 VECI Label Location The 5 9L HDC gas powered engine will have two labels One of the labels is located in front of the radiator in the engine compartment Fig 11 and will contain vacuum hose routing only The other is attach...

Page 1937: ...e 4 Turn engine off and remove PCV valve from cylinder head valve cover The valve should rattle when shaken Fig 15 5 Replace the PCV valve and retest the system i f it does not operate as described in the preceding tests Do not attempt to clean the old PCV valve 6 If the paper is not held against the opening in cylinder head valve cover after new valve is installed the PCV valve hose may be restri...

Page 1938: ...eaner housing 2 Disconnect electrical wiring connector at sole noid Fig 17 3 Disconnect vacuum harness at solenoid Fig 17 4 Remove solenoid and its support bracket from intake manifold 5 Remove EVAP canister purge solenoid from engine INSTALLATION 1 Install EVAP canister purge solenoid and its mounting bracket to intake manifold 2 Connect vacuum harness and wiring connector 3 Install air cleaner h...

Page 1939: ... nuts Tighten nuts to 11 N m 96 in lbs torque 6 Install air cleaner housing cover FUEL TANK FILLER TUBE CAP If replacement of the fuel tank filler tube cap is necessary it must be replaced with an identical 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...

Page 1940: ... 1 Fig 2 or Fig 3 is used on 5 9L V 8 and 8 0L V 10 heavy duty cycle HDC gas powered engines only The air injection system consists of A belt driven air injection AIR pump page REMOVAL AND INSTALLATION AIR INJECTION PUMP AIR FILTER 8 0L V 10 ENGINE 25 AIR INJECTION PUMP 25 ONE WAY CHECK VALVE 26 SPECIFICATIONS TORQUE SPECIFICATIONS 26 An air pressure relief valve Rubber connecting air injection ho...

Page 1941: ... air pressure relief valve Fig 1 Pressure relief holes in the relief valve will prevent excess downstream pressure I f excess down stream pressure occurs at the relief valve it will be vented into the atmosphere AIR INJECTION PUMP INLET AIR FITTING J9425 19 Fig 3 Air inlet and Air Pump Air Filter 8 0L 10 Engine Air is then routed Fig 1 from the relief valve through a tube down to a Y connector thr...

Page 1942: ... BELT NOISE 1 Loose belt or defective auto belt tensioner 2 Seized pump 1 Refer to Group 7 Cooling 2 Replace pump EXCESSIVE PUMP NOISE CHIRPING 1 Insufficient break in 1 Recheck for noise after 1600 km 1 000 miles of operation EXCESSIVE PUMP NOISE CHIRPING RUMBLING OR KNOCKING 1 Leak in hose 2 Loose hose 3 Hose touching other engine parts 4 Relief valve inoperative 5 Check valve inoperative 6 Pump...

Page 1943: ... from automatic belt tensioner and install drive belt Refer to Group 7 Cooling Sys tem See Belt Removal Installation 5 Tighten pump pulley bolts to 11 N m 105 in lbs torque 6 Install hoses and hose clamps at pump AIR INJECTION PUMP AIR FILTER 8 0L V 10 ENGINE The air filter for the air injection pump is located in the air pump filter housing The housing is located in the right front side of the en...

Page 1944: ... SPECIFICATIONS ONE WAY CHECK VALVE Description Torque REMOVAL Air Pump Mounting Bolts 40 N m 30 ft lbs 1 Remove the hose clamp at inlet side of valve Air Pump Pulley Mounting 2 Remove hose from valve Bolts 11 N m 105 in lbs 3 Remove valve from catalyst tube unscrew To One Way Check Valve to prevent damage to catalyst tube a backup Catalyst Tube 33 N m 25 ft lbs wrench must be used on the tube INS...

Page 1945: ... mounted to the intake manifold An EGR valve control containing a combination back pressure transducer and an electric vacuum solenoid Fig 1 or Fig 2 The powertrain control module PCM to control the electric solenoid portion of the valve control An EGR tube Fig 3 connecting a passage in the intake manifold near the EGR valve to the rear of the right exhaust manifold Hoses to connect the various co...

Page 1946: ...r when The powertrain control module PCM deter mines that EGR system operation is necessary The electrical portion of the EGR valve control is not energized grounded by the PCM Exhaust back pressure entering the transducer in the EGR valve control is strong enough to close its bleed valve Engine vacuum is passed through the EGR valve control to the EGR valve The inlet seat poppet valve at the bott...

Page 1947: ... and EGR valve control are connected to the proper fit tings 4 Be sure the electrical connector is firmly con nected at the valve control 5 To check EGR system operation connect the DRB scan tool to the 16 way data link connector The data link connector is located on the lower edge of the instrument panel near the steering column Refer to the appropriate Powertrain Diagnostic Pro cedures service m...

Page 1948: ... Hold engine speed at approximately 1500 rpm 10 Check for steady engine vacuum full mani fold at this hose 11 If engine vacuum full manifold is not present check vacuum line to engine and repair as necessary before proceeding to next step 12 Reconnect the rubber hose to the vacuum inlet fitting Fig 2 on the EGR valve control 13 Disconnect the rubber hose at the vacuum outlet fitting Fig 2 on the E...

Page 1949: ...g cables to top of valve cover 3 Disconnect two vacuum hoses at exhaust gas recirculation EGR valve 4 Remove 2 EGR valve mounting bolts Fig 5 and remove EGR valve Discard old gasket 5 Disconnect electrical connector at engine oil pressure sending unit 6 To prevent damage to oil pressure sending unit a special tool such as number C 4597 must be used Fig 6 Remove sending unit from engine 7 Loosen EG...

Page 1950: ...tor to sending unit 5 Clean the intake manifold and EGR valve of any old gasket material 6 Install a new EGR valve gasket to intake man ifold 7 Install EGR valve to intake manifold Tighten two mounting bolts to 23 N m 200 in lbs torque 8 Install vacuum lines to EGR valve 9 Install spark plug cable loom and plug cables to valve cover mounting stud 10 Install air cleaner housing S P E C I F I C A T ...

Page 1951: ...OW CHECK PROCEDURE 3 9L7 5 2L 5 9L ENGINES THROTTLE BODY MINIMUM 14 56 AIR HEATER ELEMENTS INTAKE MANIFOLD 14 130 AIR HEATER INTAKE MANIFOLD 14 115 AIR HEATER RELAY TEST INTAKE MANIFOLD 14 125 AIR HEATER RELAYS INTAKE MANIFOLD 14 131 AIR HEATER RELAYS DIESEL ENGINE INTAKE MANIFOLD 8W 30 8 AIR HEATER RELAYS PCM OUTPUT INTAKE MANIFOLD 14 116 AIR HEATER TEST INTAKE MANIFOLD 14 124 AIR IN FUEL SYSTEM ...

Page 1952: ...ND SEAL FRONT REAR CASE 21 409 BEARING AXLE SHAFT SEAL 3 58 BEARING CAMSHAFT 9 146 BEARING CENTER 3 2 3 8 BEARING CLEARANCE MAIN 9 178 BEARING FRONT WHEEL 5 30 BEARING NOISE GEAR 3 18 3 53 3 83 BEARING OUTPUT SHAFT FRONT 21 135 21 280 BEARING OUTPUT SHAFT REAR 21 134 21 279 BEARING PILOT 6 20 BEARING PRELOAD AND GEAR LASH DIFFERENTIAL 3 110 3 42 3 72 BEARING RELEASE 6 19 BEARINGS CAMSHAFT 9 108 9 ...

Page 1953: ...SERVO 8H 11 8H 2 CABLE TAILGATE CHECK 23 37 CABLE TEMPERATURE CONTROL 24 26 CABLE TENSIONER ADJUSTMENT PARKING BRAKE 5 44 CABLE THROTTLE 14 109 14 22 CABLES SPARK PLUG 8D 14 8D 17 80 3 CALIBRATION COMPASS 8V 4 CALIBRATION GAUGE 8E 29 CALIPER 5 41 CALIPER DISC BRAKE 5 24 5 38 CAM BORE REPAIR 9 173 CAMSHAFT 9 107 9 144 9 189 9 205 9 38 9 72 CAMSHAFT AND CRANKSHAFT POSITION SENSORS 14 52 CAMSHAFT BEA...

Page 1954: ...TPUT AIR CONDITIONING 14 119 CLUTCH RELAY PCM OUTPUT AIR CONDITIONING A C 14 37 CLUTCH SWITCH LOW PRESSURE CYCLING 24 15 24 22 24 6 CLUTCH TCC SOLENOID PCM OUTPUT TORQUE CONVERTOR 14 121 14 42 CLUTCH TORQUE CONVERTER ELECTRONIC 21 105 21 250 CLUTCH LOW REVERSE DRUM OVERRUNNING 21 178 CLUTCH LOW REVERSE DRUM REAR SUPPORT OVERRUNNING 21 220 COAT FINISH BASE COAT CLEAR 23 2 COAT HOOK 23 48 COAT CLEAR...

Page 1955: ...RATURE SENSOR DIESEL ENGINE EGR ENGINE 8W 30 8 COOLANT ROUTINE ADDING ADDITIONAL 7 33 COOLER AIR TO OIL 7 6 COOLER ELEMENT AND GASKET OIL 9 202 COOLER FLOW CHECK OIL 21 111 21 256 COOLER IN RADIATOR SIDE TANK REPLACING WATER TO OIL 7 50 COOLER INTERCOOLER CHARGE AIR 11 19 11 3 COOLER LINE AND FITTINGS TRANSMISSION 21 139 21 284 COOLER REPLACEMENT TRANSMISSION 21 139 21 284 COOLER 3 9L 5 2L 5 9L EN...

Page 1956: ...RANSMISSION 21 118 21 263 DIAGNOSIS TRAC LOK NOISE 3 57 3 87 DIAGNOSIS VACUUM DISCONNECT AXLE SHIFT MOTOR 3 21 DIAGNOSIS ALL ENGINES SERPENTINE DRIVE BELT 7 29 DIAGNOSIS DIESEL MECHANICAL SERVICE 9 21 DIAGNOSIS DIESEL PERFORMANCE SERVICE 9 14 DIAGNOSIS GASOLINE LUBRICATION SERVICE 9 13 DIAGNOSIS GASOLINE MECHANICAL ENGINE 9 12 DIAGNOSIS GASOLINE PERFORMANCE ENGINE 9 11 DIAGNOSTIC INFORMATION RWAL ...

Page 1957: ... LIGHT 0 4 DUTY VEHICLES MAINTENANCE SCHEDULES MEDIUM 0 8 EFFECTS OF INCORRECT FLUID LEVEL 21 110 21 255 EGR ENGINE COOLANT TEMPERATURE SENSOR DIESEL ENGINE 8W 30 8 EGR GAS FLOW TEST 25 28 EGR INTAKE AIR TEMPERATURE SENSOR DIESEL ENGINE 8W 30 8 EGR SOLENOID 8W 30 6 EGR SOLENOID DIESEL ENGINE 8W 30 8 EGR SYSTEM OPERATION 25 27 EGR SYSTEM TEST 25 29 EGR TUBE 25 31 EGR VALVE 25 30 EGR VALVE CONTROL E...

Page 1958: ...TION SENSOR 3 9L 5 2L 5 9L 8D 20 ENGINES CRANKSHAFT POSITION SENSOR 5 2L 5 9L V 8 8D 4 ENGINES DISTRIBUTOR CAP 3 9L 5 2L 5 9L 8D 11 ENGINES DISTRIBUTOR ROTOR 3 9I7 5 2L 5 9L 8D 11 ENGINES DUTY CYCLE EVAP CANISTER PURGE SOLENOID 3 9L 5 2L 5 9L 14 61 ENGINES ENGINE COOLANT TEMPERATURE SENSOR 3 9I75 2I7 5 9L 14 53 14 65 ENGINES ENGINE EXHAUST MANIFOLD V 6 AND V 8 11 11 11 3 ENGINES ENGINE FIRING ORDE...

Page 1959: ...SMISSION 4WD 23 45 FLOOR SHIFT BOOT MANUAL TRANSMISSION 23 45 FLOOR STOWAGE TRAY REAR 23 45 FLOW CHECK OIL COOLER 21 111 21 256 FLOW CHECK PROCEDURE 3 9L 5 2IV 5 9L ENGINES THROTTLE BODY MINIMUM AIR 14 56 FLOW RATE AND PRESSURE TEST POWER STEERING PUMP 19 3 FLOW TEST EGR GAS 25 28 FLOW TEST RADIATOR COOLANT 7 27 FLOW DIESEL COOLING SYSTEM COMPONENTS 7 3 FLOW GAS ENGINES COOLING SYSTEM COMPONENTS 7...

Page 1960: ...3 9L75 2L 5 9L 25 17 GAS RECIRCULATION EGR SYSTEM 5 9L HDC GAS ENGINE EXHAUST 25 27 GAS RECIRCULATION EGR SYSTEMS EXHAUST 25 27 GASKET FAILURE DIAGNOSIS ENGINE CYLINDER HEAD 9 7 GASKET OIL COOLER ELEMENT 9 202 GASKETS GASOLINE ENGINES FORM IN PLACE 9 1 GASOLINE OXYGENATE BLENDS 14 2 GAUGE CALIBRATION 8E 29 GAUGE COOLANT TEMPERATURE 8E 3 8E 8 GAUGE ENGINE COOLANT TEMPERATURE 8W 40 1 GAUGE FUEL 8W 4...

Page 1961: ...S BRAKE 5 8 HOSES BRAKE LINE 5 13 HOUSING ASSEMBLY TIMING PIN 9 186 HOUSING BUSHING OVERDRIVE 21 134 21 279 HOUSING COVER GEAR 9 184 HOUSING CRANKSHAFT REAR SEAL 9 196 HOUSING EXTENSION ADAPTER 21 60 HOUSING FLUID LEAK DIAGNOSIS CONVERTER 21 116 21 261 HOUSING GEAR 9 185 HOUSING HEATER A C 24 26 HOUSING NV4500 CLUTCH 6 11 HOUSING REPLACEMENT NV4500 CLUTCH 6 18 HOUSING AIR CLEANER ELEMENT AIR CLEAN...

Page 1962: ...ENSOR PCM 14 114 14 30 INPUT BATTERY VOLTAGE PCM 14 114 14 30 INPUT BRAKE SWITCH PCM 14 114 14 30 INPUT BRAKE WARNING LAMP SWITCH 8W 34 REAR WHEEL ANTI LOCK BRAKES 8W 34 2 INPUT BRAKE WARNING LAMP SWITCH 8W 35 ALL WHEEL ANTI LOCK BRAKES 8W 35 2 INPUT CAMSHAFT POSITION SENSOR 3 9LV5 2L 5 9L ENGINES PCM 14 30 INPUT CAMSHAFT POSITION SENSOR 8 0L ENGINE PCM 14 30 INPUT CRANKSHAFT POSITION SENSOR 3 9L ...

Page 1963: ... VECI 25 18 LABEL VEHICLE SAFETY CERTIFICATION lntro 2 LAMP ABS WARNING 8W 35 ALL WHEEL ANTI LOCK BRAKES 8W 35 2 LAMP ABS WARNING 8W 40 INSTRUMENT CLUSTER 8W 40 2 LAMP ABS WARNING BRAKES 5 72 LAMP AIRBAG INDICATOR 8E 11 8E 4 LAMP AIRBAG WARNING 8W 40 INSTRUMENT CLUSTER 8W 40 3 LAMP AIRBAG WARNING 8W 43 AIRBAG SYSTEM 8W 43 1 LAMP ALIGNMENT FOG 8L 6 LAMP ANTI LOCK BRAKE SYSTEM 8E 11 8E 4 LAMP BRAKE ...

Page 1964: ...NES REFRIGERANT 24 7 LINK CONNECTOR DATA 8W 30 FUEL IGNITION SYSTEMS 8W 30 2 LINK CONNECTOR DATA 8W 34 REAR WHEEL ANTI LOCK BRAKES 8W 34 1 LINK CONNECTOR DATA 8W 35 ALL WHEEL ANTI LOCK BRAKES 8W 35 2 LINK CONNECTOR DATA 8W 43 AIRBAG SYSTEM 8W 43 1 LINK CONNECTOR PCM INPUT AND OUTPUT DATA 14 120 14 38 LINKAGE ADJUSTMENT GEARSHIFT 21 225 21 360 LINKAGE ADJUSTMENT SHIFT 21 412 LINKAGE ADJUSTMENT DIES...

Page 1965: ...RS OUTSIDE POWER 8T 1 MIRRORS POWER 8W 62 1 MODE CIRCUIT ACTUATION TEST 25 4 MODE STATE DISPLAY TEST 25 4 MODEL 60 70 80 AXLES 3 114 3 79 MODEL 60 70 80 REAR AXLES 3 113 MODES OF OPERATION 14 26 MODULE ACM AIRBAG CONTROL 8W 43 1 MODULE AIRBAG 8M 2 8M 4 MODULE AIRBAG CONTROL 8M 2 8M 8 MODULE BUZZER 8W 44 INTERIOR LIGHTING 8W 44 2 MODULE BUZZER CHIME BUZZER WARNING SYSTEMS 8U 1 8U 2 8U 3 MODULE COMP...

Page 1966: ...UTOMATIC TRANSMISSION 8W 31 TRANSMISSION CONTROLS 8W 31 1 OUTPUT SHAFT SPEED SENSOR PCM INPUT 14 35 OUTPUT SPEED CONTROL SOLENOIDS PCM 14 121 14 41 OUTPUT TACHOMETER PCM 14 121 14 41 OUTPUT TEST CURRENT 8C 3 OUTPUT THREE FOUR SHIFT SOLENOID PCM 14 42 OUTPUT TORQUE CONVERTOR CLUTCH TCC SOLENOID PCM 14 121 14 42 OUTPUT TRANSMISSION RELAY PCM 14 42 OUTPUT TRANSMISSION TEMPERATURE WARNING LAMP PCM 14 ...

Page 1967: ...8 0L ENGINE PCM INPUT CAMSHAFT 14 30 POSITION SENSOR 8 0L V 10 ENGINE CAMSHAFT 8D 23 8D 6 POSITION SENSOR 8 0L V 10 ENGINE CRANKSHAFT 8D 22 8D 5 POSITION SENSOR DIESEL ENGINE THROTTLE 8W 30 4 POSITION SENSOR PCM INPUT THROTTLE 14 117 POSITION SENSORS CAMSHAFT AND CRANKSHAFT 14 52 POSITION SWITCH CLUTCH PEDAL 6 3 POSITION SWITCH PARK NEUTRAL 8W 30 FUEL IGNITION SYSTEMS 8W 30 5 POSITION SWITCH PARK ...

Page 1968: ...P PULLEY 19 8 PUMP RELAY ABS 8W 35 1 PUMP RELAY FUEL 8W 30 FUEL IGNITION SYSTEMS 8W 30 2 PUMP RELAY FUEL FUEL SYSTEM 14 15 14 57 PUMP RE LAY PCM OUTPUT FUEL 14 39 PUMP RELAYS ASD AND FUEL 14 48 PUMP RESERVOIR P SERIES 19 8 PUMP SPECIFICATION CHART 19 4 PUMP TEST FUEL INJECTION 14 82 PUMP TIMING FUEL INJECTION 14 86 PUMP WASHER 8K 3 8K 7 PUMP WATER 7 31 PUMP 5 9L DIESEL WATER 7 11 7 42 PUMP 8 0L V ...

Page 1969: ...R SRI LAMP SERVICE 8W 40 INSTRUMENT CLUSTER 8W 40 3 REMINDER INDICATOR SRI LAMP SERVICE EMISSION CONTROL SYSTEMS 25 1 REMINDER INDICATOR SRI LAMP PCM OUTPUT SERVICE 14 41 REMINDER LAMP SEAT BELT 8E 16 8E 6 REPAIR ALUMINUM THREAD 21 131 21 276 REPAIR CAM BORE 9 173 REPAIR CYLINDER BORE 9 171 REPAIR DAMAGED OR WORN THREADS 9 5 REPAIR PRODUCTS AFTERMARKET 23 3 REPAIR WIRING 8W 01 7 REPAIRING LEAKS 22...

Page 1970: ... SENSOR FRONT SPEED 5 76 SENSOR FUEL LEVEL 14 16 SENSOR GOVERNOR SOLENOID AND PRESSURE 21 136 21 281 SENSOR INTAKE AIR TEMPERATURE 8W 30 5 SENSOR INTAKE MANIFOLD AIR TEMPERATURE FUEL SYSTEM 14 130 SENSOR INTAKE MANIFOLD AIR TEMPERATURE IGNITION SYSTEM 8D 14 8D 25 8D 7 SENSOR MANIFOLD ABSOLUTE PRESSURE 8W 30 4 SENSOR MANIFOLD ABSOLUTE PRESSURE MAP 8D 25 8D 6 SENSOR MAP 8D 11 SENSOR 02S 3 9L 5 2L 5 ...

Page 1971: ... 2 22 2 9 SHOCK ABSORBER DIAGNOSIS SPRING 2 22 SHOCK DIAGNOSIS 2 16 2 9 SHOCK DIAGNOSIS SPRING 2 21 SHUT DOWN ASD RELAY AUTOMATIC 8W 30 2 SHUT DOWN RELAY DIESEL ENGINE FUEL 8W 30 7 SHUTDOWN ASD RELAY AUTOMATIC FUEL SYSTEM 14 126 14 57 SHUTDOWN ASD RELAY AUTOMATIC IGNITION SYSTEM 8D 20 8D 7 SHUTDOWN ASD RELAY TEST AUTOMATIC 14 123 SHUTDOWN ASD RELAY 3 9L 5 2L7 5 9L ENGINES AUTOMATIC 8D 4 SHUTDOWN A...

Page 1972: ...ER AIRBAG 8W 43 1 STABILIZER BAR 2 11 2 18 STALL TEST ANALYSIS 21 115 21 260 STALL TEST CONVERTER 21 114 21 259 STANDARD DIFFERENTIAL 3 39 3 65 3 99 STANDARD DIFFERENTIAL OPERATION 3 16 3 81 STANDARD SERVICE INFORMATION 9 1 START TEST 3 9L 5 2L 5 9L ENGINES FAILURE TO 8D 9 STARTER 8B 2 8B 8 STARTER RELAY 8B 10 8B 2 STARTING PROCEDURE JUMP 0 21 STARTING SYSTEM 8B 10 8B 1 8B 2 STARTING TOWING AND HO...

Page 1973: ... BRAKE 8E 11 8E 4 SYSTEM LEAKS REFRIGERANT 24 15 SYSTEM LUBRICATION 9 128 9 164 9 59 9 94 SYSTEM METRIC Intro 10 SYSTEM OPERATION AIR INJECTION 25 23 SYSTEM OPERATION CHARGING 8C 1 SYSTEM OPERATION EGR 25 27 SYSTEM OPERATION RWAL 5 51 SYSTEM POSITIVE CRANKCASE VENTILATION PCV 25 16 SYSTEM POWER MIRROR 8T 1 SYSTEM POWER SEAT 8R 1 SYSTEM POWER WINDOW 8S 1 SYSTEM PRESSURE FUEL 14 23 SYSTEM PRESSURE R...

Page 1974: ...D 9 TEST 3 9L 5 2L 5 9L ENGINES IGNITION COIL 8D 8 TEST 3 9L 5 2L 5 9L ENGINES MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 14 50 TEST 8 0L ENGINE MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 14 51 TEST 8 0L V 10 ENGINE CAMSHAFT POSITION SENSOR 8D 13 TEST 8 0L V 10 ENGINE CRANKSHAFT POSITION SENSOR 8D 12 TEST ALL ENGINES WITH PRESSURE TEST PORT FUEL PUMP PRESSURE 14 6 TESTS CHARGING SYSTEM RESISTANCE 8C 3 TESTS...

Page 1975: ...PEED 8W 31 1 TRAY REAR FLOOR STOWAGE 23 45 TREAD WEAR INDICATORS 22 3 TRIM PANEL FRONT DOOR 23 25 TRIM PANEL QUARTER 23 41 TRIM PANEL CLUB CAB QUARTER 23 41 TRIM PANELS INTERIOR 23 15 TRIM REAR CLOSURE PANEL 23 41 TRIP DEFINITION 25 13 TRIP ODOMETER 8E 10 8E 4 TROUBLE CODES DIAGNOSTIC 25 4 TROUBLE CODES RWAL DIAGNOSTIC 5 53 TROUBLE CODES SPEED CONTROL DIAGNOSTIC 8H 7 TROUBLESHOOTING TESTS 8W 01 6 ...

Page 1976: ...5 16 VENTILATION SYSTEM 8 0L V 10 ENGINE CRANKCASE 25 17 VERIFICATION TEST RWAL 5 66 VERSION CLOSE RATIO 21 4 VERSION WIDE RATIO 21 3 VIBRATION 3 18 3 53 3 83 3 3 VIBRATION DAMPER 9 104 9 141 9 36 9 69 VIBRATION DRIVELINE 3 3 VIBRATION TIRE NOISE OR 22 4 VIEW MIRROR LOW MOUNTED SIDE 23 24 VIEW MIRROR SIDE 23 24 VISCOUS FAN DRIVE 7 12 7 28 VISOR SUN 23 47 VISOR VANITY LAMPS 8W 44 2 VISUAL INSPECTIO...

Page 1977: ...S Y S T E M W I N D S H I E L D 8 K 1 W I P E R S 8 W 5 3 1 W I R E C O D E I D E N T I F I C A T I O N 8 W 0 1 2 W I R I N G D I A G R A M I N D E X 8W 12J O I N T C O N N E C T O R S 8 W 1 2 1 W I R I N G D I A G R A M I N D E X 8 W 2 0 C H A R G I N G S Y S T E M 8 W 2 0 1 W I R I N G D I A G R A M I N D E X 8 W 2 1 S T A R T I N G S Y S T E M 8W 21 1 W I R I N G D I A G R A M I N D E X 8 W 3 0...

Page 1978: ...i ...

Page 1979: ...errors have you found Please include page number What topics are hard to locate confusing or not covered completely What comments or suggestions do you have Your Name Dealership Address Manual Name and Model Year Note All comments become the property of Chrysler Corporation ...

Page 1980: ...Fold Here Place Stamp Here C h r y s l e r C o r p o r a t i o n CIMS 424 81 55 25999 Lawrence Ave Center Line Mi 48015 Fold Here ...

Page 1981: ... errors have you found Please include page number What topics are hard to locate confusing or not covered completely What comments or suggestions do you have Your Name Dealership Address Manual Name and Model Year Note All comments become the property of Chrysler Corporation ...

Page 1982: ...Fold Here Place Stamp Here Chrysler Corporation C 1 M S 4 2 4 8 1 5 5 2 5 9 9 9 L a w r e n c e A v e C e n t e r L i n e M i 4 8 0 1 5 Fold Here ...

Page 1983: ...errors have you found Please include page number What topics are hard to locate confusing or not covered completely What comments or suggestions do you have Your Name Dealership Address Manual Name and Model Year Note All comments become the property of Chrysler Corporation ...

Page 1984: ...Fold Here Place Stamp Here Chrysler Corporation CIMS 424 81 55 25999 Lawrence Ave Center Line Ml 48015 Fold Here ...

Page 1985: ......

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