Dodge RAM 1995 Service Manual Download Page 775

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Summary of Contents for RAM 1995

Page 1: ...1 9 9 5 SERVICE MANUAL RAM TRUCK 1500 3500 ft 2 WHEEL DRIVE 4 WHEEL DRIVE C H R Y S L E R W CORPORATION...

Page 2: ...R TRANSMITTED IN ANY FORM OR BY ANY MEANS ELECTRONIC ME CHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corporation reserves the righ...

Page 3: ...e which Group contains the information 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...

Page 4: ...HHjj 7 Cooling System 8 Electrical v i 9 Engines 11 Exhaust System and Intake Manifold 13 Frame and Bumpers 14 Fuel System 16 Propeller Shafts 19 Steering v 21 Transmissions and Transfer Cases 22 Whee...

Page 5: ......

Page 6: ...and Hour SlDH of final assembly VEHICLE IDENTIFICATION NUMBER VIN PLATE The Vehicle Identification Number VIN plate is attached to the top left side of the instrument panel Fig 2 The VIN contains 17 c...

Page 7: ...E SHELL ENGINE TRIM TRANSMISSION V I N AAARKET 9 3 I N 8 Refer to Group 21 Transmissions for all transmis sion transfer case identification data 1AJ0R COiPONENT IDENTIFICATION Refer to the applicable...

Page 8: ...t Code U C B M Digit 6 Open Space Digit 7 2 3 Vehicle Identification No Line 2 Digit 1 3 Paint Procedure Digit 4 Open Space Digit 5 8 Primary Paint Digit 9 Open Space Digit 1 0 1 3 Secondary Paint Dig...

Page 9: ...8 Note All dimensions are in inches unless noted J94IN 26 VEHICLE INTERIOR DIMENSIONS CLUB CAB Front Rear A Head Room 40 2 39 4 B Hip Room 65 8 66 8 C Shoulder Room 66 3 67 7 D Seat Width 60 2 NA E Se...

Page 10: ...ll Width At Front Wheel Lip 79 4 79 4 79 4 79 51 G Track Front 68 5 68 5 68 6 68 6 Rear 68 0 68 0 68 0 73 0 H Tailgate Load Height 31 2 35 6 31 5 35 6 31 5 35 6 31 4 35 6 1 Overhang Front 37 9 37 9 37...

Page 11: ...66 9 68 5 68 6 68 9 68 6 68 9 69 8 G Rear 66 9 66 9 68 0 68 0 73 0 H Tailgate Load Height 31 3 33 9 31 3 34 4 34 4 373 33 3 37 2 33 8 37 8 I Overhang Front 37 9 37 9 37 9 37 9 37 9 J Overhang Rear Wi...

Page 12: ...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...

Page 13: ...8 INTRODUCTION BR VEHICLE WEIGHTS Payload The Vehicle Weight charts provides Curb weight for each vehicle type wheelbase Gross vehicle weight rating GVWR...

Page 14: ...son TYD LT215 85R16 all season TVV GAWR Front 3 300 3 300 3 300 4 000 4 000 Rear 3 800 3 800 4 670 6 085 7 460 SHORT BOX p i f WB BAYB OAD1 M A G N U M 3 9L V6 2 000 2 365 M A G N U M 5 2L V8 2 230 _...

Page 15: ...5 75R16 all season TWP LT245 75R16 all season TYD LT215 85R16 all season TVV GAWR Front 3 500 3 500 4 500 4 500 Rear 3 600 4 670 6 085 7 060 S H O R T BOX 119 WB PAYLOAD1 MAGNUM 5 2L V8 1 885 M A G N...

Page 16: ...85R16 all season all season all season TRY TYD TW GAWR Front 3 650 4 500 4 500 Rear 3 800 6 085 7 500 SHORT BOX 139 WB PAYLOAD 1 Magnum 5 2LV8 1 830 Magnum 5 9L V8 1 750 3 920 IASE CURB WEIGHT Front...

Page 17: ...15 85R16 all season all season all season TWA TYD TW GAWR Front 3 800 4 850 4 670 Rear 3 600 j 6 085 7 500 PAYLOAD i Magnum 5 2L V8 1 455 Magnum 5 9L V8 1 365 3 615 BASE CURB WEIGHT Front 2 965 3 145...

Page 18: ...6 all season TYD LT215 85R16 all season TVV LT245 75R16 all season TYD LT215 85R16 all season TVV GAWR Front 4 000 4 000 4 500 4 500 Rear 6 085 7 500 6 085 7 500 mm mm m W B PAYLOAD1 MAGNUM 8 0L V10 3...

Page 19: ...85R16 LT245 75R16 LT215 85R16 all season all season all season all season TYD TW TYD TW GAWR Front 4 500 4 500 4 850 4 670 Rear 6 085 7 500 6 085 7 500 PAYLOAD 1 Maqnum 8 0LV10 3 285 4 660 2 860 4 735...

Page 20: ...V GAWR Front 4 000 4 500 3 570 Rear 6 085 8 000 7 060 j m t r w i ffto CA PAYLOAD2 4 360 _ CURB W E I G H Front 2 870 Rear 1 570 Total 4 440 _ ia W i p f A PAYLOAD2 6 400 CURB W E I G H Front 3 065 Re...

Page 21: ...s LT245 75R16E TYD LT215 85R16D TVV LT215 85R16D TVV GAWR Front 4 500 4 500 4 500 Rear 6 085 8 000 8 000 135 W B CA 3 800 CURB W E I G H Front 3 285 _ Rear 1 715 Total 5 000 l i t wft 60 C A PAYLOAD1...

Page 22: ...16E TYD LT245 75R16E TYD LT215 85R16D TVV LT215 85R16D TVV GAWR Front 4 000 4 000 4 500 4 500 Rear 6 085 6 085 8 000 8 000 Mn W l 54 CA PAYLOAD1 3 825 4 115 CURB WEIGHT Front 3 200 3 490 _ Rear 1 775...

Page 23: ...LT245 75R16E TYD LT245 75R16E TYD LT215 85R16D TVV LT215 85R16D TVV GAWR Front 4 500 4 500 4 500 4 500 Rear 6 085 6 085 8 000 8 000 135 W B 56 CA PAYLOAD1 3 385 3 090 CURB WEIGHT Front 3 590 3 880 Re...

Page 24: ...OWING SPECIFICATIONS The Trailer Towing Specification charts provides Maximum trailer weight rating INTRODUCTION 19 Maximum trailer tongue weight rating Maximum combined weight of the trailer load tow...

Page 25: ...utomatic 4 speed O D 3 21 3 55 3 902 3 55 3 902 6 010 6 400 6 010 6 400 6 010 6 400 3 500 3 700 3 300 7 800 8 000 7 600 5 2L M A G N U M 8 Manual 5 speed O D Automatic 4 speed O D H D 3 21 3 55 3 90 3...

Page 26: ...ual Rear Wheels Tongue Wt 1 200 5o L 0 cummins Diesel Manual 5 speed O D H D Automatic 4 speed O D H D 3 54 4 10 3 54 4 10 10 500 10 500 10 500 10 500 8 500 12 000 8 500 12 500 14 500 18 000 14 500 18...

Page 27: ...0 3 54 4 10 8 800 8 800 8 800 8 800 8 200 11 700 8 200 11 700 14 500 18 000 14 500 18 000 2500 HD 4 x 4 REGULAR CAB 8 0 BOX Tongue Wt 900 8 0L M A G N U M 1 0 Manual 5 speed O D H D Automatic 4 speed...

Page 28: ...0 Tongue Wt 900 8 0L Magnum V10 Manual 5 speed OD HD Automatic 4 speed OD HD 3 54 4 10 3 54 4 10 8 800 8 800 13 600 3 13 600 3 19 000 19 000 3500 4x2 CLUB CAB Dual Rear Wheels 5 9L Magnum V8 Manual 5...

Page 29: ...Wt 900 8 0L Magnum V I 0 Manual 5 speed OD HD Automatic 4 speed OD HD 3 54 4 10 3 54 4 10 8 800 8 800 13 200 2 13 200 2 19 000 19 000 3500 4x4 CLUB CAB Dual Rear Wheels 5 9L Magnum V8 Manual 5 speed...

Page 30: ...9L M A G N U M V8 HDC Manual 5 speed O D M D Automatic 4 speed O D H D 3 54 4 09 3 54 4 09 8 800 8 800 8 800 8 800 2 15 000 15 000 15 000 15 000 5 9L 1 6 CUMMINS Diesel Manual 5 speed O D H D Automat...

Page 31: ...torque value by 10 percent when the bolt threads are lubricated and by 20 percent if new BOLT THREAD AND GRADE CLASS IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt nut threads are not the s...

Page 32: ...0 1 400 101 6 1 8 80 69 in lbf 9 90 78 in lbf 8 1 25 19 195 1 4 21 210 15 6T 10 1 25 39 400 29 44 440 32 12 1 25 71 730 53 80 810 59 14 1 5 110 1 100 80 125 1 250 90 16 1 5 170 1 750 127 6 1 10 5 110...

Page 33: ...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 The metric strength cla...

Page 34: ...mber 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 M b N m Mb N m Mb N m Mb 1 4 20 9 7 8 6 1...

Page 35: ...4T Stud bolt 61 Hexagon flange bolt w washer hexagon bolt J J No mark 4T Stud bolt Grooved j 61 Hexagon head bolt Two f protruding lines 51 Stud bolt Grooved j 61 Hexagon flange bolt w washer hexagon...

Page 36: ...793 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 3...

Page 37: ...tection for each owner s vehicle Conditions can vary with individual driving habits It is necessary to schedule maintenance as a time in terval as well as a distance interval It is the owner s respons...

Page 38: ...he vis cosity of engine oil SAE 30 specifies a single viscos ity engine oil Engine oils also have multiple viscosities These are specified with a dual SAE vis cosity grade which indicates the cold to...

Page 39: ...8 0 L Oil filter must be changed with every oil change Cooling System 3 9 L 19 L 20 0 qts 5 2 L 19 L 20 0 qts 5 9 L Gas 19 L 20 0 qts 5 9 L Diesel 24 5 L 26 0 qts 8 0 L 22 7 L 24 0 qts Automatic Trans...

Page 40: ...heck windshield washer solvent and add as re quired ONCE A MONTH Check tire pressure and look for unusual tire wear or damage Check fluid levels of coolant reservoir brake mas ter cylinder power steer...

Page 41: ...an and repack if required 4x2 Inspect brake linings 97 500 MILES 156 OOOKM OR AT 78 MONTHS Change engine oil 105 000 MILES 168 OOOKM OR AT 84 MONTHS Change engine oil Replace engine oil filter Flush a...

Page 42: ...Inspect engine air cleaner element replace as necessary 48 000 MILES 77 OOOKM Change engine oil Replace engine oil filter Drain and refill automatic transmission fluid Re place filter and adjust bands...

Page 43: ...ent replace as necessary Inspect front wheel bearings Clean and repack if required 4x2 108 000 MILES 173 OOOKM Change engine oil Replace engine oil filter Drain and refill automatic transmission fluid...

Page 44: ...and add as required Check windshield washer solvent and add as re quired ONCE A MONTH Check tire pressure and look for unusual tire wear or damage Check fluid levels of coolant reservoir brake mas ter...

Page 45: ...ce filter and adjust bands Drain and refill transfer case fluid Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings 78 000 MILES 125 OOOKM OR AT 78 MONTHS Change engine...

Page 46: ...x4 Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings 27 000 MILES 43 OOOKM Change engine oil Replace engine oil filter 8 0L only 30 000 MILES 48 OOOKM Change engine o...

Page 47: ...ront axle fluid 4x4 Inspect front wheel bearings Clean and repack if required 4x2 Inspect brake linings 75 000 MILES 120 OOOKM Change engine oil Replace engine oil filter 8 0L only 78 000 MILES 125 OO...

Page 48: ...d Re place 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 Off the highway operat...

Page 49: ...GE Inspect exhaust system Inspect brake hoses Rotate the tires at each oil change interval shown 6 000 miles 9 600 km on Schedule A or every other interval shown on Schedule B Check engine coolant lev...

Page 50: ...een 30 000 miles 48 000 km or 24 months since last change 84 000 MILES 134 400KM OR AT 84 MONTHS Change engine oil Replace engine oil filter Replace fuel filter Inspect water pump weep hole for blocka...

Page 51: ...ssary Inspect water pump weep hole for blockage Drain and refill automatic transmission fluid Re place filter and adjust bands Drain and refill transfer case fluid Change rear axle fluid Change front...

Page 52: ...rake linings Inspect charge air cooler connections for leaks or at 12 month intervals 87 000 MILES 140 OOOKM Change engine oil Replace engine oil filter 90 000 MILES 144 OOOKM Change engine oil Replac...

Page 53: ...an if necessary Frozen battery Yellow or bright color test indicator if equipped Low battery fluid level Generator drive belt condition and tension Fuel fumes or leakage correct if necessary CAUTION I...

Page 54: ...loor jack posi tioned under An axle tube A body side sill A steering linkage component A drive shaft The engine or transmission oil pan The fuel tank A front suspension arm Use the correct frame rail...

Page 55: ...clearance at the oppo site end of the vehicle especially when towing over rough terrain or steep rises in the road If necessary remove the wheels from the lifted end of the vehicle and lower the vehic...

Page 56: ...D WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROB LEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY CONTACT YOUR DEALER OR GOV ERNMENT AGENCY FOR LOCA...

Page 57: ...ance Schedules T O CHANiE ENGINE OIL Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface Fig 3 Oil Level indicator Dipstick 2 Hoist and support vehicle o...

Page 58: ...ith little effort the system would have low internal pressure and should be safe to open to the first safety notch of the radiator cap Refer to Group 7 Cooling System COOLING SYSTEM INSPECTION Coolant...

Page 59: ...roperly for the emissions system and engine con troller to function correctly Do not immerse paper air element in cleaning sol vents damage can result 10 SERVICE lii CLEANER ASSEMBLY 1 Raise hood of v...

Page 60: ...starting and driveability problems In addition dam age may be done to critical fuel system compo nents Methanol Methyl or Wood Alcohol is used in a va riety of concentrations blended with unleaded ga...

Page 61: ...deterioration exists replacement is required To reduce deteriora tion of rubber components Chrysler Corporation rec ommends Mopar Foamy Engine Degreaser or equivalent be used to clean engine compartme...

Page 62: ...ngines tend to consume more fuel and oil un til after the break in period has ended ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase...

Page 63: ...ed in this sec tion 8 Install oilfillcap 9 Start engine and inspect for leaks 10 Stop engine and inspect oil level ENGINE OIL FILTER OIL FILTER SPECIFICATION The quality of replacement filter cartridg...

Page 64: ...ra diator cap Cooling system freeze protection should be tested at the onset of the winter season or every BR 12 months Service is required if coolant is low con taminated rusty or freeze protection i...

Page 65: ...r equivalent be used to clean engine compartment of oil and road grime EXHAUST SYSTEM DIESEL The exhaust system should be inspected when un der vehicle service is performed or as specified in the Lubr...

Page 66: ...ETROLEUM OR WA TER BASE LIQUIDS TO CONTAMINATE CLUTCH FLUID SEAL DAMAGE AND CLUTCH FAILURE CAN RESULT The clutch reservoir level Fig 3 should be in spected when other under hood service is performed F...

Page 67: ...is performed Refer to Group 21 Transmission for proper service proce dures CAUTION To minimize fluid contamination verify that dipstick i s seated in the fill tube after fluid level reading is taken...

Page 68: ...rface before inspecting oil level LUBRICANT SPECIFICATION Use API GL 5 SAE 80W 90 Mopar Multipurpose Gear Lubricant or equivalent to fill the front axle LUBRICANT SPECIFICATION Chrysler Corporation re...

Page 69: ...the fill hole in the differen tial cover Fig 10 The vehicle must be positioned on a level surface before inspecting oil level LUBRICANT SPECIFICATION Use API GL 5 SAE 80w 90 Mopar Multipurpose Gear L...

Page 70: ...dy hoses and tubing These conditions include The extent and quality of vehicle maintenance The geographic area of vehicle operation The length of exposure time to excess heat and chemical contaminants...

Page 71: ...ed at the intervals described in the Maintenance Schedules section of this Group Refer to Group 2 Front Suspension and Axles for proper service proce dures LUBRICANT SPECIFICATION Use Mopar Multi purp...

Page 72: ...o not disconnect the caliper brake fluid hose unless the caliper must also be removed for maintenance Support the caliper with a hanger to prevent brake fluid hose damage 2 Remove the dust cap the cot...

Page 73: ...to the top of the indicator window With disc brakes the fluid level can be expected to fall as the brake pads wear However a low fluid level can also be caused by a leak and repair will then be necess...

Page 74: ...ing For proper service proce dures refer to Group 5 Brakes BRAKE LINE INSPECTION The metal brake lines should be inspected when other under vehicle service is preformed If a line is pinched kinked or...

Page 75: ...tire replacement and tread wear indicators ROTATION Tires wheels should be rotated according to the rec ommended interval The first tire wheel rotation is the most important for establishing the prev...

Page 76: ...xle shaft tubes extending from either side They are equipped with a vacuum disconnect to ac tivate the 4WD Tube axle 2WD is a one piece tube This axle mounts to the same bracketry as the four wheel dr...

Page 77: ...ationship to the suspen sion The bar extends across the front underside of the chassis and mounts on the frame rails Links connected the bar to the lower suspension arms Sta bilizer bar mounts are iso...

Page 78: ...el a greater distance than the inside wheel in or der to complete a turn This difference must be com pensated for in order to prevent the wheels from scuffing and skidding through the turn To accom pl...

Page 79: ...nside edges and trailing inside edges of the front tires Fig 1 2 Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear The wheel toe position is the final fro...

Page 80: ...adjusted by rotating the cams on the lower suspension arm Fig 3 Refer to the Align ment Specification Chart for the correct setting TOE POSITION The wheel toe position adjustment should be the fi nal...

Page 81: ...Cor rection Chart to obtain the correct caster angle Fig 6 4x2 Fig0 4 Drag Link Adjustment PRE ALIGNMENT INSPECTION IFS SUSPENSION Before starting a front wheel alignment the follow ing inspection and...

Page 82: ...ber and caster angle adjustments involve changing the position of the upper suspension arm FRONT SUSPENSION AND AXLE 2 7 Fig 7 Caster Camber Adjustment Location pivot bar Fig 7 Refer to the Alignment...

Page 83: ...0 4 x 2 8800 134 7 3 45 0 50 4 x 2 8800 154 7 3 65 0 50 4 x 2 10500 134 7 3 25 0 50 4 x 2 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...

Page 84: ...C 3894A 4 Remove the bolt and flag nut from the axle bracket and remove the track bar Fig 1 Fig 1 Track Bar page Shock Diagnosis 10 Stabilizer Bar 9 Track Bar 9 Upper Suspension Arm 11 INSTALLATION 1...

Page 85: ...ock Absorber and Bracket 3 Remove the lower bolt from the axle bracket Fig 4 Remove the shock absorber from engine com partment SHOCK lOtJ J9402 47 Fig 4 Shock Absorber Axle Mount INSTALLATION 1 Posit...

Page 86: ...1 Raise and support the vehicle 2 Paint or scribe alignment marks on the cam ad justers and suspension arm for installation reference Fig 5 3 Remove the lower suspension arm nut cam and cam bolt from...

Page 87: ...ing on both sides Tighten the bolts to 47 N m 35 ft lbs torque 2 Install links on stabilizer bar and lower suspen sion arm Install grommets retainers and nuts Tighten nuts to 34 N m 25 ft lbs torque F...

Page 88: ...Place jack under arm in front of shock mount 7 Remove cotter pin and nut from lower ball stud Separate ball stud with remover C 4150A 8 Remove lower shock bolt from suspension arm 9 Lower jack and su...

Page 89: ...far outboard as possible The upper suspension arms must not contact the rebound bumpers 2 Install a dial indicator and clamp assembly to the lower suspension arm 3 Position indicator plunger against k...

Page 90: ...in knuckle Install nut and tighten to 75 N m 55 ft lbs torque Install replace ment cotter pin 3 Remove jack from lower suspension arm 4 Install tire and wheel assembly 5 Remove support and lower vehi...

Page 91: ...n the nut to 41 54 N m 30 40 ft lbs torque to preload bearing while rotating the hub ro tor Stop hub rotor and loosen nut to completely re lease bearing preload torque Tighten the nut finger tight and...

Page 92: ...uce noise If a mis adjustment condition is not corrected component failure can re sult page Low Speed Knock 18 Vibration 18 Excessive bearing preload may not be noisy This condition will cause high te...

Page 93: ...r nut Excessive pinion yoke run out Bent axle shaft Check for loose or damaged front end components or engine transmission mounts These components can contribute to what appears to be a rear end vi br...

Page 94: ...rque g Readjust as necessary h If necessary replace scuffed gears a Replace broken axle shaft after correcting axle shaft tube alignment b Replace broken axle shaft Avoid excessive weight on vehicle c...

Page 95: ...er and clean flange and reseal a Refill differential housing b Drain flush and refill with correct amount of the correct lubricant c Readjust bearings d Inspect gears for excessive wear or scoring Rep...

Page 96: ...ash is adjusted by the use of shims The shims are located between the differential bearing cones and case Pinion bearing preload is set and maintained by the use of a collapsible spacer LUBRICANT SPEC...

Page 97: ...ide comfort could be affected and premature bushing 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 t...

Page 98: ...rque after seal installation 7 Remove the pinion yoke nut and washer Use Remover C 452 and Holder C 3281 to remove the pinion yoke Fig 2 C 452 J9I02 31 Fig 2 Pinion Yoke Removal 8 Mark the positions o...

Page 99: ...b nut 5 Remove the hub to knuckle bolts Fig 6 Re move the hub bearing from the steering knuckle and axle shaft Fig 6 Hub and Knuckle 6 Remove the brake dust shield 7 On 4WD vehicles remove the axle sh...

Page 100: ...a wire brush Ensure that all the rust and foreign matter are removed from the bores 2 Inspect the yokes for distortion cracks and worn bearing cap bores 3 Replace the complete U joint if any of the co...

Page 101: ...SHOULD BE BETWEEN 10 20 IN HG 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 DICONNECT THE SHIFT...

Page 102: ...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 FO...

Page 103: ...ed into the shift collar groove 5 Install the shift motor housing shield and at taching bolts Tighten the bolts to 11 N m 96 in lbs torque 6 Add 148 ml 5 ounces of API grade GL 5 hy poid gear lubrican...

Page 104: ...l installation 60 axle 8 Insert the axle shaft into the tube Engage the splined end of the shaft with the shift collar Refer to Hub Bearing and Axle Shaft in this section 9 Install the vacuum motor ho...

Page 105: ...2 30 FRONT SUSPENSION AND AXLE B R Fig 17 Upper Ball Stud Install Fig 19 Lower Ball Stud Install...

Page 106: ...ll ball stud Fig 23 KNUCKLE KNUCKLE SPECIAL TOOL 6758 SPECIAL TOOL 6759 SPECIAL TOOL 6760 SPECIAL TOOL C 4212F J9402 41 J9402 39 Fig 2f Upper Ball Stud Install LOWER BALL STUD REPLACEMENT 60 AXLE 1 Po...

Page 107: ...mbly and axle shafts must be removed Refer to the removal procedures in this Group 1 Note the installation reference letters stamped on the bearing caps and housing ma chined sealing surface Fig 24 Fi...

Page 108: ...Gear Removal 4 Remove the pinion gear mate shaft roll pin and shaft 5 Rotate the differential side gears and remove the pinion mate gears and thrust washers Fig 31 7 Remove the differential side gears...

Page 109: ...5 7 Remove the collapsible preload spacer Fig 36 8 Remove the inner bearing from the pinion with Bearing Splitter 1130 and Bearing Splitter Bridge 938 Fig 37 9 Remove the oil slinger select thickness...

Page 110: ...nstall new shims if necessary DIFFERENTIAL ASSEMBLY 1 Install the following components in the differ ential case Differential side gears and thrust washers Pinion gears and thrust washers Pinion gear...

Page 111: ...H SET UP OR CHECKING Fig 40 INNER PINION SEARING rON END CENTERLINE OF RING GEAR J9403 56 Fig 40 Pinion Gear Standard Depth Distance Compensation for depth variance is achieved by a selected thickness...

Page 112: ...ch 0 025mm Sub tract this amount from original shim Refer to the Pinion Gear Depth Variance Chart DIFFERENTIAL AND PINION MEASUREMENT DIFFERENTIAL ZERO END PLAY MEASUREMENT 1 Place Master Differential...

Page 113: ...t other BR Fig 45 Pinion Height Block axle sizes Pick correct size step for axle being serviced Fig 46 Gauge Tools In Housing 3 Firmly place Scooter Block and Dial Indicator on pinion height block too...

Page 114: ...he pinion gear Install rear inner bearing on pinion gear with In staller W 262 for 44 axle or Installer C 3095A for 60 axle Fig 50 Use press and installer for this opera tion INSTALLER HANDLE Fig 49 P...

Page 115: ...ue necessary to rotate the pinion gear should be Original Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 26 to 4 52 N m 20 to 40 in lbs DIFFERENTIAL SHIM PACI MEASUREMENT AND ADJUSTMENT 1 Place Ma...

Page 116: ...Installer C 4190 for 60 axle 10 Position the remaining zero end play shims on hub at opposite side of case Include an additional 0 015 in 0 38 mm thick shim on this hub This will provide the required...

Page 117: ...2 Apply a thin coat of hydrated ferric oxide to the drive and coast side of the ring gear 3 Rotate the ring gear several revolutions in both directions while a load is being applied Insert a pry bar b...

Page 118: ...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 REQUI...

Page 119: ...erential can result in lubricant foaming and overheating 4 Refill the differential housing with the specified quantity of MOPAR Hypoid Gear Lubricant 5 Install the fill hole plug and tighten to 34 N m...

Page 120: ...m 55 ft lbs Upper Suspension Arm Bolts 244 N m 180 ft lbs Ball Stud Nut 75 N m 55 ft lbs Stabilizer Bar Clamp Bolt 47 N m 35 ft lbs Link Nuts 34 N m 25 ft lbs DESCRIPTION TORQUE Fill Hole Plug 34 N m...

Page 121: ...ing A stamped metal axle gear ratio identification tag is attached to the housing cover The rear wheel anti lock RWAL or four wheel an ti lock ABS brake speed sensor is mounted on top of the different...

Page 122: ...4 Model 70 and 80 Differential Cover divided and distributed equally between the two side gears As a result the pinion gears revolve with the pinion mate shaft but do not rotate around it Fig 5 When t...

Page 123: ...hould have a API GL 5 quality specifica tions The lubricant recommended for Track Lok and Power Lok differential is API grade GL 5 Friction modifier must also be added to the lubricant Refer to Group...

Page 124: ...er to Spring and Shock Absorber Diagnosis chart for further infor mation Incorrect weight distribution should be con sidered as a possible cause for erratic steering spring failure or tire wear SHOCK...

Page 125: ...by the tires 9 On 6 010 to 10 500 GVW vehicles tighten the spring clamp retaining nuts to 149 N m 110ft lbs torque On 11 000 GVW cab chassis vehicles tighten nuts to 163 N m 120 ft lbs torque 10 On 6...

Page 126: ...nt failure can result page Low Speed Knock 7 Rear Axle Alignment 7 Vibration 7 GEAft AND BEARING NOISE GEAR NOISE Axle gear noise can be caused by insufficient lubri cant Incorrect backlash tooth cont...

Page 127: ...l both reference marks face the front of the vehicle Measure the dis tance between the outside edges of the two pieces of tape Record this measurement as the front of tire FTR measurement 4 Rotate the...

Page 128: ...ue g Readjust as necessary h If necessary replace scuffed gears a Replace broken axle shaft after correcting axle shaft tube alignment b Replace broken axle shaft Avoid excessive weight on vehicle c R...

Page 129: ...d clean flange and reseal a Refill differential housing b Drain flush and refill with correct amount of the correct lubricant c Readjust bearings d Inspect gears for excessive wear or scoring Replace...

Page 130: ...ON SUPPORT 11 Remove the axle assembly from the vehicle page Lubrication Change 10 Pinion Depth Measurement and Adjustment 18 Pinion Seal Replacement 13 12 Wash and clean the outer surface of the hou...

Page 131: ...IFFERENTIAL HOUSING VENT FITTING FRONT BEARING SEAL AXLE AXLE SHAFT SHAFT BEARING TUBE BEARING CAP WASHER LOCK STUD NUT BOLT DIFFERENTIAL BEARING SIDE GEAR CLIP BEARING CUP ADJUSTER LOCK COVER BOLT PL...

Page 132: ...nd drain the lubri cant from the housing 6 Remove the lock screw and the pinion mate gear shaft from the case Fig 3 7 Push the axle shaft in and remove axle shaft C clip lock from axle shaft Fig 4 8 R...

Page 133: ...he axle shaft seal lip 2 Insert the C clip lock in the recessed groove Fig 4 Push the axle shaft outward to seat the C clip lock 3 Align and install pinion gear mate shaft in the case Align hole in sh...

Page 134: ...required 3 Install pinion shaft seal with Installer C 4109A and Handle C 4735 Seal is correctly installed when seal flange contacts face of differential housing flange 4 Install yoke on pinion shaft w...

Page 135: ...re measuring the ring gear runout 2 Attach Dial Indicator to Pilot stud C 3288B Place the indicator plunger at a right angle 90 to the ring gear Fig 12 3 Measure runout by turning the ring gear sev er...

Page 136: ...0 005 inch 0 13 mm case flange runout should be measured Install the case with the bearing cups and the threaded adjusters close to their original position 2 Install the bearing caps and bolts Tighten...

Page 137: ...t use a torch to heat the ring REAR SUSPENSION AND AXLE 3 17 PILOT Fig 18 Case To Ring Gear Alignment 7 Install replacement ring gear bolts with left hand threads Alternately and evenly tighten each b...

Page 138: ...t and rear bearings with gear lubri cant Re tighten the compression nut tool to 1 3 N m 15 25 in lbs torque Rotate the pinion gear several complete revolutions to align the bearing rollers Install Gau...

Page 139: ...SS J8902 46 14 Install the pinion yoke with Installer W 162D and Holder 6719 Fig 23 It is necessary to use tools above to correctly seat the front bearing on drive pinion gear shaft Fig 28 YOKE INSTAL...

Page 140: ...e value is with replacement bearings and pinion nut tightened to a minimum of 285 N m 210 ft lbs torque Fig 25 When using original pinion rear bearing and a replacement front bearing The correct pre l...

Page 141: ...described above Fig 27 Threaded Adjuster Tooi 2 Install Dial Indicator Fig 28 Position the plunger against the drive side of a ring gear tooth Measure the backlash at 4 positions 90 degrees apart arou...

Page 142: ...THICKNESS 0 0 3 7 NEW SIDE GEAR CLEARANCE 0 0 3 J9203 31 Fig 30 Side Gear Calculations measure the thrust washer thickness Record the thickness and re install the thrust washer Assemble the differenti...

Page 143: ...T 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...

Page 144: ...al axle gear ratio identification tag is attached to the housing cover with one cover bolts This tag also identifies the number of ring and pinion teeth An addition tag will be attached if equipped wi...

Page 145: ...Fig 1 Model 70 and 80 Rear Axle cn...

Page 146: ...nnect drive shaft to pinion yoke with the ref erence marks aligned Tighten U joint clamp bolts to 21 N m 16 ft lbs 186 in lbs torque 8 Install wheels and tire assemblies 9 Fill the differential housin...

Page 147: ...icant on the lip of pinion seal Install the new seal with Installer D 187B 2 Align the installation reference marks and po sition the yoke on the pinion gear 3 Install yoke with Installer D 191 Fig 5...

Page 148: ...2 J9102 31 Fig 8 Pinion Yoke Removal SPECIAL TOOL 7794A PINION SEAL J9402 59X Fig 9 Seal Removal INSTALLATION 1 Apply a light coating of gear lubricant on the lip of pinion seal Install seal Installer...

Page 149: ...lean the gasket contact surface area on the flange with an appropriate solvent Install a new flange gasket and slide the axle shaft into the tube 2 Install the bolts and tighten to 122 N m 90 ft lbs t...

Page 150: ...SEmBLW Remove RWAL ABS brake sensor hold down bolt and pull the sensor from the differential housing The sensor must be removed to pre vent damage when disassembling or assembling the differential com...

Page 151: ...ars and thrust washers Fig 19 14 Remove the differential side gears and thrust washers PINION REMOVAL DISASSEMBLY meMOWAl DISASSEMBlY 1 Remove the pinion yoke nut and washer Use Remover C 452 and Wren...

Page 152: ...AL TOOL 7794A PINION SEAL J9402 59X Fig 21 Pinion Seal Removal housing opening Draw the wire and cloth from the housing outward through the tube Clean oil chan nels in housing 3 Inspect the differenti...

Page 153: ...yoke as necessary 7 Inspect the pinion bearing preload shims for cracks damage and distortion Install replacement shims if necessary for the preload torque adjust ment 8 Inspect the RWAL ABS brake exc...

Page 154: ...differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignment 6 Press the exciter ring onto the differential case using the ring gear as a pilot Fig 26 SLOT 8...

Page 155: ...m 5 375 inches Model 80 axle the standard depth distance is 147 625 mm 5 812 inches Compensation for depth variance is achieved by two methods One method is shims placed between the pinion gear rear b...

Page 156: ...6730 and Dial Indicator C 3339 Fig 32 DIAL INDICATOR ARBOR DISC J9403 45 Fig 32 Pinion Gear Depth Gauge Tools 1 Install front pinion bearing cup with Fig 33 Model 60 and 70 Installer C 4203 and Handle...

Page 157: ...tep for axle being serviced Fig 35 Pinion Height Block ARBOR DISC PINION BLOCK PINION HEIGHT BLOCK Fig 36 Gauge Tools In Housing 5 Firmly place Scooter Block and Dial Indicator on pinion height block...

Page 158: ...ed onto pinion and install pinion gear in hous ing 12 Install pinion front bearing and oil slinger 13 Apply a light coating of gear lubricant on the lip of pinion seal Install the new seal with Model...

Page 159: ...16 Check bearing preload torque with an inch pound torque wrench Fig 43 The torque necessary to rotate the pinion gear should be Original Bearings 1 3 N m 10 20 in lbs New Bearings 2 5 N m 20 40 in lb...

Page 160: ...e housing a maxi mum distance of 0 38 mm 0 015 in with the spreader tool Measure the distance with the dial indicator 15 Remove the dial indicator preload and backlash These shim must be placed on the...

Page 161: ...above good gear teeth contact pat terns should exist Fig 48 Ring Gear Backlash Measurement RING GEAR TEETH CONTACT PATTERN ANALYSIS The ring gear teeth contact patterns will show if the pinion gear d...

Page 162: ...T 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...

Page 163: ...h wheels slip due to unequal traction Trac Lok operation is normal In extreme cases of dif ferences of traction the wheel with the least traction may spin NOISE DIAGNOSIS If a noise occurs when turnin...

Page 164: ...components are illustrated in Fig 4 Re TORQUE WRENCH Fig 3 Power Lok Test fer to this illustration during repair service for com ponent detail and their location DISASSEMBLY Service to the Trac Lok di...

Page 165: ...DIFFERENTIAL Fig 7 Pinion Gear Mate Shaft Lock Pin Removal SPECIAL TOOL C 4487 1 DIFFERENTIAL SIDE CASE GEAR J9203 4 Fig 8 Step Plate Tool Installation 10 Use a small screw driver position it in slot...

Page 166: ...ears Replace any gear that is worn cracked chipped or damaged 4 Inspect differential case and pinion shaft Re place if worn or damaged Fig 11 Pinion Gear Removal SIDE GEAR DIFFERENTIAL AND CLUTCH DISC...

Page 167: ...87 1 on first clutch pack Fig 15 8 Install the upper side gear and clutch disc pack Fig 15 UPPER SIDE GEAR AND CLUTCH DISC PACK DIFFERENTIAL CASE SPECIAL TOOL C 4487 1 J9203 6 Fig 15 Upper Side Gear C...

Page 168: ...nts with compressed air CLUTCH PLATES BUTTON HALF FLANGE HALF J9203 73 Fig 19 Cover Half Removal 2 Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one compo nent...

Page 169: ...SIDE GEAR PINION MATE GEAR BUTTON HALF CROSS SHAFT J9503 8 FLANGE HALF Fig 20 Trac Lok Dana 80 Components CLUTCH RING PINION MATE GEAR PLATE DISHED PLATE DISHED DISC DISC PINION MATE CROSS SHAFT SCRE...

Page 170: ...50 REAR SUSPENSION AND AXLE BR Fig 23 Clutch Pack Installation Fig 25 Case Half Installation...

Page 171: ...004 0 009 in Pinion Std Depth 127 0 mm 5 000 in Pinion Bearing Preload Original Bearing 1 3 N m 10 20 in lbs New Bearing 2 5 N m 20 40 in lbs MODEL 70 AXLE Axle Type Hypoid Lubricant Thermally Stable...

Page 172: ...Cover Bolt 47 N m 35 ft lbs Bearing Cap Bolt 136 N m 100 ft lbs Pinion Nut 285 N m 210 ft lbs Ring Gear Bolt 102 N m 75 ft lbs Backing Plate Bolt 64 N m 48 ft lbs RWAL ABS Sensor Bolt 24 N m 18 ft lbs...

Page 173: ...um Brakes Rear drum brakes are dual shoe units with an au tomatic adjustment mechanism Three different drum brake assemblies are used 1500 models have 11 x 2 in rear drum brakes 2500 models have 13 x...

Page 174: ...clean the system components These fluids damage rubber cups and seals If system contamination is suspected check the fluid for dirt discoloration or separation into distinct layers Drain and flush th...

Page 175: ...ilock system The light illuminates only when a fault occurs within the RWAL or ABS system page Hard Pedal or High Pedal Effort 5 Low Brake Pedal 4 Low Vacuum Switch Diesel Models 3 Master Cylinder Pow...

Page 176: ...rred 3 If hard pedal or excessive pedal effort is expe rienced return to shop Problem is caused by faulty brake booster booster check valve binding pedal or master cylinder 3 During road test make nor...

Page 177: ...return port or faulty power booster that binds and does not re lease BRAKE FADE Brake fade is a product of overheating caused by brake drag However overheating and subsequent fade can also be caused b...

Page 178: ...worn tires with very little tread left can pro duce a grab like condition as the tire loses and recovers traction Flat spotted tires can cause vibration and wheel tramp and generate shudder during bra...

Page 179: ...ake action again Booster should provide two or more vacuum assisted pedal applications If vacuum assist is not provided perform booster and check valve vacuum tests Also check vacuum output on diesel...

Page 180: ...ading again 4 Vacuum should range from 8 5 to 25 inches vac uum at various throttle openings Vacuum should hold steady and not drop below 8 5 inches 5 If vacuum output is OK check booster and check va...

Page 181: ...all serviceable parts The take up valve is the only non serviceable compo nent The valve is available only as part of a com plete cylinder body assembly MASTER CYLINDER APPLICATION Three master cylin...

Page 182: ...wear if fluid level is very near the MIN level Always clean the master cylinder reservoir and cover before removing the cover to add fluid If this is not done dirt from the cover or reservoir could e...

Page 183: ...e fittings by hand to avoid cross threading 1 Apply Mopar rust penetrant to master cylinder combination valve and antilock valve brakeline fit tings Work penetrant between fittings and brake lines to...

Page 184: ...ner 3 Clamp cylinder body in vise Clamp vise jaws on one of the cylinder mounting ears as shown Fig 10 4 Remove reservoir with a rocking motion Use a pry tool to help ease reservoir out of cylinder bo...

Page 185: ...lace the cylinder body if the valve is faulty Inspect condition of the secondary piston Replace the piston if it is scored corroded or doubt exists about its condition MASTER CYLINDER REASSEMBLY 1 Coa...

Page 186: ...eding Procedure 1 Mount master cylinder in vise Clamp vise jaws on one of the cylinder mounting ears 2 Install bleed tubes in cylinder outlet ports and direct tube ends into appropriate reservoir cham...

Page 187: ...3 4 threads to secure each line in place 4 Install rear brake antilock valve in combination valve bracket Fig 17 Be sure bracket tab is seated in valve before installing valve attaching bolt Then inst...

Page 188: ...unting bracket attached to the dash page Power Brake Booster Identification 16 Power Brake Booster Installation 18 Power Brake Booster Operation 17 Power Brake Booster Removal 17 Power Brake Booster S...

Page 189: ...heck valve in the booster housing The check valve is a one way device that prevents vacuum leak back How Brake Boost Is Generated Power assist is generated by utilizing the pressure differential betwe...

Page 190: ...en booster mounting stud nuts to 23 34 N m 200 300 in lbs torque 4 Connect booster push rod to brake pedal Fig 4 BR Fig 7 Power Brake Booster Mounting 5 Install knee bolster 6 Connect vacuum hose to b...

Page 191: ...reset switch plunger as follows a Pull switch plunger all the way out to fully extended position b Push switch plunger inward 4 detent posi tions or clicks This is required preset position for switch...

Page 192: ...dal shaft and to pedal and bracket bushings 3 Position brake pedal in mounting bracket 4 Slide pedal shaft into bracket and through pedal from passenger side 5 Push pedal shaft out driver side of moun...

Page 193: ...p malfunction the pump must be replaced as an assembly Do not disassemble or attempt to repair the pump The combined vacuum and steering pump assembly must be removed for access to either pump However...

Page 194: ...eaking If leak age is noted and pump is noisy replace pump 2 Disconnect supply hose to booster Connect vac uum gauge to this hose and run engine at various throttle openings Output should range from 8...

Page 195: ...ne Connection At Pump 7 Remove lower bolt that attaches pump assem bly to engine block Fig 6 8 Remove bottom inboard nut that attaches adapter to steering pump Fig 6 This nut secures a small bracket t...

Page 196: ...to align tangs on vacuum pump shaft with coupling Fig 10 6 Verify that pump is seated in adapter and cou pling 7 Install and tighten pump attaching nuts and washers PUMP ADAPTER REPLACEMENT 1 Remove c...

Page 197: ...bly in place at this time 4 Working from under vehicle install pump as sembly lower attaching bolt Then tighten upper and lower bolt to 77 N m 57 ft lbs torque 5 Position bracket on steering pump inbo...

Page 198: ...ANTILOCK VALVE EXCITER RING J9305 45 Fig 1 Rear Wheel Antilock RWAL Brake System The RWAL system retards rear wheel lockup dur ing periods of high wheel slip and deceleration Re tarding lockup is acco...

Page 199: ...e activated only when braking effort and rate of wheel slip and deceleration are high antilock mode During normal braking the valves allows free flow of brake fluid to the rear brake units In antilock...

Page 200: ...pressure to the rear wheel cylinders as needed Closing the valves prevents further fluid flow to the rear wheel cylinders This action isolates the rear brakes from the master cylinder The net effect i...

Page 201: ...The RWAL diagnostic connector is at the left side of the steering column near the parking brake re lease handle The black 2 way diagnostic connector has only one wire attached to it This is the 20 gau...

Page 202: ...pite the fact that an actual fault has not occurred Another driver induced fault involves holding the brake pedal in an applied position while starting the engine This practice causes the stoplamp swi...

Page 203: ...WAL valve to combination valve Fig 10 Tighten line fit tings to 16 23 N m 140 200 in lbs torque 3 Tighten RWAL valve attaching bolt to 23 34 N m 200 300 in lbs torque 4 Install master cylinder on boos...

Page 204: ...ment panel 5 Disconnect harness wires from module Fig 14 RWAL J948F 7 Mule Lower Attaching Screw Location J948F 8 Fig 15 RWAL Module Upper Attaching Screw Location 6 If module is to be replaced remove...

Page 205: ...Fig 18 3 Disconnect sensor harness at axle connector 4 Unclip sensor harness from plastic retainer that secures harness and rear brake hose Fig 19 5 Remove rear harness from vehicle 6 Install new har...

Page 206: ...wheel driver side front wheel 8 Observe following precautions during bleeding procedure Do not pump brake pedal at any time while bleed ing Air in system will be compressed into small bub bles that a...

Page 207: ...lightly in order to bleed the front brakes Use a clip style tool such as Special Tool C 4121 to hold the stem in or out Do not use pliers or similar tools a the stem and valve will be damaged 1 Fill b...

Page 208: ...e operated by the antilock sys tem electronic control module The antilock valve provides two channel pressure control of the front brakes One channel controls the left front brake unit The second chan...

Page 209: ...MBLY J9405 96 Fig 3 Combination Waive And integral Mounting Bracket The module controls front rear valve solenoid oper ation during all phases of antilock braking Module electrical inputs are provided...

Page 210: ...tronic module RFTAINING _ SCREW CABLE CLAMP BRAKE LINE C O V E R SENSOR A X L E _ HOUSING Fig 6 Rear Wheel Sensor Location The ABS valve provides two channel pressure con trol of the front brakes Eac...

Page 211: ...movement of the switch valve A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle forward or rearward in re sponse to the pressure differential Movem...

Page 212: ...be felt through the brake pedal during antilock mode braking This is a nor mal occurrence and should not be mistaken for a sys tem fault Loss Of Sensor Input Wheel speed sensor malfunctions will most...

Page 213: ...apply brake pedal and observe red brake warning light 2 Raise vehicle on hoist 3 Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid 4 Have...

Page 214: ...and RWAL valve Fig 12 GROUND RWAL VALVE HARNESS AND CONNECTOR PRESSURE DIFFERENTIAL SWITCH WIRE J9405 77 Fig 12 Valve Harness Connector And Ground Wire Locations 2 Disconnect lines to front and rear...

Page 215: ...and connect all remaining brakelines Figs 16 and 17 Tighten line fittings to 16 23 N m 140 200 in lbs torque 9 Connect harness wires to RWAL valve and to combination valve switch Fig 17 10 Fill and bl...

Page 216: ...t entry when sensor is removed from housing Mopar brake cleaner or carb cleaner are equally acceptable for cleaning purposes 3 Disconnect harness wires from sensor 4 Remove screw that secures brake ca...

Page 217: ...cessary to hold the front brake metering valve open in order to bleed the front brakes The valve can be held open with a tension clip tool or by hand It will also be necessary that a suitable size pre...

Page 218: ...the original valve is still in the vehicle bleed the valve as described in step 8 7 If a new front antilock valve and motor as sembly is being installed bleed new valve as fol lows a Loosen bleed plug...

Page 219: ...ed no special precautions are required Just bleed the brakes in ac cordance with the equipment manufacturers instruc tions Fig 25 Front Antilock Valve Bleed Tool Installation Pressure Heeding If press...

Page 220: ...Brakeshoe Types And Wear Tabs The outboard brakeshoes on all BR models have wear tabs The metal tabs are attached to the trail ing end of each outboard brakeshoe Figs 1 2 and 3 The tabs contact the r...

Page 221: ...e inner surface of the disc brake rotor Fig 5 At the same time fluid pressure within the piston bore forces the caliper to slide inward on the mount ing bolts This action brings the outboard brakeshoe...

Page 222: ...WAL 1 Raise vehicle 2 Remove wheel and tire assemblies 3 Press caliper piston back into bore with large flat blade screwdriver Fig 7 Use large C clamp to bottom piston in bore if additional force is r...

Page 223: ...INSPECTION Inspect the brakeshoe lining for wear Replace riv eted lining if worn to within 1 5 mm 1 16 in of rivet heads Replace bonded lining if thickness is 3 mm 3 16 in or less If the brakeshoes w...

Page 224: ...roperly aligned and seated in caliper piston Fig 18 and 19 4 Install outboard brakeshoe in caliper Be sure spring ends are seated in dimples in caliper Fig 19 APPLY SILICONE GREASE WHERE INDICATED BUS...

Page 225: ...iper rearward off rotor and out of steering knuckle support ledges Fig 10 7 Remove front brake hose fitting bolt completely and remove caliper and brakeshoes as assembly 8 Cover open end of front brak...

Page 226: ...the bore if necessary The bore should be free of corrosion pitting or scoring Discoloration of the bore is a normal condition and not cause for replacement The bore can be lightly polished by hand bu...

Page 227: ...f clean fresh brake fluid 3 Install new dust boot on piston as follows a Lightly lubricate lip of new boot with Dow or GE silicone grease Then work boot lip into boot groove at top of piston Fig 25 b...

Page 228: ...e Installation DISC BRAKE CALIPER INSTALLATION 1 Clean caliper and steering knuckle slide sur faces with wire brush Fig 16 Then apply coat of Mopar multi mileage grease or Dow GE silicone grease to sl...

Page 229: ...specified on the rotor hub or on the outer edge of the rotor ventilated sur face ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pul sation noise and shudder Measure rotor th...

Page 230: ...ore Use screwdriver or large C clamp to press piston back to bottom of caliper bore Fig 7 4 Remove caliper mounting bolts Figs 8 and 9 5 Remove caliper from rotor Position caliper on steering knuckle...

Page 231: ...e to bearing races as well Then install inner bearing in hub and install new grease seal 2 Apply liberal coat of bearing grease to spindle interior of rotor hub grease seal lip and seal surface of spi...

Page 232: ...ver or large C clamp to press piston back to bottom of caliper bore Fig 7 4 Remove caliper mounting bolts Figs 8 and 9 5 Remove caliper from rotor Position caliper on steering knuckle and secure it in...

Page 233: ...bly in rotor hub if necessary Refer to procedure in this section DISC BRAKES 5 61 Fig 42 Hub Spacer Removal 3 Insert two rearmost top and bottom rotor hub bolts in steering knuckle Insert bolts throug...

Page 234: ...it is only necessary to drive out the wheel studs with a copper mallet in order to sep arate the rotor bearing and hub for replacement pur poses Fig 44 Fig 44 Front Wheel Stud Removal With Unit Style...

Page 235: ...anchor pin The net result is that each shoe helps the other exert ex tra force against the drum It is servo action that cre page Drum Brake Adjustment 71 Drum Brake Operation 63 General Service Inform...

Page 236: ...djuster screw has a right hand thread And the passenger side adjuster screw has a left hand thread Do not interchange them as the brake shoes will not adjust properly 8 Remove secondary brakeshoe hold...

Page 237: ...0 Engage parking brake strut in secondary brakeshoe and install oval shaped spring on opposite end of strut spring end of strut goes in primary shoe 11 Install primary brakeshoe on support plate Use n...

Page 238: ...E REMOfAL 13 INCH BRAKE 1 Raise vehicle 2 Remove rear wheel and tire assemblies 3 Remove brake drums 4 Remove primary front brakeshoe return spring from anchor pin with brake spring pliers Fig 6 5 Rem...

Page 239: ...edure in this section BRAKESHOE INSTALLATION 13 INCH BRAKE 1 Clean support plate with Mopar brake cleaner Then smooth shoe contact pads with wire brush or emery cloth 2 Lubricate adjuster levers and a...

Page 240: ...n lever tang 9 Attach shoe spring to secondary brakeshoe Long end of spring goes in secondary shoe 10 Install oval shaped spring on park brake strut and engage spring end of strut in secondary brake s...

Page 241: ...and expander spring They are not reusable parts 5 Remove bleed screw from cylinder PRIMARY BRAKESHOE PRIMARY SHOE RETURN SPRING PARK BRAKE STRUT SHOE SPRING HOLDDOWN SPRING PIN RETAINERS J9405 19 ins...

Page 242: ...xpander spring and remaining piston cup and piston 4 Start piston dust boots in each end of cylinder bore by hand Then seat boots in cylinder with a bench vise Fig 14 Press boots into place until flus...

Page 243: ...7 8 Repeat adjustment at opposite brakeshoe as sembly 9 Install brake drums and wheels and lower ve hicle BRAKE SHOES Fig 17 Adjusting Brakeshoes To Gauge 10 Make final adjustment as follows a Drive v...

Page 244: ...ally a drum can be ma chined to a maximum of 1 5 mm 0 060 in oversize Always replace the drum if machining would cause drum diameter to exceed indicated size limit BRAKE DRUM RUNOUT Measure drum diame...

Page 245: ...age front cable from arm on foot pedal assembly Fig 3 9 Insert new cable through floorpan grommet Fig 3 Then feed cable up to arm on pedal assembly Fig 2 10 Hook cable T connector in arm on pedal as s...

Page 246: ...port plate 9 Insert cable through support plate seat cable retainers and attach cable to parking brake lever on secondary brakeshoe 10 Install brakeshoes but do not install brake drum at this time 10...

Page 247: ...into alignment with tensioner bracket Fig 8 CAUTION Do not loosen or tighten the tensioner adjusting nut for any reason after completing ad justment 10 Lower vehicle until rear wheels are 15 20 cm 6 8...

Page 248: ...H J9405 175 s ITEM T O R Q U E A 21 34 N m 200 300 in lbs 17 Raise vehicle 18 Adjust parking brake cable tensioner Refer to procedure in this section Fig 9 Parking Brake Pedal Mounting 16 Install kne...

Page 249: ...317 5x38 mm 12 5x1 5 in Drum Brake Size 1 2 Ton Models 11x2 in 279x51 mm 3 4 Ton Models 13x2 5 in 330x63 5 mm 1 Ton Models 13x3 5 in 330x89 mm Drum Brake Type All Dual Shoe With Self Adjusting Mechani...

Page 250: ...hydraulic slave cylinder mounted in the housing The slave cylinder is operated by a clutch FACING MATERIAL page CLUTCH LINKAGE SERVICE 16 CLUTCH PEDAL INSTALLATION 17 CLUTCH PEDAL POSITION SWITCH 3 C...

Page 251: ...PRINGS 5 Lviol J9406 9 Fig 3 dutch Disc WW Engine FACING MATERIAL LMESELj J9406 10 Fig 4 dutch Disc Diesei Engine CLUTCH COVER APPLICATION Two clutch covers are used for all applications The 281 mm co...

Page 252: ...ction or diagnosis indicates additional fluid may be needed use Mopar brake fluid or an equiv alent meeting SAE and DOT standards J1703 and DOT 3 Do not use any other type of fluid CLUTCH COMPONENT LU...

Page 253: ...ce roughness on the flywheel face can be cleaned up by scuff sanding with 180 grit emery cloth However if the surface is warped or severely scored replace the flywheel Clean the crankshaft flange befo...

Page 254: ...problems Tighten the clutch housing bolts to proper torque before installing any struts Also be sure the align ment dowels are in place and seated in the block and housing beforehand The use of non st...

Page 255: ...nly if seized noisy or damaged 11 Check clutch cover diaphragm spring and release fingers Replace cover ir spring or fingers are bent warped broken cracked Do not tamper with factory spring setting as...

Page 256: ...n 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 PRE...

Page 257: ...er 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 ins...

Page 258: ...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 Che...

Page 259: ...orque 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 Replac...

Page 260: ...UT DOWN RELAY DISTRIBUTION CENTER TO IGNITION SWITCH A41 20YL AUTOMATIC TRANSMISSION CLUTCH PEDAL POSITION SWITCH ON CLUTCH CYLINDER PUSH ROD A41 18YL MANUAL TRANSMISSION J9406 24 Fig 10 Clutch Pedal...

Page 261: ...c in place when cover bolts are removed 7 If clutch cover will be reused loosen cover bolts evenly only few threads at a time and in a diagonal pattern Fig 5 This relieves cover spring tension evenly...

Page 262: ...in diameter bolts to 41 N m 30 ft lbs 9 Remove release lever and release bearing from clutch housing Apply Mopar high temperature bear ing grease to bore of release bearing release lever CLUTCH COVER...

Page 263: ...stall transmission 14 Check fluid level in clutch master cylinder CLUTCH HOUSING REPLACEMENT NV4500 Only the NV4500 clutch housing is serviced sepa rately The NV3500 clutch housing is part of the tran...

Page 264: ...re fork is not distorted or worn Replace fork spring clips if bent or damaged 6 Lubricate crankshaft pilot bearing input shaft splines bearing retainer slide surface lever pivot ball stud and release...

Page 265: ...worn or damaged 12 Verify that cap on clutch master cylinder res ervoir is tight This will avoid spillage during re moval 13 Remove screws that attach clutch fluid reser voir to dash panel 14 Remove r...

Page 266: ...fore op erating linkage 17 Operate linkage several times to verify proper operation CLUTCH PEDAL REMOVAL 1 Remove retaining ring flat washer and wave washer that secure brake and clutch pedals to push...

Page 267: ...l bolt torques are 75 N m 55 ft lbs for gas engine flywheels 137 N m 101 ft lbs for diesel flywheels Inspect the teeth on the starter ring gear If the teeth are worn or damaged the flywheel should be...

Page 268: ...ailable in 0 007 0 014 and 0 021 in sizes for this purpose Fig 23 Refer to Correcting Housing Bore Runout for dowel installation On diesel engines the acceptable maximum TIR for housing bore runout is...

Page 269: ...lling shims between the clutch housing and transmission Fig 27 The shims can be made from shim stock or similar materials of the re quired thickness As an example assume that face runout is the same a...

Page 270: ...locations INDICATOR PLUNGE DIAL INDICATOR CLUTCH HOUSING FACE INDICATOR MOUNTING 1 STUD OR ROD J90G6 29 Fig 25 Measuring Clutch Housing Face Runout CUT DRILL iOLT HOLE TO SIZE SHIM STOCK MAKE SHIM 1 I...

Page 271: ...um 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 am...

Page 272: ...7 2 COOLING SfSTEi BR THERMOSTAT OPEN LOW FLOW J9407 1 Fig 1 Typical Cooling System Flow Gas Powered Engines Fig 2 Typical Cooling System Flow Diesel Powered Engine...

Page 273: ...B R COOLING SYSTEM 7 3 Fig 3 Cylinder Block Coolant Routing Diesel Engine...

Page 274: ...as recognized an abnormal signal in a circuit or the system A DTC may indicate the result of a failure but never iden tify the failed component directly It is possible that a DTC for a monitored circu...

Page 275: ...d overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more air flow is recom mended 2 TRAILER TOWING Consult Trailer Towing section of owners...

Page 276: ...LANT 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 amb...

Page 277: ...dition 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...

Page 278: ...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 correc...

Page 279: ...n 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 a...

Page 280: ...pair 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...

Page 281: ...ea 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 conditio...

Page 282: ...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 tra...

Page 283: ...is 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 shoul...

Page 284: ...mal 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 aft...

Page 285: ...g 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...

Page 286: ...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 k...

Page 287: ...low it away 1 Occasional steam emitting from this area is normal No repair is necessar COOLANT COLOR 1 Coolant color is not necessarily an indication of adequate corrosion or temperature protection Do...

Page 288: ...of bearing shaft damage or leaking shaft seal the mechanical cooling fan assembly should also be inspected Inspect for fa tigue cracks loose blades or loose rivets that could have resulted from excess...

Page 289: ...n drive assembly do not place the thermal viscous fan drive in the hori zontal position If stored horizontally the silicone fluid in the viscous drive could drain into its bearing assembly and contami...

Page 290: ...ON Do not pry the water pump at timing chain case cover The machined surfaces may be damaged resulting in leaks Fig 7 Coolant Return Tube 3 91 V 6 or 5 2 5 9L V 8 LBG Gas Engines Fig 8 Coolant Return...

Page 291: ...ce a bar or screwdriver between water pump pulley bolts Fig 4 to prevent pulley from rotating 10 Relax tension from automatic belt tensioner Figs 5 or 6 Install drive belt CAUTION When installing the...

Page 292: ...ons are found Also check condi tion of the thermal viscous fan drive Refer to Viscous Fan Drive in this group 1 Disconnect negative battery cable from battery 2 Drain cooling system Refer to Draining...

Page 293: ...cous fan drive in the hori zontal position If stored horizontally the silicone fluid in the viscous drive could drain into its bearing assembly and contaminate the bearing lubricant Do not remove the...

Page 294: ...water pump assembly if it has any of the following conditions The body is cracked or damaged Water leaks from the shaft seal This is evident by traces of coolant below the vent hole Loose or rough tu...

Page 295: ...correct belt routing The correct belt with correct length must be used AUTOMATIC TENSIONER J9307 55 Fig 21 Belt Routing 8 0L V 10 Engine With A C 11 Position fan shroud and fan blade viscous fan drive...

Page 296: ...Fig 26 is used be tween the intake manifold and water pump on all gas powered engines To test for leaks refer to Test ing Cooling System for Leaks in this group FAN BLADE WATER WATER PUMP VISCOUS FAN...

Page 297: ...acket Typical WARNING THE A C SYSTEM IS UNDER PRESSURE EVEN WITH THE ENGINE OFF REFER TO REFRIG ERANT WARNINGS IN GROUP 24 HEATING AND AIR CONDITIONING 1 Disconnect negative battery cable from battery...

Page 298: ...side of the A C generator mounting bracket 10 Disconnect throttle body control cables Refer to Accelerator Pedal and Throttle Cable in Group 14 Fuel System 11 Remove heater hose coolant return tube m...

Page 299: ...6 Install coolant return tube and its mounting bolt to engine Figs 32 or 33 7 Connect throttle body control cables 8 Install oil dipstick mounting bolt 9 3 9L V 6 or S 2 S 9L 8 LDC Gas Engines Instal...

Page 300: ...at 8 9L V 6 or 5 2 5 9L V 8 Gas Powered Engines TEMP GAUGE SENDING UNIT COOLANT TEMP SENSOR FOR PCM HEATER SUPPLY FITTING BOLTS 6 HOUSING GASKET THERMOSTAT RUBBER LIP SEAL J9407 16 Fig 39 Thermostat 8...

Page 301: ...n control module PCM de tects low engine coolant temperature it will record a Diagnostic Trouble Code DTC in the PCM memory The DTC number for low coolant temperature is 17 Do not change a thermostat...

Page 302: ...thermostat housing HOSE CLAMP HOSE J9207 36 Fig 42 Hose Clamp Tool Typical 5 Position the wiring harness behind the ther mostat housing to gain access to thermostat hous ing 6 Remove thermostat housin...

Page 303: ...g The cor rect belt with the correct length must be used 8 Fill cooling system Refer to Refilling Cooling System in this group 9 Connect negative battery cable to battery 10 Start and warm engine Chec...

Page 304: ...rubber seal 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 t...

Page 305: ...be normal Typically complaints of low engine coolant temper ature are observed as low heater output when com bined with cool or cold outside temperatures To help promote faster engine warm up the elec...

Page 306: ...FETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps Fig 43 If re placement is necessary use only an original equip ment...

Page 307: ...es at 22 C 8 F 50 50 Ethylene Glycol and Water Is the recom mended mixture it provides protection against freez ing to 37 C 35 F The antifreeze concentration must always be a minimum of 44 percent yea...

Page 308: ...cause the thermostat to open later which in turn causes higher coolant temperature Air trapped in cooling system also reduces the amount of coolant circulating in the heater core This may result in lo...

Page 309: ...shing gun CAUTION Internal radiator pressure must not ex ceed 138 kPa 20 psi as damage to radiator may re sult Allow radiator to fill with water When radiator is filled apply air in short blasts Allow...

Page 310: ...eplace cap if cams are bent Attach pressure tester 7700 or an equivalent to radiator filler neck Fig 57 Fig 57 Pressure Testing Cooling System Typical Operate tester pump to apply 103 4 kPa 15 psi pre...

Page 311: ...RESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR Drain sufficient coolant to allow thermostat re moval Refer to Thermostat Replacement Disconnect water pump drive belt Add coolant to radiator to bring lev...

Page 312: ...e Cap and Filler Neck Typical A vent valve in the center of cap allows a small coolant flow through cap when coolant is below boil ing temperature The valve is completely closed when boiling point is...

Page 313: ...water to tool Turn tool upside down and recheck pressure cap to confirm that cap needs replacement INSPECTION Hold cap at eye level right side up The vent valve Fig 61 at bottom of cap should open If...

Page 314: ...cement is necessary use only an original equip ment clamp with a matching number or letter 4 Remove hose clamps and hoses from radiator TYPICAL HOSE CLAMP NUMBER LETTER LOCATION J9407 39 Fig 63 Clamp...

Page 315: ...rve 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 s...

Page 316: ...xcept 8 0L V 10 Engine Unsnap coolant reserve overflow tank from fan shroud and lay aside The tank is held to shroud with T shaped slots Do not disconnect hose or drain coolant from tank TYPICAL CONST...

Page 317: ...m 17 ft lbs torque 2 Position fan shroud and fan blade viscous fan drive assembly to vehicle as a complete unit 3 Install fan shroud 4 Install fan blade viscous fan drive assembly to water pump shaft...

Page 318: ...a silicone fluid filled coupling used to connect the fan blades to the water pump shaft The coupling allows the fan to be driven in a normal manner This is done at low engine speeds while limiting th...

Page 319: ...ngine ignition timing light The timing light is to be used as a strobe light This step cannot be used on the diesel engine 4 Block the air flow through the radiator Secure a sheet of plastic in front...

Page 320: ...em For Leaks sections in this group If the transmission operates properly after repairing the leak drain the transmission and remove the transmission oil pan Inspect for sludge and or rust Inspect for...

Page 321: ...from A shaped support bracket by removing two upper mounting strap bolts and mounting straps at support bracket Fig 1 13 Remove oil cooler from the A shaped radiator support bracket ALIGNMENT DOWELS...

Page 322: ...with both a main water to oil cooler and a separate air to oil cooler Both cool ers are supplied as standard equipment on diesel engine powered models when equipped with an auto matic transmission Tr...

Page 323: ...gs from the transmission lines These are located near the power steering gearbox Refer to Group 21 Transmissions for procedures 5 Remove the charge air cooler to oil cooler bolt Fig 5 6 Remove two mou...

Page 324: ...of publication If anything differs between these schematics and the Belt Routing Label use the schematics on Belt Routing Label This label is located in the en gine compartment BELT TENSION ALL ENGIN...

Page 325: ...from heat and excessive slippage 1 Replace automatic belt tensioner 2 Replace belt 3 Replace belt and clean pulleys 4 Replace faulty component bearing 5 Replace belt GROOVE JUMPING5 5 BELT DOES NOT MA...

Page 326: ...sioner Fig 7 2 Rotate tensioner assembly clockwise as viewed from front until tension has been relieved from belt 3 Remove belt from idler pulley first 4 Remove belt from vehicle AUTOMATIC TENSIONER J...

Page 327: ...sed on all belt configurations such as with or without power steering or air conditioning For more information refer to Automatic Belt Tensioner proceeding in this group PULLEY BOLT IDLER AlUik PULLEY...

Page 328: ...ection Refer to Figs 5 or 6 for correct engine belt routing The correct belt with correct length must be used 1 Position drive belt over all pulleys except wa ter pump pulley 2 Attach a 3 8 inch ratch...

Page 329: ...mounting bracket two bolts Do not remove coil mounting bracket from cylinder head 4 Remove tensioner assembly from mounting bracket one nut Fig 13 WARNING BECAUSE OF HIGH SPRING PRES SURE DO NOT ATTE...

Page 330: ...ounting bracket A dowel pin is located on back of tensioner Fig 14 Align this to dowel hole Fig 15 in tensioner mount ing bracket Tighten bolt to 41 N m 30 ft lbs torque 3 Install drive belt Refer to...

Page 331: ...RTS The 3 9L 5 2L 5 9L gas powered engine has the block heater located on the right side of engine next to the oil filter Fig 1 The 8 0L V 10 engine has the block heater located on the right side of e...

Page 332: ...y clean the cylinder block freeze plug hole and block heater seat 2 Install new o ring seal s to heater _ _ _ _ BR 3 Insert block heater into cylinder block 4 With heater fully seated tighten center s...

Page 333: ...pacities shown include vehicles with air conditioning and or heavy duty cooling systems J9407 21 T O R Q U E Description _ j Automatic Belt Tensioner Pulley Bolt 3 9L 5 2L 5 9L LDC Gas Engine 61 N m 4...

Page 334: ...cle to start and charge properly all of the components involved in these systems must perform within specifications Group 8A covers battery starting Fig 1 and charging Fig 2 system diagnostic procedur...

Page 335: ...tery are caused by movement of excess or free electrons between the positive and negative plate groups This movement of electrons produces a flow of electrical current through the load device attached...

Page 336: ...dary battery on the passenger side is dedicated to providing cur rent for the operation of the intake manifold air heater The primary battery on the driver s side is dedicated to all other vehicle ele...

Page 337: ...AND TIGHT YES NO CLEAN AND NO TIGHTEN AS REQUIRED 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...

Page 338: ...intenance bat tery with removable cell caps A low electrolyte level may be caused by an over charging condition See Charging System in this group to diagnose an over charging condition WARNING DO NOT...

Page 339: ...variation is more than 50 points 0 050 at the end of the charge period replace the battery When the specific gravity of all cells is above 1 235 and cell variation is less than 50 points 0 050 the ba...

Page 340: ...stabilize to open circuit voltage It may take up to 5 minutes for voltage to stabilize 5 Rotate the load control knob to maintain a load equal to 50 of CCA rating Fig 9 After 15 seconds record the loa...

Page 341: ...ion Some battery chargers are equipped with polarity sensing circuitry This circuitry protects the charger and or battery from being damaged if improperly con nected If the battery state of charge is...

Page 342: ...sing circuitry This circuitry protects the charger and or battery from being damaged if im properly connected If the battery state of charge is too low for the polarity sensing circuitry to detect the...

Page 343: ...onnect a typical 12 volt test lamp low watt age bulb between the negative cable clamp and the battery negative terminal Make sure that the doors remain closed so that illuminated entry is not acti vat...

Page 344: ...tch provides ground only with the transmis sion in NEUTRAL or PARK If the vehicle is equipped with a manual transmission the starter re lay coil ground terminal is always grounded With the starter rel...

Page 345: ...ter relay battery including all ground connections Clean tighten and repair all connections as re quired SOLENOli RELAY AND SWITCH I1SPECTI0NS Inspect the solenoid relay and ignition switch to determi...

Page 346: ...charged or 1 See Battery in this group Charge or ENGAGES faulty replace battery if required FAILS TO TURN 2 Starting circuit wiring 2 See Cold Cranking Test in this group ENGINE faulty Test and repair...

Page 347: ...that the cable connectors or clamps are attached to not to the cable connectors or clamps For example When testing between the battery and solenoid touch the voltmeter leads to the battery post and th...

Page 348: ...Fig W Test Ground Circuit Resistance 898A 26 Fig 17 Test Starter Ground Typical If resistance tests detect no feed circuit problems remove the starter and see Solenoid Test in this group CONTROL CIRC...

Page 349: ...rminal 30 is connected to battery voltage and should be hot at all times If OK go to next step If not OK check circuit to fuse F12 in Power Distribution Center PDC Repair as re quired POWER DISTRIBUTI...

Page 350: ...85 If not OK and vehicle has manual trans mission repair circuit as required If not OK and vehicle has automatic transmission refer to Group 21 Transmission and Transfer Case for testing and service...

Page 351: ...cling the ground path to control the strength of the rotor magnetic field The generator voltage regulator circuitry monitors system line voltage and ambient temperature It then com pensates and regula...

Page 352: ...ITION POSSIBLE CAUSES CORRECTION LOW OR UNSTEADY CHARGING 1 Battery discharged or faulty 2 Loose or faulty generator drive belt 3 Loose generator mounting 4 Loose or corroded charging circuit wiring c...

Page 353: ...Load Test in this group for instructions TEST 1 Start engine Immediately after starting re duce engine speed to idle 2 Adjust engine speed and carbon pile to main tain 20 amperes flowing in circuit Ob...

Page 354: ...re to ground Refer to Group grams for more information 8W Wiring Dia TEST 1 Start engine Immediately after starting re duce engine speed to idle 2 Adjust carbon pile and engine speed in incre ments un...

Page 355: ...s function cycle the ignition switch ON OFF ON OFF ON within 5 seconds This will cause any DTC stored in the PCM memory to be displayed The malfunction indicator Check Engine lamp will display a DTC b...

Page 356: ...up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw J948B 26 M a n u f a c t u r e r N i p p o n d e n s Engine Application 8 0L Part Number and Power...

Page 357: ...ONS B R GENERATOR SPECIFICATIONS P A R T N u m n P U L L E Y G R O O V E S E N G I N E R A T I N G NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS NIPPONDENSO 53008647 7 ALL GASOLINE 90 AMPS NIPPONDENSO 5...

Page 358: ...ed to service Refer to Group 8A Battery Starting Charging Systems Diagnostics The factory installed maintenance free battery Fig 1 has non removable battery vent caps Water can not be added to this ba...

Page 359: ...age that could result in electrolyte leaks Also check battery terminal posts for looseness Batteries with damaged cases or loose posts must be replaced 7 Inspect battery built in test indicator sight...

Page 360: ...inal cleaner and sodium bicarbonate baking soda and warm water cleaning solution TERMINAL BRUSH Fig 7 Left Battery Tray with Speed Control DIESEL RIGHT SIDE BATTERY TRAY J948B 12 Fig 8 Right Battery T...

Page 361: ...ttery cables are con nected to the correct battery terminals Reverse po larity can damage electrical components 12 Place oiled felt washer on battery positive ter minal post 13 Install and tighten bat...

Page 362: ...er component fails the entire assembly must be replaced STARTER RELAY The starter relay is an International Standards Or ganization ISO type relay It is located in the Power Distribution Center PDC Th...

Page 363: ...N m 32 ft lbs solenoid lead nut 6 N m 55 in lbs battery lead nut 10 N m 90 in lbs STARTER RELAY REMOVE INSTALL 1 Disconnect battery negative cable s 2 Remove starter relay by unplugging unit from Powe...

Page 364: ...BATTERY STARTER GENERATOR SERVICE 8B 7...

Page 365: ...OUTPUT WIRE FROM GENERATOR FAILURE TO DO SO CAN RESULT IN INJURY 1 Disconnect battery negative cable s 2 Remove generator drive belt Refer to Group 7 Cooling System for procedure 3 Remove the generato...

Page 366: ...hould be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw J948B 26 Manufacturer Nippondenso Engine Application 8 0L Part Number and Power Rating 5600...

Page 367: ...B R GENERATOR SPECIFICATIONS TYW PART N U M B E R PULLEY G R O O V E S ENGINE R A T I N G NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS NIPPONDENSO 53008647 7 ALL GASOLINE 90 AMPS NIPPONDENSO 53008651 7...

Page 368: ...flag can exceed the compensating ability of the compass unit if placed on the roof panel Magnetic bit drivers used on the fasten ers that hold the assembly to the roof header can also affect compass...

Page 369: ...module 1 See Sensor Circuit Test in this group Repair wiring if required 2 See Sensor Test in this group Replace sensor if required 3 Replace compass thermometer display module if required J958C 1 CO...

Page 370: ...K then the electronic module is faulty and should be replaced SENSOR TEST 1 Turn the ignition switch to OFF Unplug sensor connector 2 Measure resistance of sensor A t 40 F the re sistance is 336K ohms...

Page 371: ...ally the variation number must also be reset See Variation Adjustment Procedure in this group Calibrate the compass manually as follows 1 Start the engine 2 Depress both the US METRIC and COMP TEMP bu...

Page 372: ...ool at least 4 inches either side of the roof center line and 11 inches back from the windshield header 6 With the degaussing tool still energized slowly back it away from the roof panel until the tip...

Page 373: ...se removal procedures to install READING COURTESY LAMPS LENS OB BULB REMOVE INSTALL 1 Insert a long flat bladed tool at the notch on the curved edge of the lens Carefully pry the lens from the housing...

Page 374: ...gas powered engines can be eas ily identified by the use of an engine mounted air in jection pump The 3 9L V 6 engine the 5 2 5 9L V 8 LDC gas engines or the diesel engine will not use an air injectio...

Page 375: ...system consists of Spark Plugs Ignition Coil multiple coils with the 8 0L V 10 en gine Secondary Ignition Cables Distributor Contains rotor and camshaft position sensor 3 9L V 6 or 5 2 5 9L V 8 engin...

Page 376: ...eir re spective cylinders The sensor generates electrical pulses These pulses signals are sent to the power train control module PCM The PCM will then de termine crankshaft position from both the cams...

Page 377: ...te if the PCM does not re ceive a crankshaft position sensor input For component testing refer to the Diagnostics Ser vice Procedures section of this group For removal and installation of this compone...

Page 378: ...ng is con trolled by the PCM base ignition timing Is not adjustable on any of these engines IGNITION SYSTEMS 80 5 Fig 11 Ignition Coii 3 9L V 6 or 5 2 5 9L V 8 LDC Gas Engines Fig 12 Ignition Coil 5 9...

Page 379: ...val Installation section of this group IGNITION COIL PACKS 8 0L V 10 ENGINE The ignition system used on the 8 0L V 10 engine does not use a conventional mechanical distributor It will be referred to a...

Page 380: ...section of this group For removal and installation of the coil packs refer to the Component Removal Installation section of this group IGNITION CONTROL MODULE 8 0L V 10 ENGINE MODULE OPERATION For ig...

Page 381: ...Installation section of this group For diagnostics refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool OXYGEN SENSOR 02S For an operational des...

Page 382: ...gnostic Procedures ser vice manual AUTOMATIC SHUTDOWN ASD RELAY TEST To perform a complete test of this relay and its cir cuitry refer to the DRB scan tool Also refer to the appropriate Powertrain Dia...

Page 383: ...ion of ignition system com ponents refer to the Component Removal Installa tion section of this group For system operation and component identification refer to the Component Identification System Ope...

Page 384: ...or 3 Place an ohmmeter across terminals B and C Fig 3 Ohmmeter should be set to lK to lOK scale for this test The meter reading should be open no resistance Replace sensor if a low resis tance is Indi...

Page 385: ...ernal ballast resistor 3 SL V 6 or 5 2 5 SL 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 9 This bracket is mounted on top of t...

Page 386: ...o figure 16 for resistance specifica tions To test the primary resistance of the front coil pack attach an ohmmeter between the B coil termi nal and either the right cylinders 3 2 center cylin ders 7...

Page 387: ...escription diagnosis and re moval and installation procedures refer to Group 14 Fuel System TO LEFT COIL TO RIGHT COIL 1 TERMINAL FRONT OF ENGINE J948D 17 Fig 15 Checking Coil Primary Resistance Rear...

Page 388: ...cap 3 Remove a cable from one spark plug 4 Using insulated pliers hold the cable terminal approximately 12 mm 1 2 in from the engine cylin der head or block while rotating the engine with the starter...

Page 389: ...COII NEGATIVE RB1003 Fig 23 Special Jumper Ground to Coil Negative Terminal 7 If spark is generated replace the powertrain control module PCM 8 If spark is not seen use the special jumper to ground th...

Page 390: ...and fouled cracked or broken por celain insulators Keep plugs arranged in the order in which they were removed from the engine An iso lated plug displaying an abnormal condition indicates that a probl...

Page 391: ...de posits in the combustion chamber These deposits ac cumulate on the spark plugs during continuous stop and go driving When the engine is suddenly subjected to a high torque load deposits partially l...

Page 392: ...RHEATING Overheating is indicated by a white or gray center electrode insulator that also appears blistered Fig 32 The increase in electrode gap will be consider ably in excess of 0 001 inch per 1000...

Page 393: ...ove cable from spark plug Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap Resistance should be 250 to 1000 Ohms per inch of cable If not remove c...

Page 394: ...iption of all DTC s for accessing a DTC and for erasing a DTC refer to On Board Diagnostics This can be found in the General Diagnosis sections of Group 14 Fuel System For numeric flash lamp J9414 62...

Page 395: ...fer to PDC cover Fig 1 Power Distribution Center PDC REMOVAL 1 Disconnect negative battery cable at battery 2 Remove the cover at PDC 3 Remove the relay from the PDC by pulling straight up page Igniti...

Page 396: ...face of the sen sor Fig 4 to position the depth of sensor to the up per cam gear sprocket This rib can be found on both the new replacement sensors and sensors that were originally installed to the en...

Page 397: ...rocking action until the sensor is aligned to scribe line 11 Install sensor mounting bolt and tighten to 6 N m 50 in lbs torque 12 Connect engine wiring harness to sensor har ness SENSOR REPLACEMENT N...

Page 398: ...e 5 Coat the threads of the oil pressure sending unit with thread sealant Do not allow any of the thread sealant to get into the sending unit opening or the opening at the engine Install sending unit...

Page 399: ...e are controlled by the powertrain control module PCM Because a con ventional timing light can not be used to adjust dis tributor position after installation note position of distributor before remova...

Page 400: ...wn clamp and clamp bolt Do not tighten bolt at this time 6 Rotate the distributor housing until rotor is aligned to CYL NO 1 alignment mark on the cam shaft position sensor Fig 12 7 Tighten clamp hold...

Page 401: ...1 Disconnect the primary wiring from the igni tion coil Figs 14 or 15 2 Disconnect the secondary spark plug cable from the ignition coil Figs 14 or 15 WARNING 3 9L V 6 OR 5 2 5 9L V 8 LDC GAS EN GINES...

Page 402: ...fender Fig 18 Po sition the tank to the side Do not drain coolant from tank 3 Disconnect the electrical connector at the ICM 4 Remove the ICM from inner fender two bolts Fig 18 IGNITION CONTROL MODUL...

Page 403: ...should have a small air gap to the top of the heat shield Fig 21 Fig 21 Heat Shields 3 9L V 6 or S 2 5 9L V 8 Engines If removal of the heat shield s is necessary remove the spark plug cable and comp...

Page 404: ...porcelain insulator When replacing the spark plug and ignition coil ca bles route the cables correctly and secure them in the appropriate retainers Failure to route the cables properly can cause the r...

Page 405: ...he spark plug boots from damage due to engine heat generated by the exhaust manifolds and should not be removed After the spark plug cable has been installed the lip of the cable boot should have a sm...

Page 406: ...or 3 5 Gently pull switch away from column Release connector locks on 7 terminal wiring connector then remove connector from ignition switch 6 Release connector lock on 4 terminal connector then remov...

Page 407: ...g 9 a Place transmission shifter in PARK position b Place ignition switch in lock position The switch is in the lock position when column lock flag is parallel to ignition switch terminals Fig 9 c Pos...

Page 408: ...nition switch rotate ignition key to end of travel 6 Install retaining screw into bracket and lock cylinder Tighten screw to 3 5 N m 26 4 in lbs torque 7 Install steering column covers Tighten screws...

Page 409: ...Equipment Replacement Application Gap Tightening Torque Size 3 9L V 6 RC12YC RC12YC All 035 0 9 mm 41 N m 30 ft lbs 14 mm Thread 3 4 Reach 5 2 5 9L V 8 RC12YC RC12YC All 035 0 9 mm 41 N t t i 30 ft lb...

Page 410: ...Temp Sensor All Engines Torque Ignition Coil Mount Bolts 3 9L 5 2L 5 9L Engines nuts and bolts bolts only ignition Coil Mount Bolts 8 0L V 10 Engine Intake Manifold Air Temp Sensor All Engines RIGHT...

Page 411: ...rument cluster bezel allows ac cess to the cluster assembly switches the climate controls and the radio Removal of the cluster as sembly allows access to the individual gauges illumi nation and indica...

Page 412: ...ENTER In addition to the warning lamps found in the in strument cluster a message center area directly be low the climate controls Fig 3 has a provision for up to 5 warning lamps These lamps may or ma...

Page 413: ...n Spec ifications GEAR SELECTOR INDICATOR The gear selector indicator is used on models with an automatic transmission to show the position of the transmission gear selector lever The indicator is mec...

Page 414: ...s for more information BRAKE WARNING LM P The brake warning lamp warns the driver that the parking brake is applied or that the pressures in the two halves of the split brake hydraulic system are uneq...

Page 415: ...le Code DTC in electronic memory for a circuit or component mal function Refer to Group 14 Fuel System for more information MASTER LIGHTING INDICATOR LAMP This lamp is used only on certain export mode...

Page 416: ...ition If OK go to next step If not OK repair open in circuit from ignition switch and or refer to Group 8D Ignition Systems for test ing of ignition switch 3 Turn ignition switch to OFF Disconnect bat...

Page 417: ...uit to ground as required 4 Remove instrument cluster bezel and cluster assembly Disconnect instrument cluster connector B black connector 5 Probe cavity 11 of cluster connector B Check for continuity...

Page 418: ...d ground There should be no continuity If OK go to next step If not OK repair short circuit as required NO IDENTIFICATION 1 SENSOR GAUGE OUTPUT 2 SENSOR LAMP OUTPUT J958E 21 Fig 11 Oii Pressure Sendin...

Page 419: ...ve cable Unplug PCM connector Remove instrument cluster bezel and clus ter assembly Disconnect instrument cluster connec tor B black connector 3 Probe cavity 3 of cluster connector B Check for continu...

Page 420: ...8E 10 INSTRUMENT PANEL AND GAUGES B R INSTRUMENT CLUSTER CONNECTIONS...

Page 421: ...TER PRINTED CIRCUIT BOARD HIGH LINE VOLTMETER SCREWS SPEEDOMETER SCREWS TACHOMETER SCREWS COOLANT TEMPERATURE GAUGE SCREWS AIR BAG D ILLUMINATION f TURN SIGNAL INDICATORS HIGH BEAM INDICATOR LOW FUEL...

Page 422: ...WS FUEL GAUGE SCREWS OIL PRESSURE GAUGE SCREWS COOLANT TEMPERATURE GAUGE SCREWS 1 ILLUMINATION 2 TURN SIGNAL INDICATORS 3 HIGH BEAM INDICATOR 4 AIS 5 MAINTENANCE INDICATOR 6 BRAKE 7 UPSHIFT INDICATOR...

Page 423: ...2 Connect battery negative cable Check for bat tery voltage between bulb terminals on printed cir cuit within 6 seconds after turning ignition switch to ON position If OK replace faulty bulb If not O...

Page 424: ...urn ignition switch to ON position Lamp should light If OK go to next step If not OK replace faulty bulb 4 Turn ignition switch to OFF position Discon nect battery negative cable Unplug cluster connec...

Page 425: ...y Disconnect instrument cluster con nector B black connector 3 Probe cavity 4 of cluster connector B and check for continuity to a good ground There should be no continuity If OK go to next step If no...

Page 426: ...attery negative cable Unplug cluster connector b Check for continuity between cavity 6 of cluster connector B and a good ground There should be no continuity If OK go to next step If not OK repair sho...

Page 427: ...age center connector and PCM connector Check for continuity between cavity 8 of message center connector and a good ground There should be no continuity If OK go to next step If not OK repair short ci...

Page 428: ...t side of cavity for fuse 13 There should be continuity If OK replace illumination bulb s If not OK repair open circuit as required 4 Check for continuity between cavity 3 of cluster connector A and c...

Page 429: ...r instrument panel 3 Reverse removal procedures to install FUSEBLOCK MODULE REMOVE INSTALL 1 Disconnect battery negative cable 2 Remove knee blocker as described in Knee Blocker Remove Install 3 Remov...

Page 430: ...STER REMOVE INSTALL 1 Disconnect battery negative cable 2 Remove cluster bezel as described in Cluster Bezel Remove Install 3 Remove knee blocker as described in Knee Blocker Remove Install 4 Pull PRN...

Page 431: ...emoval procedures to install 5 To adjust PRND21 indicator place shift selector in PARK position Now adjust indicator by turning recessed hex head screw 9 64 inch hex key wrench underneath cable retain...

Page 432: ...uster as described in In strument Cluster Remove Install 2 Remove all lamp socket assemblies 3 If equipped remove low fuel circuit as de scribed in Low Fuel Circuit Remove Install 4 Remove gauge mount...

Page 433: ...ECIAL TOOL C 4597 2 Remove sensor by loosening sensor coupling nut from the pinion gear adapter until sensor is free Fig 18 3 Reverse removal procedures to install Tighten coupling nut to 17 N m 150 i...

Page 434: ...ment bulb in socket 5 Reverse removal procedures to install HEADLAMP SWITCH REMOVE INSTALL WARNING IF HEADLAMP SWITCH WAS ON WAIT 5 MINUTES TO ALLOW THE CERAMIC DIMMER TO COOL IF THE CERAMIC DIMMER IS...

Page 435: ...g strap to be removed 3 The door and bin are removed by lifting door off hinges Fig 25 4 Reverse removal procedures to install GLOVE BOX LAMP SWITCH LATCH STRIKER REMOVE INSTALL 1 Open glove box until...

Page 436: ...egative cable 2 Remove left and right cowl side panel trim 3 Remove knee blocker as described in Knee Blocker Remove Install 4 Remove 6 screws and lower instrument panel support Fig 28 5 Unplug airbag...

Page 437: ...Fig 30 Steering Column Shrouds J918J 1 CONNECTOR Fig 31 Multi Function Switch Connector INSTRUMENT PANEL AND GAUGES 8E 27 SWITCH CONTROL J918J 2 Fig 32 Steering Column Connectors Fig 33 Steering Colum...

Page 438: ...lower center instrument panel mount ing screw 25 Loosen lower instrument panel pivot bolts 26 Roll instrument panel down 27 Using a screwdriver or pointed tool push through plastic flashing to release...

Page 439: ...Low Normal 3 361 7 ohms High Normal 3 77 ohms ENGINE INDICATION V6 V8 100 HZ 3000 RPM 200 Diesel V10 125 HZ 3000 RPM 200 TEMPERATURE GAUGE CALIBRATION DIESEL ENGINE SPEEDOMETER CALIBRATION POINTER POS...

Page 440: ...aker in each B pillar The premium speaker option upgrades the speak ers in the above locations to Infinity models The two B pillar speakers are coaxial units and each front door has two separate speak...

Page 441: ...nity premium speaker package and all speakers lack bass or low frequency re sponse see Filter Choke Speaker Relay diagnosis 2 Turn radio off Disconnect battery negative ca ble Remove instrument cluste...

Page 442: ...ound There should be continuity Repair radio ground if required 5 Exchange or replace radio if required NO MEMORY 1 Fuse faulty 2 Radio connector faulty 3 Wiring faulty 4 Radio faulty 1 Check ignition...

Page 443: ...REAR SPEAKER FEED 6 LEFT REAR SPEAKER FEED 7 SWITCHED FEED TO PWR AMP ANT i Z SPEAKER CONNECTOR STANDARD NO IDENTIFICATION FRONT TWEETER CONNECTOR STD 1 SPEAKER RETURN NO IDENTIFICATION 2 SPEAKER FEED...

Page 444: ...er lead to the antenna base Check for continuity 3 There should be no continuity If continuity is found replace defective or damaged antenna base and cable assembly TEST 2 Test 2 checks the antenna fo...

Page 445: ...move assembly SJ csi REMOVE yx SCREWS J948E 9 Fig 3 Ash Receiver Remove 4 Carefully pry bezel away from instrument panel to disengage clips Fig 4 J948E 46 Fig 4 Instrument Bezel Remove Install 5 Unplu...

Page 446: ...tab Fig 9 SWITCH BEZEL RETAINING TAB J948S 3 3 Pull rear of switch up and away from door 4 Unplug connectors from switch Fig 10 CONNECTOR LOCKING TABS SWITCH PANEL FRONT CLIP J948S 8 Fig 10 Door Swit...

Page 447: ...im as follows Fig 14 B Pitiar Trim Typicai a Gently unhook top 2 retainer clips by pulling inward and forward b Remove 2 plastic push in fasteners from bot tom of panel c Loosen rear screws of cowl si...

Page 448: ...panel Fig 17 and remove module Fig 17 RWAL Module Upper Mounting 4 Remove 2 screws and relay choke assembly Fig 18 Fig 18 Relay Choke Assembly 5 Reverse removal procedures to install ANTENNA REMOVE IN...

Page 449: ...n far enough to gain access to antenna body Fig 21 6 Remove antenna lead and body by pulling an tenna cable out of cowl and through opening in cowl reinforcement CAP NUT FRONT RIGHT FENDER ANTENNA BOD...

Page 450: ...diaphragm type horn is located on a bracket behind the left end of the front bumper It is grounded through its wiring connector and cir cuit to the horn bracket mounting bolt and receives battery fee...

Page 451: ...re the resistance between the black wire of the horn wiring connector and a good chassis ground The meter should read zero ohms If OK re place faulty horn s If not OK repair circuit to ground as requi...

Page 452: ...onnect battery negative cable 2 From underside of steering wheel remove speed control switch or trim bar mounting screws Fig 2 SPEED CONTROL SWITCHES IBf J948H 9 Fig 2 Speed Control Switch Trim Bar Re...

Page 453: ...ort Fig 9 1 Eaise and support vehicle 2 Disconnect horn s electrical connector s 3 Remove bolt holding horn bracket to bumper support and remove horn Fig 6 Horn Button Remove LOCKING TABS Fig 9 Horn R...

Page 454: ...bution Center PDC Fig 10 Remove PDC cover 3 Refer to the label on the underside of PDC cover for relay location and unplug relay from PDC cavity 4 To install relay align terminals with cavities in PDC...

Page 455: ...f the dual function stop lamp switch Refer to Group 5 Brakes for more information on stop lamp switch service and adjustment procedures SERVO CABLE The speed control servo cable is connected between t...

Page 456: ...S DO NOT PERMIT MAINTAINING A to the Powertrain Diagnostic Procedures manual for CONSTANT SPEED SUCH A S IN HEAVY TRAFFIC testing of this component Refer to Group 14 Fuel OR ON ROADS THAT ARE WINDING...

Page 457: ...NOSTIC TROUBLE CODES Diagnostic Trouble Codes DTC are two digit num bers flashed on the malfunction indicator Check En gine lamp that identify which circuit is bad A DTC description can also be read u...

Page 458: ...em SETTING AFTER SET COAST BUTTON IS PRESSED AND RELEASED S P E E VARIATIONS AT LOWSPBDS ON MfUSOR IN TRANJER TOWING LOCK IN TOO HIGH OR TOO IOW f f FUSE BLOWN TORQUE CONVERTER CLUTCH ROUGHNESS ENGINE...

Page 459: ...I VEHICLE RESUMES SPEED I DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE SPEED CONTROL DISENGAGES N O RESUME WHEN BUTTON IS PRESSED I DEFECTIVE SWITCH I N O SYSTEM DISENGAGEMENT W H E N itASCE P E...

Page 460: ...P SWITCH ADJUSTMENT FAULTY ELECTRICAL CIRCUIT PUSH ON CRUISE BUTTON TO ON POSITION PUSH AND RELEASE SET DECEL BUTTON I REMOVE FOOT FROM ACCELERATOR SPEED SHOULD BE CONTROI1ED HUNTING SURGE OR SPEED VA...

Page 461: ...PUSH RESUME ACCEL SWITCH VEHICLE SHOULD RESUME PREVIOUSLY MEMORIZED SPEED DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE SPEED CONTROL DISENGAGES DEFECTIVE SWITCH FAULTY ELECTRICAL CIRCUIT NO SYS...

Page 462: ...ING ANY AIRBAG SYS TEM COMPONENT REMOVAL OR INSTALLATION REMOVE AND ISOLATE THE NEGATIVE CABLE FROM THE BATTERY THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE B E FORE FURTHER SYSTEM SERVICE...

Page 463: ...ssis ground near the servo Unplug the 4 way connector going to the servo Fig 4 Push the speed control switch to the ON position Check for battery voltage at servo harness connector cavity for pin 2 Fi...

Page 464: ...tch Test If the switch is not at fault then check the main harness and repair as necessary 6 Touch the positive lead of the voltmeter to the terminal in cavity number 50 The voltmeter should read zero...

Page 465: ...e with hole in servo pin and install hairpin clip 9 Insert servo studs through holes in cable sleeve 10 Install 2 attaching nuts and tighten to 6 N m 50 in lbs 11 Connect vacuum hose to servo 12 Conne...

Page 466: ...With throttle blocked to full open position align hole in cable sleeve with hole in servo pin and install hairpin clip BR Fig 14 Servo Cable Hairpin Clip 15 Insert servo studs through holes in cable s...

Page 467: ...O DISABLE THE AIRBAG SYS TEM FAILURE TO DO THIS COULD RESULT IN AC CIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE INJURY Fig 16 Switch Connector Remove lnstail 1 Disconnect battery negative cable 2 From und...

Page 468: ...e tabs on speed control cable and push 5 Reverse removal procedures to install out of locking plate 4 Remove servo cable from servo as described in Speed Control Servo Remove Install Fig 18 Servo Cabl...

Page 469: ...haft regardless of how carefully it is installed Fig 20 Removing Wiper Arms 2 Remove weatherstrip along front edge of cowl screen Fig 21 Fig 21 Cowl Screen Weatherstrip 3 Release plastic anchor screws...

Page 470: ...module Fig 1 It contains one fixed contact point and one contact point attached to a flexible bimetal arm The contact points are normally closed When a turn signal is activated current flows through...

Page 471: ...nal 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 8A Battery Starting Cha...

Page 472: ...er L9 circuit If OK go to next step If not OK repair open circuit between fuse and flasher 3 Replace hazard flasher with known good unit of the same rating The lamps should flash If OK dis card faulty...

Page 473: ...th upper and lower shrouds from col umn Fig 4 4 Remove multi function switch tamper proof mounting screws tamper proof torx bit Snap On TTXR20B2 or equivalent required 5 Gently pull switch away from c...

Page 474: ...ueegees is suggested to remove de posits of salt and road film The wiper blades arms and windshield should be cleaned with a sponge or cloth and a mild detergent or non abrasive cleaner If the squeege...

Page 475: ...ith a variable resistor in the wiper switch and is accomplished by electronic circuitry within the intermittent wipe module If the washer knob is de pressed while the wiper switch is in the OFF posi t...

Page 476: ...orn linkage bushings if required 3 Check wiring for continuity between motor and switch Repair wiring if required 4 See diagnosis for Multi Function Switch in this group Replace if required 5 See diag...

Page 477: ...r washer switch to HIGH position Move voltmeter test lamp lead from terminal H to terminal L of the wiring harness If voltage is present there is a short in the wiring or wiper washer switch CONDITION...

Page 478: ...continuity the problem is an open in wiring or a faulty wiper washer switch IULTI FUNCTION SWITCH Use an ohmmeter to test for continuity no resis tance between the terminals of the switch as shown in...

Page 479: ...ection at the instru ment panel is making good connection free from paint and is tight 2 Verify that the motor ground strap is making good contact and that the motor mounting bolts are tight 3 Verify...

Page 480: ...sliding out of the claws 3 Reverse removal procedures to install WIPER ARM REMOVE INSTALL CAUTION The use of a screwdriver or other prying tool to remove an arm may distort it This distortion could a...

Page 481: ...tab connectors from wiper motor Fig 17 9 Remove crank arm from drive link by prying retainer bushing from crank arm pin with a suitable size screwdriver Fig 18 10 Remove 3 screws securing motor to lin...

Page 482: ...procedures to install Tighten fasteners as follows multi function switch connector screw 1 9 N m 17 in lbs multi function switch retaining screws 1 9 N m 17 in lbs WASHER RESERVOIR REMOVE INSTALL WAR...

Page 483: ...rommet Care must be taken not to puncture reservoir FAN SHROUD WASHER FLUID RESERVOIR UPPER RADIATOR HOSE J948K 11 Fig 23 Upper Radiator Hose Remove Install FAN SHROUD WASHER RESERVOIR LOW WASHER FLUI...

Page 484: ...continuity of the circuit ground Refer to Group 8W Wiring Diagrams for component location and circuit information S1FETY PRECAUTIONS WARNING EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONE...

Page 485: ...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 repai...

Page 486: ...d 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 cir...

Page 487: ...olumn upper bracket nuts Do not remove nuts 8 Move upper fixed column shroud to gain access to rear of multi function switch 9 Remove switch connector Fig 3 and 4 10 Use an ohmmeter to test for contin...

Page 488: ...SBEC Refer to Group 8W Wiring Diagrams for component location and circuit information iYvj M RUNNING M jV MiLf S M t 1 Release hood latch an open hood 2 Disconnect wire connector from DRLR Fig 6 8 Rem...

Page 489: ...Console 13 Overhead Console Reading Lamp Bulb 13 Park and Turn Signal Lamp Bulb 9 Park Turn Signal and Side Marker Lamp 9 Rear Identification ID Lamp Bulbs 12 Rear Identification ID Lamps 12 Roof Cle...

Page 490: ...re HEADLAMP BULB On driver side and on vehicles with dual batteries the headlamp assembly must be removed to service the headlamp bulb J958L 23 Fig 2 Aero Headlamp Alignment alignment screen 100 mm 4...

Page 491: ...fingers or other oily surfaces Reduced bulb life will result I Position bulb in headlamp Fig 5 Headlamp Bulb Removal 2 Install retaining ring holding bulb to headlamp Fig 5 3 Connect wire connector t...

Page 492: ...module 2 Disengage clip holding park lamp to headlamp module 3 Separate park lamp headlamp module 4 Remove park and turn signal socket from back of lamp 5 Remove side marker socket from back of lamp 6...

Page 493: ...COUNTED STOP L A 1 P CHMSL mm 1 Remove screws holding CHMSL to roof panel 2 Separate CHMSL from roof 3 Remove socket from lamp Fig 9 4 Pull bulb from socket mmwMLLAwmm 1 Install bulb in socket 2 Insta...

Page 494: ...ail lamp to mounting bracket Fig 11 2 Disengage tail lamp wire connector from body wire harness 3 Separate tail lamp from vehicle Reverse the removal procedure BRACKET J948L 9 Fig 11 Tail Stop Turn Si...

Page 495: ...arate ID lamp from vehicle INSTALLATION Reverse the removal procedure REAR IDENTIFICATION ID LAMP BULBS The bulbs in the rear ID lamps can not be re placed If a bulb should fail the entire lamp would...

Page 496: ...forcement Fig 15 4 Place dome lamp lens on dome lamp and snap into place OVERHEAD CONSOLE To service overhead console refer to Group 8C Overhead Console OWERHEAi CONSOLE READING LAiP 1ULB REMOVAL 1 I...

Page 497: ...C after the component is removed from the vehicle Contact local dealer for location of nearest ASC When illumination goes out in the Electronic Instrument Cluster EIC the complete button module must b...

Page 498: ...UBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE BUT IN TERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION THE FASTENERS S C R E W S AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECI...

Page 499: ...bly consists of a flat ribbon like electrically conductive tape which winds and unwinds with the steering wheel rotation AIRBAG CONTROL MODULE The airbag control module ACM contains the saf ing sensor...

Page 500: ...t Since this powder can irritate the skin eyes nose or throat be sure to wear safety glasses rubber gloves and a long sleeved shirt during cleanup Fig 1 Fig 1 Wear Safety Glasses And Rubber Gloves If...

Page 501: ...l and unplug connector Fig 5 4 Using a small screwdriver remove right rear steering wheel cover Fig 6 5 Remove 4 nuts attaching airbag module to steering wheel Fig 7 6 Remove airbag module from steeri...

Page 502: ...ug connector from sensor and remove sen sor Fig 15 5 To install connect sensor wiring lead from har ness to connector on body of sensor 6 Mount sensor arrow pointed forward using 3 screws provided wit...

Page 503: ...connect sensor wiring lead from harness to connector on body of sensor 13 Mount sensor arrow pointed forward using 3 screws provided with new sensor Tighten screws to 4 5 N m 35 45 in lbs 14 Plug har...

Page 504: ...forward using 3 screws provided with new sensor Tighten screws to 4 5 N m 35 45 in lbs 6 Do not connect negative battery cable at this time See Airbag System Check for proper procedure AIRBAG CONTROL...

Page 505: ...at lower left corner of instrument panel 11 To remove clockspring pull assembly from steering column by lifting locating fingers as neces sary The clockspring cannot be repaired and must be replaced i...

Page 506: ...battery negative cable and isolate If airbag is undeployed wait 2 minutes for system capacitor to discharge before further service 3 Remove airbag module Remove steering wheel with steering wheel pul...

Page 507: ...oor lock switches The motor can not be repaired If faulty the entire motor must be replaced D I A G N O S I S POWER LOCI SWITCH 1 Check fuse 19 in fuseblock module If OK go to next step If not OK repl...

Page 508: ...er above test repair wire harness between motor and switch as required If disconnect ing one motor causes the other motor to become func tional go back to step 2 to test the disconnected motor S E R V...

Page 509: ...motor Fig 7 POWER LOCKS SP 3 Fig 7 Lock Motor and Latch Remove install 6 Remove 3 screws holding lock motor and latch assembly to door 7 Disconnect linkage rods 8 Pull motor and latch out far enough...

Page 510: ...switch to the FORWARD or REARWARD position When a switch is actuated battery feed and a ground path are applied through the switch contacts to the motor s The motor s operate to move the seat in the s...

Page 511: ...OK go to next step If not OK repair wir ing to circuit breaker 3 Check for continuity between black orange wire at switch connector and a good ground There should be continuity If OK replace faulty s...

Page 512: ...ASE TABS 3 J948R 2 Fig 1 Seat Switch and Bezel Remove 3 Remove 2 screws holding switch to bezel Fig 2 J948R 3 Fig 2 Seat Switch Remove 4 Pull switch from seat far enough to access con nector and unplu...

Page 513: ...ove Fig 4 Center Seat Section Attachment 5 Unplug power seat wire harness connector lo cated under seat 6 Remove driver s seat assembly from vehicle 7 Remove 4 screws attaching seat track to seat Fig...

Page 514: ...otect the motor from overloads The power window motor and gearbox assembly can not be repaired If faulty the entire assembly must be replaced CIRCUIT BREAKER An automatic re setting circuit breaker in...

Page 515: ...ace the switch POWER WINDOW MOTOR Before you proceed with this diagnosis confirm proper switch operation See Power Window Switch diagnosis VIEW SHOWN FROM BACK OF SWITCH SWITCH POSITION CONTINUITY BET...

Page 516: ...g 5 TABS FRONT CLIP J948S 8 Fig 5 Door Switch Connectors 5 Plug connector onto new switch 6 Install a new switch by inserting front of switch into trim panel then pushing down rear of switch POWER WIN...

Page 517: ...glass as far rearward into channel as possible and push down Tighten 2 window track screws to 12 N m 105 in lbs 17 Attach door glass by sliding 2 nuts into the slots on the channel Figs 9 and 10 Tigh...

Page 518: ...mirror to be adjusted The switch knob is then moved in a joystick fashion to control move ment of the selected mirror up down right or left AUTOMATIC DAY NIGHT MIRROR The automatic day night mirror a...

Page 519: ...d See Mirror Test chart Fig 3 for correct jumper wire connections at the power mirror switch connector harness side not switch side If mirror s don t respond as indicated remove mirror connector as de...

Page 520: ...window lock switch by reaching through door pull cup opening and depressing rear switch retaining tab Fig 6 Fig 6 Switch Bezel Rear Retaining Tab 3 Pull rear of switch up and away from door 4 Unplug...

Page 521: ...ocedures to install Fig 11 Power Mirror Remove Install AUTOMATIC DAY NIGHT MIRROR REMOVE INSTALL 1 If so equipped remove wire cover by grasping lower portion of wire cover and sliding into upper porti...

Page 522: ...laced DRIVER S DOOR JAMB SWITCH The driver s door jamb switch is mounted to the driver s door hinge pillar The switch closes a path to ground for the buzzer module through the key in switch or headlam...

Page 523: ...fuseblock module If OK go to next step If not OK repair circuit to fuse 11 in fuseblock module 7 Turn ignition switch to OFF position Check for continuity between cavity for buzzer terminal 3 and a g...

Page 524: ...k module as required 3 Check continuity between headlamp switch ter minal for connector cavity with black light blue wire and terminal for cavity with light blue wire There should be no continuity wit...

Page 525: ...cess to buzzer module 5 Pull buzzer module out of fuseblock module 6 Reverse removal procedures to install SWITCHES REMOVE INSTALL Service procedures for switches used in the buzzer system can be foun...

Page 526: ...In addition all switches compo nents and modules are shown in the at rest posi tion with the doors closed and the key removed from the ignition If a component is part of several different circuits it...

Page 527: ...ON SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE AN AUTOMATIC TRANSMISSION SHOULD B E IN PARK A MANUAL TRANSMISSION SHOULD B E IN NEUTRAL OPERATE THE ENGINE ONLY IN A WELL VENTI LATED AREA KEEP AW...

Page 528: ...MALE TERMINAL FEMALE TERMINAL CONNECTOR IDENTIFICATION NUMBER 948W 191 Fig 3 Circuit Identification Fig 4 Connector Identification For viewing connector pin outs with two terminals or greater refer to...

Page 529: ...RESISTOR SPLICE VARIABLE RESISTOR S100 SPLICE IDENTIFICATION SERIES RESISTOR r f t p THERMAL ELEMENT COIL TIMER TIMER vfl Lr 11 STEP UP COIL y y y MULTIPLE CONNECTOR 1 OPEN CONTACT OPTIONAL W I R I N...

Page 530: ...ered up by the vehicle electri cal system can cause damage to the equipment and provide false readings Probing Tools These tools are used for probing terminals in connectors Fig 7 Select the proper si...

Page 531: ...ct or isolate all items on the fused circuit 2 Replace the blown fuse 3 Supply power to the fuse by turning ON the ig nition switch or re connecting the battery 4 Start connecting the items in the fus...

Page 532: ...ter the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 9 Secure the wire to the existing...

Page 533: ...he harness 4 Stagger cut all wires on the harness side at 1 2 inch intervals Fig 17 5 Remove 1 inch of insulation from each wire on the harness side 6 Stagger cut the matching wires on the repair conn...

Page 534: ...on each part of the exposed wires Fig 11 example 1 11 Push the two ends of wire together until the strands of wire are close to the insulation Fig 11 ex ample 2 12 Twist the wires together Fig 11 exam...

Page 535: ...e Block 8W 10 6 Fuse 2 PDC 8W 10 6 Fuse 3 PDC 8W 10 3 5 Fuse 5 Fuse Block 8W 10 4 Fuse 6 Fuse Block 8W 10 4 Fuse 6 PDC 8W 10 8 Fuse 7 Fuse Block 8W 10 4 Fuse 8 Fuse Block 8W 10 4 Fuse 9 Fuse Block 8W...

Page 536: ...8W 10 2 8W 10 FUSE FUSE BLOCK B R C241 J958W 9...

Page 537: ...0 G R E E N 8W 10 6 C B 1 30 CIRCUIT B R E A K E R 8W 10 6 C B 2 30 CIRCUIT B R E A K E R 8W 10 4 T U R N SIGNAL FLASHER C A Y CIRCUIT F U N C T I O N SECTION PAGE 1 L6 20RD GY T U R N S I G N A L F L...

Page 538: ...8W 21 2 A31 12BK WT C241 FUSE BLOCK D S CB2 30A 8 2 0 A iS ioaS 15AS 20AS L F37 14RD LB C2Q2 F37 14RD LB V6 16DB BK C303 F37 14RD LB POWER SEAT SWITCH 8W 63 2 HOT IN ACC AND RUN 4 J C241 F30 18RD 0R L...

Page 539: ...J JOINT C O N N E C T O R C BEHIND KNEE BOLSTER V34 22WT RD 8W 70 27 VEHICLE S P E E D C O N T R O L SWITCH 8 W 3 3 2 F14 18LG YL I FUSED I I IGN SW I OUTPUT I I START 1 L f N l J AIRBAG C O N T R O...

Page 540: ...CONTROL NODULE RIGHT DOOR POWER WINDOW SWITCH 8W 60 3 A20 A20 18RD 18RD DB DB L10 22BR LG C209 BACK UP Lo LAMP I 2 8 SWITCH I 1 OUTPUT J F23 18DB YL fJ5 JOINT L CONNECTOR C BEHIND KNEE BOLSTER A20 18R...

Page 541: ...T A L L T I N E S 4 1 1 C 2 4 1 C 2 4 1 19 2 0 A 17 J_5A J O I N T C O N N E C T O R B N E A R R E A R OF FUSE B L O C K I 1 S 2 1 6 8 W 7 0 3 0 F 3 5 1 6 R D I P O W E R M I R R O R S P L I C E S W...

Page 542: ...3 A 3 1 2 R D L6 A 7 1 2 R D B K F 3 3 2 0 P K R D S203 8W 70 23 A 3 1 2 R D L G I TS204 8W 70 24 A 7 1 2 R D BK F U S E B L O C K r 1 241 HOT A T ALL TIMES41 1 JOINT C O M l E C T P R C F U S E D C20...

Page 543: ...Relay 8W 11 4 Engine Starter Motor Relay 8W 11 7 Fuel Pump Relay 8W 11 8 Fuse 1 PDC 8W 11 5 Fuse 2 PDC 8W 11 7 Fuse 3 PDC 8W 11 9 Fuse 4 PDC 8W 11 4 Fuse 5 Fuse Block 8W 11 9 Fuse 5 PDC 8W 11 6 Fuse...

Page 544: ...8W 11 7 FUSE 6 A3 3 2RD LG 40 FUSED B 8W 11 7 FUSE 7 A6 14RD TN 30 FUSED B 8W I1 4 FUSE 8 A H 16RD WT 20 FUSED B 8 1 M 1 8 FUSE 8 a m tsm m 20 FUSED B 8W 11 8 FUSE A CAV CIRCUIT AMPS FUNCTION SECTION...

Page 545: ...T FUSED B 8W 11 8 85 K51 22DB YL ASD FUEL P U M P RELAY C O N T R O L 8W 11 8 85 K51 22DB YL ASD FUEL P U M P RELAY C O N T R O L 8W 11 8 86 F18 20LG BK FUSED IGNITION SWITCH O U T P U T START RUN 8W...

Page 546: ...R BATTERY P O S I T I V E TERMINAL POWER D I S T R I B U T I O N CENTER S P L I C E S106 8 W 7 0 3 TRAILER TOW CONNECTOR 8 W 5 4 2 SPLICE SI38 8W 70 17 8 0L ENGINE ONLY S P L I C E S133 8 W 7 0 1 4 S...

Page 547: ...i F31 I 20VT 85 1 1 86 30 ft 8 7 F18 20L6 B K CI3 22DB OR C3 F31 18DB 20VT BK CI2S C127 C13 20DB O R C3 18DB BK SPLICE S1 4 8 V 7 0 6 C135 34 I A C COMP I CLUTCH RELAYs CONTROL J POWERTRAIN CONTROL MO...

Page 548: ...220B YL AUTOMATIC SHUT DOWN RELAY 8 V 1 1 4 C 1 8 0 AM IBRD W T GENERATOR 8 W 8 0 S 8 W 2 0 4 F18 20LG BK K51 2 2 D B YL C126 A61 1606 BK C125 AM 1 6 R D W T SPLICE S 1 1 4 8 W 7 0 6 K5i 2 0 D B YL 1...

Page 549: ...IC 0 N W K T 5 R C SWITCH BEHIND OUTPUT KNEE START RUN I BOLSTER C133 HAZARD WARNING FLASHER 8 W 5 2 3 CLUTCH PEDAL POSITION SWITCH O R JUMPER 8 W 2 1 2 POWER OUTLET 8 W 4 1 2 TURN SIGNAL FLASHER 8 W...

Page 550: ...DRL Module 8W 12 6 8 Fuse 1 PDC 8W 12 2 4 Fuse 2 PDC 8W 12 8 Fuse 3 PDC 8W 12 6 Fuse 6 PDC 8W 12 4 Fuse 11 Fuse Block 8W 12 6 Fuse 13 Fuse Block 8W 12 2 5 Fuse 15 Fuse Block 8W 12 8 Fuse 18 Fuse Block...

Page 551: ...OVERDRIVE SWITCH 8 W 3 1 2 C 13 5 A 71 8 FUSE BLOCK ISA I C24l SPLICE S106 8 W 7 0 3 f L7 I8BK Y L RADIO 8 W 4 7 2 8W 47 4 Ei 20TN O R F33 20PK R D C133 L7 20BK Y L L7 18BK Y L 4 C208 H E A D i P A R...

Page 552: ...YL C208 C 2 0 I C240 M 2 22YL M 2 22YL M 2 22YL 1 M 2 22YL TIME DELAY RELAY 8 W 4 4 3 HEADLAMP SWITCH l 1 C204 13 20BK O R D O M E W J8 C A R G O f 3 204 M 2 20YL 1 206 3 D O M E LAMP B W 4 4 3 M 2 20...

Page 553: ...5 8W 70 25 AIRBAG ABS DATA LINK CONNECTOR 8 W 3 2 H RADIO CHOKE 8 W 4 7 5 GLOVE BOX LAMP AND SWITCH 8 W 4 4 6 RADIO 8 W 4 7 2 8 W 4 7 4 STOP LAMP SWITCH 8 W 3 3 3 REAR WHEEL ANT1 LOCK CONTROL MODULE C...

Page 554: ...D JZJZJiA HEADLAMP I v n H SWITCH I OUTPUT HEATER SWITCH OR HVAC SWITCH 8 W 4 2 3 t 8 W 4 2 4 OVERHEAD CONSOLE C3381 I E2 220R E2 220R f i3 H jJftJ JP AIITmiT FUSED JOINT CONNECTOR A NEAR REAR OF FUSE...

Page 555: ...22DB WT F H 7 C208 F12 22DB WT 20 21 19 OVERHEAD CONSOLE f fusTd 1 IGNITION 1 SWITCH OUTPUT START RUN 1 F12 220B WT C209 22 I I Gil 22WT BK Gil 20WT BK 10 DAYTIME LAMPS 3 1 PARK 1 BRAKE SWITCH i SENS...

Page 556: ...LD STOP LAMP SWITCH 8 W 3 3 3 8W 70 5 V40 20WT PK 133 Y40 22WT PK 31 32 13 14 616 22BK LB 616 22BK LB 12 C209 616 22BK LB C A O I G16 18BK LB C206 6 I O x I OFF PARK C208 HEAD 5 626 18LB 8W 12 7 REAR...

Page 557: ...ER T BRAKE I WARNING I I LAMP DRIVER I 133 L IL C 2 1 6 69 226Y BK 69 226Y BK l REAR WHEEL ANTI LOCK CONTROL MODULE CENTER f BRAKE I WARNING I I LAMP DRIVER I J C228 69 226Y BK 69 226Y BK L t I 26 23...

Page 558: ......

Page 559: ...4 1 VEHICLE SPEED CONTROL SERVO 8 W 3 3 2 Zl 12BK 9 GND I I Zl I2BK DAYTIME RUNNING LAMPS MODULE LEFT FENDER SIDE SHIELD Zl 12BK VACUUM SENSOR 8 W 3 2 5 8W 32 I1 Zl 18BK GROUND JOINT NEXT TO PDC C I 2...

Page 560: ...8BK Zl 20BK G102 GROUND JOINT NEXT TO PDC 1 GROUND J L _ 3 _ _ J C123 J RIGHT PARK AND TURN SIGNAL LAMP 8 W 5 0 5 RIGHT HEADLAMP 1 8 W 5 0 3 Z2 18BK LG ABS 2 WAY POWER FEED 8 W 3 2 1 0 f G107 8W 15 4...

Page 561: ...WITH TRAILER TOW Z13 12BK Z13 16BK LEFT HEADLAMP 8 W 5 0 3 Zl 20BK GAS ENGINE ONLY S I I S 8W 70 7 Zl Zl 14BK 12BK Zl 16BK Z13 Z13 16BK 12BK 6 1 0 5 G106 C133 Z2 18BK LG SPLICE S 3 1 1 8 W 7 0 3 3 SP...

Page 562: ...0BK T N EMSINI COOLANT TEMPERATURE SENSOR 8 W 4 0 5 Z12 20BK TN SPLICE S11S LEFT HEATED OXYGEN SENSOR 8W 30 29 8 W 7 0 7 8W 30 3S f Z12 20BK TN C12S T41 22BK W T ENGINE STARTER MOTOR RELAY 8 W 1 1 7 8...

Page 563: ...AL 8W 20 4 FOG LAMP SWITCH 8 W 5 0 7 INTERMITTENT WIPER CONTROL MODULE Z 3 2 0 B K 0 R Z 3 2 0 B K 0 R HEADLAMP SWITCH 8 W 4 4 3 T O P R E A R C E N T E R O F I P SPLICE SI 15 8 W 7 0 2 9 Z 3 2 0 B K...

Page 564: ...2 CIGAR LIGHTER 8 W 4 1 2 Z3 18BK 0R SPLICE S206 1 8W 70 26 HEATER SWITCH Z3 OR HVAC SWITCH 20BK 8 W 4 2 3 O R 8 W 4 2 4 Z3 16BK 0R GLOVE BOX LAMP AND SWITCH I 8 W 4 4 6 L OVERHEAD CONSOLE G R O U N...

Page 565: ...AND LOCKS Z3 18BK 0R G3Q2 LEFT DOOR POWER i WINDOW SWITCH 8 W 8 0 2 POWER MIRROR 1 SWITCH 8 W B 2 2 Z3 18BK 0R G3Q3 RIGHT DOOR JAMB SWITCH 8 W 4 9 3 OVERHEAD CONSOLE i 1 GROUND LEFT OUTBOARD I D E N...

Page 566: ...cuit A142 Circuit A142 splices to connect to the generator connector supplying battery voltage to the generator field The Powertrain Control Module PCM has an in ternal voltage regulator that controls...

Page 567: ...C 40A r OA C 30A A16 14GY WT C180 A16 14GY WT A2 12PK BK Al 12RD C133 Al 12RD GENERATOR I POWERTRAIN t i t L U CONTROL S134 I CONTROL L 2 0 I MODULE 8W 70 14 K20 18DG K20 18DG I RIGHT SIDE J C135 OJ D...

Page 568: ...m 5 J 2 A 1 6 1 4 G Y WT A 2 it2PK B K POWER DISTRIBUTION CENTER Y T 4 0 12BR C l l S T 4 0 1 2 B R A O S R D C181 C180 3 0 125 R T 4 1 2 2 B K W T C180 AUTOMATIC SHUT DOWN RELAY S139 Z12 2 0 B K T N...

Page 569: ...6RD AO 6RD A16 14GY WT POWER DISTRIBUTION CENTER A16 14GY WT A2 1 2 P K B K Al 1 2 R D POWERTRAIN CONTROL MODULE G E N E R A T O R A S D J l G H J I FIELD RELAY ISIDE O F CONTROL OUTPUT I Jt s 1 20 57...

Page 570: ...LAY ENGINE STARTER MOTOR RELAY 87 C180 C125 87 85 30 S146 8W 70 20 Y A2 12PK BK 86 Z12 20BK TN S139 8W 70 18 Z12 14BK TN I C180 G i l l A41 14YL 8W 15 5 A2 12PK BK Al 12RD A142 1406 OR I G N I T I O N...

Page 571: ...ced and supplies power for the fuel shut down solenoid MANUAL TRANSMISSION The Power Distribution Center PDC supplies bat tery voltage to the engine starter motor solenoid on circuit T40 when the coil...

Page 572: ...aw 21 2 8W 21 STARTING SYSTEM BR BATTER P O S I T I V E TERMINAL AO 6RD SPLICE S 2 0 1 8 W 7 0 2 2 BYPASS JUMPER AUTOMATIC TRANSMISSION C212 A22 12BK 0R START J958W 9...

Page 573: ...on switch is in the START or RUN position it connects circuit Al from fuse 3 in the PDC to circuit A21 Circuit A21 powers circuits F18 V34 F12 and F14 through the fuse block Separate fuses protect eac...

Page 574: ...ides the ground for the injectors The PCM grounds two injec tors at the same time Injectors are paired as follows 1 and 10 2 and 7 3 and 6 4 and 9 5 and 8 Circuit K116 provides ground for injectors 1...

Page 575: ...of the PCM con nector Circuit K40 connects to cavity 40 of the PCM con nector Circuit K59 connects to cavity 59 of the PCM con nector Circuit K60 connects to cavity 60 of the PCM con nector VEHICLE S...

Page 576: ...uit K4 Circuit K4 connects to cavity 4 of the PCM connector HELPFUL INFORMATION Circuit K7 splices to supply 8 volts to the camshaft position sensor and the vehicle speed sensor Circuit K4 splices to...

Page 577: ...trol Module PCM The PARK NEUTRAL position switch provides an input to the PCM TCC SOLENOID The TCC solenoid and overdrive solenoid are molded together They are only used on automatic transmissions The...

Page 578: ...e data link con nector HELPFUL INFORMATION If the system loses ground for the Z12 circuits the vehicle will not operate POWER DEVICE GROUND Circuit Z12 connects to cavities 11 and 12 of the Powertrain...

Page 579: ...he generator field Circuit A142 also connects to cav ity 57 of the PCM BATTERY FEED Circuit A14 from the Power Distribution Center PDC supplies battery voltage to cavity 3 of the Pow page Ignition Swi...

Page 580: ...efer to Group 14 Fuel Systems for fuel shut down solenoid operation INTAKE MANIFOLD AIR HEATER RELAYS When the ignition switch is in the START or RUN position it connects circuit Al from fuse 3 in the...

Page 581: ...r the vehicle speed sensor signal circuit G7 through circuit K4 Circuit K4 connects to cavity 4 of the PCM connector HELPFUL INFORMATION Circuit G7 splices to connect to the speedometer in the instrum...

Page 582: ...1 4 6 C133 A2 12PK BK 8W 70 20 HOT IN ACC OR RUN S J l 8 1 20A 6 15A A3i 12BK WT C 2 4 1 V6 1SDB BK X12 IBRD W T 5 20A FUSE BLOCK I C 2 4 1 L5 20BK F30 IBRD OR F30 18RD OR L5 20BK X12 18RD WT V6 16DB...

Page 583: ...B K W T 1 2 D B VEHICLE SPEED SPLICE CONTROL BUS SWITCH 8 W 7 0 6 8 W 3 3 2 FIB 20LG BK V 3 4 2 2 W T R D A3 12BK WT HOT I N RUN OR START F u s g b l o c k i IL IL SPLICE S209 8 W 7 0 2 7 F14 1BLG YL...

Page 584: ...F L P I 1 I FUSED I B i i y S 2 0 1 8W 70 22 A22 12BK OR A22 12BK OR A22 12BK OR F21 14TN CI 1206 HOT I N RUN ONLY 14 S 16 10A WITH ABS ISA C 2 4 1 1 S F2 CB1 FUSE C 30A 3QAI 1 BLOCK j C 2 4 1 F23 18D...

Page 585: ...33 4 A 1 4 2 160G 0R A142 1 6 D G 0 R 8 W 7 0 1 4 K l l 1 8 W T DB K13 1 8 Y L WT IPLE AIR CONTROL MOTOR ON THROTTLE BODY 4 3 2 d C150 K 3 8 18GY K59 K 4 0 K 6 0 K 3 9 1 8 V T 1 8 B R 1 8 Y L 1 8 G Y...

Page 586: ...16D6 OR K14 A142 18LB 1606 BR OR K58 A142 18BR 16DG DB OR S13S 8W 70 15 A142 16DG 0R A142 16DG 0R A142 14DG OR I G N I T I O N COIL RIGHT FRONT OF ENGINE K12 18TN K M 18LB BR K58 18BR DB A142 16DG OR...

Page 587: ...Z12 20BK TN S O I l8W 70 18 zit I6BK W T Z12 14BK TN G i l l Z12 16BK TN Z12 16BK TN F18 20LG BK SPLICE S132 8 W 3 0 1 3 CJL36 C133 V40 20WT PK V40 22WT PK S i l l 8W 70 5 V40 22WT PK V40 20WT PK REAR...

Page 588: ...NGINE C152 C152 CRANKSHAFT POSITION SENSOR 8W 30 18 K7 200R K7 200R K4 I8BK LB r K7 180R VEHICLE SPEED SENSOR 8 W 3 0 1 9 S13Q 8W 70 12 K4 20BK LB INTAKE AIR TEMPERATURE SENSOR RIGHT FRONT OF INTAKE M...

Page 589: ...IB 1 8 L 6 B K C133 621 2 2 G Y L B 63 2 2 B K P K CI27 CI28 FIB 2 0 L G B K 5 Q 2 EXHAUST GAS RECIRCULATION SOLENOID C148 R I G H T R E A R O F E N G I N E L E F T R E A R O F E N G I N E 621 2 0 G Y...

Page 590: ...30 18 MAP SENSOR ON THROTTLE B O D Y 8W 30 FUEL iGNITiOi 3 J L EIGINE B R CRANKSHAFT POSITION SENSOR COO RIGHT REAR O F ENGINE I M A P I SENSOR POWERTRAIN CONTROL MODULE RIGHT SIDE O F DASH PANEL J958...

Page 591: ...K4 20BK LB K4 20BK LB THROTTLE POSITION SENSOR 8 W 3 0 1 8 MAP SENSOR 8 W 3 0 1 8 CRANKSHAFT POSITION SENSOR 8 W 3 0 I 8 SPLICE S 1 3 0 8 W 3 0 I 6 K7 mm t 3 K4 18BK LB f K7 180R VEHICLE SPEED SENSOR...

Page 592: ...F18 20LG BK CI25 A142 1406 OR HEATED OXYGEN SENSOR C160 IN RIGHT EXHAUST DOWN PIPE SPLICE S139 8 W 3 0 1 5 A142 14DG 0R K4 18BK LB K41 18BK D6 111 18BK WT I S14 8W 7Q 19 SPLICE S136 8 W 3 0 1 9 S133...

Page 593: ...D POWER OISTR1BUTIOM CENTER I FUSE 3 40A I fS j C180 C133 K H p V p Al 12RD Al 12RD cai2 f i IGNSTION SWITCH A C C O F F R U N S T A R T C2I2 6 A21 1208 FI8 20L6 B K S114 18W 70 61 F18 20LG B K C133 C...

Page 594: ...0 2 3 K13 A142 18YL 16DG WT OR K38 AH2 18GY I606 OR K l l 18MT DB A142 16DG 0R AH2 16D6 0R IDLE AIR CONTROL MOTOR ON THROTTLE BODY K5S K40 K60 K39 18VT 18BR 18YL 186Y BK WT BK RD 16 I N J 1 DRIVER 17...

Page 595: ...1 6 D G D B O R SOS 8W 70 15 INJECTOR 8 K18 A142 18RD 1 6 D G Y L O R A142 16DG 0R A142 16DG 0R A142 16DG 0R K12 18TN K18 18RD Y L K14 18LB B R K58 18BR D B A142 1606 m I G N I T I O N COIL RIGHT F R...

Page 596: ...S B K 1 4 B K W T T N Z12 Z12 16BK 1 6 B K T N T N F18 20LG B K SPLICE S132 8 W 3 0 1 3 C136 C133 V40 2 0 W T P K V40 2 2 W T P K S i l l 8W 70 5 V40 2 2 W T P K V40 2 0 W T P K REAR W H E E L A N T...

Page 597: ...I N E C152 C1S2 S129 8 W 70 121 CRANKSHAFT POSITION SENSOR 8 W 3 0 2 7 K7 200R K7 200R S130 INTAKE AIR TEMPERATURE SENSOR 157 1 RIGHT FRONT OF INTAKE K4 MANIFOLD K21 20BK 1BBK LB RD K7 180R VEHICLE S...

Page 598: ...B 6 2 4 2 2 6 Y P K 6 3 2 0 B K P K C127 CMS FIB 2 0 L 6 B K EXHAUST GAS RECIRCULATION SOLENOID C146 R I 6 H T R E A R O F ENGINE L E F T R E A R O F ENGINE 6 2 1 2 0 6 Y L B 624 2 0 6 Y P K 6 3 2 0...

Page 599: ...27 MAP S E N S O R ON THROTTLE BODY CRANKSHAFT P O S I T I O N S E N S O R R I G H T R E A R O F E N G I N E C I 3 8 C13S I MAP SENSOR 24 CRANK POSITION SENSOR SIGNAL P O W E R T R A I N CONTROL MODU...

Page 600: ...W 3 0 2 5 C133 SPLICE S129 8 W 3 0 2 5 G 7 2 0 W T O R S 2 1 0 8 W 7 0 2 8 THROTTLE POSITION SENSOR 8 W 3 0 2 7 MAP SENSOR 8 W 3 0 2 7 CRANKSHAFT POSITION SENSOR 8 W 3 0 2 7 VEHICLE SPEED SENSOR R E...

Page 601: ...BATTERY P O S I T I V E TERMINAL 8W 3Q FUEL IGNITION 8W 3D 29 5 2L AND J L ENGINE A 1 6 1 4 G Y W T I N L E F T E X H A U S T mm p i p e CONTROL MODULE R I G H T S I D E O F D A S H P A N E L J 9 5 8...

Page 602: ...WER A 0 D I S T R I B U T I O N 6RD CENTER FUSE 3 40A C180 C133 Al 1 2 R D Al 12RD C 2 1 2 1 I G N I T I O N SWITCH ACC OFF C212 AUTOMATIC SHUT DOWN A21 RELAY 12DB 8 W 1 0 2 9 F 8 20LG BK SIM 8W 7Q 1...

Page 603: ...2 Kl 13 20LB BR A142 1WG 0R A142 16D6 0R S133 A142 16D6 0R INJECTORS 3 7 A N D 9 8 W 3 0 3 S 8W 70 14 A142 1406 O R C12S A142 14D6 0R S138 8W 70 17 A142 16DG OR wmmmm 8 W 2 0 2 A142 14DB A142 A142 H...

Page 604: ...8W 3S FUEL IGNITION 8J L ENSUE BR IMJECTOR 3 INJECTOR B SI33 C154 2 A142 16DG 0R 1115 1 8 T N Kl15 18TN I I N J I 3 S D R I V E R 58 INJ 2 7 DRIVER POWERTRAIN CONTROL MODULE J958W 9 RIGHT SIDE OF DAS...

Page 605: ...TART RUN 9 DWELL SIGNAL 1 C12S F18 20LG BK S I 3 2 8W 70 13 Z12 20BK TN ZI2 18BK TN SPLICE S I AO 8 W 7 0 1 9 Z l l 16BK WT T41 20BK W T ENGINE DATA LINK CONNECTOR RIGHT SIDE OF DASH PANEL F18 20LG BK...

Page 606: ...30 34 8W 30 FUEL SGN1TION 3J L ENGINE BR JOINT CONNECTOR C i 1 STOP L A M P B E H I N D SWITCH I KNEE OUTPUT BOLSTER R I G H T S I D E O F D A S H P A N E L J958W 9 mmum can B PACK RIGHT SIDE OF ENGI...

Page 607: ...6Y PK 63 22BK PK K4 18BK LB C127 ENGINE COOLANT TEMPERATURE SENSOR 2 FRONT v OF EN6INE C152 C11G 621 206Y LB A 43 TACH 624 206Y PK 1 G3 20BK PK K4 16BK LB I SPLICE S I 3 0 8 W 3 0 3 7 K4 20BK LB 1 INT...

Page 608: ...E 8 W 3 0 3 3 ENGINE DATA LINK CONNECTOR 8 W 3 0 3 3 SPLICE S 1 1 4 8 W 7 0 6 TRANSMISSION OVERDRIVE SOLENOID 8 W 3 1 2 9 F U S E D I G N I T I O N S W I T C H O U T P U T S T A R T R U N R I G H T S...

Page 609: ...6 1 B B K 1 8 B K I 8 0 R 1 8 V T L B L B D B W T i K 7 2 0 0 R K 7 1 8 0 R S136 8 W 3 0 3 8 S137 K 6 1 8 V T W T 8 W 7 0 1 7 y K 7 1 8 0 R K 7 I 8 0 R I G N I T I O N MODULE 8 W 3 0 3 4 Kl 1 8 D G R...

Page 610: ...4 I 8 8 K L B K 4 1 8 B K L B K 4 1 8 B K L B O I80R C127 67 22HT 0R 67 20MT 0R S 2 1 0 8 W 7 0 2 8 6 7 20MT O R C H i V S S 1 J INSTRUMENT CLUSTER C13S K 7 mm h X G 7 2 0 W T O R 1 3 5 4 7 V S S S U...

Page 611: ...XHAUST DOWN PIPE SPLICE S139 8 W 3 0 3 3 Z12 14BK TN SPLICE S129 8 W 3 0 3 5 Z l l 18BK W T I K41 18BK 06 Z l l s t 4 Q 16BK I8W 70 19 WT Zll 18BK WT K4 18BK LB V n POWER D I S T R I B U T I O N CENTE...

Page 612: ...WER DISTRIBUTION CENTER f I FUSE 3 R m c m CI33 12RD Al 12RD 2 i ION I T ION SWITCi O F F j ACC 18 r r 0 F RUN START 212 6 AUTOMATIC SiUT DOWN A21 RELAY 12DB 8 W 3 0 3 9 FIB 20LG BK S114 F18 20LG BK 1...

Page 613: ...F18 20L6 BK HEATED INTAKE AIR SYSTEM RELAY 1 HEATED INTAKE AIR SYSTEM RELAY 2 M i HEATED INTAKE AIR SYSTEM on AI22 6 B K INSTRUMENT CLUSTER M I L 9 T A C H j 1 2 C2I5 G 3 2 2 B K P K T 63 2 2 B K P K...

Page 614: ...8W 30 42 8W 30 FUEL IGNITION DIESEL ENGINE BR PARK NEUTRAL POSITION SWITCH 8 W 3 1 5 ENGINE STARTER MOTOR RELAY 8 W 2 1 2 POWERTRAIN CONTROL MODULE RIGHT SIDE OF DASH PANEL J958W 9...

Page 615: ...B K 8 6 3 0 8 5 FUEL PUMP RELAY 8 W 3 0 4 8 K 5 1 2 2 D B Y L 8 7 T C18Q POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY C180 A 1 4 2 HOG O R C12S A 1 4 2 1406 O R GENERATOR 8 W 2 0 4 A142 14DB S...

Page 616: ...ERMINAL AO 6RD POWER D I S T R I B U T I O N CENTER FUSE 3 40A 1 CX8Q C133 f Al l2RD Al 12RD AUTOMATIC SHUT DOWN RELAY 8 W 3 0 4 3 I S M I T I O N SWITCH F18 20L6 BK S 1 1 4 J 8W 70 6 F18 20LG BK C133...

Page 617: ...3 14RD B K FUEL HEATER LEFT SIDE O F ENGINE C177 FUEL HEATER RELAY N E A R B R A K E M A S T E R CYLINDER F18 20LG B K C177 Z12 14BK T N Z12 1 6 B K T N S 1 4 2 8W 70 I9 FUEL SHUT DOWN RELAY N E A R B...

Page 618: ...K L B K 4 I 8 B K L B K 4 K 2 2 K 6 2 G B K 2 0 0 R 2 0 V T L B D B W T S136 8 W 7 0 I 6 INTAKE AIR TEMPERATURE SENSOR R E A R O F I N T A K E M A N I F O L D WATER IN FUEL SENSOR L E F T S I D E O F...

Page 619: ...K7 180R 67 S O I 8W 70 13 G7 20WT 0R C127 G7 20WT OR 67 22WT OR S130 K7 200R 8W 70 12 C133 67 20WT OR S 2 1 0 8W 70 28 K24 206Y BK K7 200R 67 20WT OR 24 EN6INE SPEED SENSOR 7 8V SUPPLY 47 VEHICLE SPEE...

Page 620: ...RELAY 8 W 1 1 4 C128 A61 1 6 D 6 B K FUSE BLOCK C241 i OA I mm 64 20DB Al 12RD 1 1 I G N I T I O N SWITCH ACC OFF RUN C328 JL L I C241 A21 12DB START C2121 6 212 C125 i T K51 20DB YL ASO FUEL C126 T A...

Page 621: ...rain Control Module PCM operates the overdrive solenoid by providing a ground path on circuit T60 Circuit T60 connects to PCM cavity 55 Circuit F18 supplies battery voltage to the overdrive solenoid T...

Page 622: ...INAL f AO 6 R D 8W 31 TRANSMISSION CONTROLS BR JOINT CONNECTOR POWER DISTRIBUTION CENTER FOG LAMP SWITCH 8 W 5 0 7 SPLICE S215 SPLICE S132 8 W 7 0 2 9 8 W 7 0 1 3 POWERTRAIN CONTROL MODULE R I G H T S...

Page 623: ...8W 70 2 B 4MD I sw I OUT l l C121 n ANTI LOCK BRAKE SYSTEM CONTROL MODULE L E F T F E N D E R S I D E S H I E L D Z l 18BK 0 1 0 2 8 W 1 5 3 RE R WHigL ANTI LOCK CONTROL MODULE C E N T E R O F I P t...

Page 624: ...k O F F R U N S 2 0 1 C212 8 W 7 0 2 2 S T A R T A 2 2 1 2 B K 0 R O I A22 1 2 B K O R J C24t SiO A I FUSE BLOCI i 2 4 1 LIO 22BR L6 28 29 2 S I I JOINT CONNECTOR C 1 BEHIND J K N E E B O L S T E R 2...

Page 625: ...A C K U P LAMP S W I T C H MANUAL TRANSMISSION LtO 18BR L6 o LI 18VT BK Ll 18VT U2 8W 70 8 TRAILER TOM ONLY C M i LI 18VT BK 133 Li 22VT BK C2Q8 T Ll 18VT BK 118 LIO 18BR LG LIO 18BR LG T41 18BK WT L...

Page 626: ...es 2 and 6 in the PDC and fuse 20 in the fuse block are connected directly to battery voltage and are HOT all times Fuse 14 in the fuse block is HOT when the ignition switch is the RUN Position In the...

Page 627: ...ch CLOSES Circuit G i l from the park brake switch connects to cavity 5 of the RWAL module BRAKE WARNING LAMP SWITCH INPUT Circuit G9 from provides an input to the Rear Wheel Anti Lock RWAL control mo...

Page 628: ...signals to ABS control module from left front wheel speed sensor Circuit B8 which provides the LOW signal connects to cavity 16 of the ABS control module Circuit B9 connects to cavity 3 of the module...

Page 629: ...ntact side of the relay BRAKE WARNING LAMP SWITCH INPUT Circuit G9 provides an input to the ABS control mod ule The module receives the input when either the ig nition switch is in the START position...

Page 630: ...12BK G9 22GY BK 1 G1Q1 8W 15 2 A22 12BK OR A20 18RD DB S 2 0 1 8W 70 22 INSTRUMENT CLUSTER R WARNING I LAMP I DRIVER C21S G19 22LG RD A22 12BK OR JL FUSE I BLOCK C 2 4 1 I C 9flA I I Y A20 18RD DB 20...

Page 631: ...PK S i l l 8W 70 5 STOP LAMP SWITCH 8W 33 3 V40 22WT PK C133 F32 V40 18PK 20WT DB PK V40 22WT PK V40 20WT PK mm i132 _ _ J F32 20PK DB NEAR REAR OF FUSE BLOCK C1 9 31 33 JOINT CONNECTOR BEHIND KNEE J...

Page 632: ...OINT CONNECTOR C BEHIND KNEE BOLSTER J C209 Gil 22WT BK PARK BRAKE SWITCH PTO OR 4K4 SWITCH ON TRANSFER CASE zaq7 r C407 G107 18BK GY f G107 20BK GY i y 2 Zl 18BK Zl 20BK C133 S103 G107 20BK GY 8W 70...

Page 633: ...Bl 13 i 20RD VT i 1 330 Bl 13 Bl 14 20R0 20WT VT VT i 5 C12i i Bl 13 Bl H 20RD 20WT VT VT i C133 Y Bl 13 B I H 22RD 22WT VT VT DASHED LINES INDICATE TWISTED PAIR B U 3 B114 REAR ANTI LOCK VALVE LEFT F...

Page 634: ...BR BATTERY POSITIVE TERMINAL SW 32 ANTI LOCK BRAKES 8W 32 9 POWER DISTRIBUTION CENTER 5201 8W 70 22 ANTI LOCK BRAKE SYSTEM CONTROL MODULE LEFT FENDER SIDE SHIELD J958W 9...

Page 635: ...W E R F E E D O N A B S C O N T R O L M O D U L E B 2 4 9 1 8 W T T N B 2 4 8 1 G D G WT B 1 8 B 2 4 5 2 0 V T 1 8 W T L G L G B 2 4 3 1 6 D G B K B 5 2 0 V T R D C 1 2 1 C 1 3 3 w o P R E M I U M R A...

Page 636: ...BR 8W 32 ANTI LOCK BRAKES 8W 32 11 REAR WHEEL ANTI LOCK BRAKE SENSOR ENGINE DATA LINK CONNECTOR 8 W 3 0 1 5 81 30 14 8 2 3 0 3 3 8 2 3 0 4 2 D21 20PK L E F T F E N D E R S I D E S H I E L D J958W...

Page 637: ...2 13 j hll C 2 4 J A22 12BK 0R A22 12BK OR S201 SW 70 22 20A I C241 A20 18RD DB 133 FUSE BLOCK 69 16GY BK SPLICE s i n 8 W 7 0 5 V40 20WT PK f A20 18RD DB A20 18RD DB ABS PUMP RELAY 8 W 3 2 9 C133 I G...

Page 638: ...OR C BEHIND C209 KNEE BOLSTER G107 20BK GY C133 REAR WHEEL ANTI LOCK CONTROL MODULE CENTER j OF L P G9 22GY BK 6107 22BK 6Y C216 C215 6107 I8BK GY 1 T 6107 20BK GY IGNITION SWITCH PTO Of 414 SWITCH ON...

Page 639: ...signal Circuit V32 signals to the PCM that the speed con trol switch is in the ON position The V32 circuit con nects to cavity 49 of the PCM Circuit V32 also connects to the stop lamp switch In the C...

Page 640: ...TTERY C109 17 16 15 32 31 C209 n VEHICLE SPEED 3 CONTROL SWITCH 1 OFF f f ON _ J C2Q9 5 RESUME ACCEL M t O F F O N 2 4 S108 3 Zl 20BK V32 V32 V40 22YL 22YL 22WT RD RD PK 32 22YL RD SET COAST OFF ON 4...

Page 641: ...CTOR B I FUSED I I NEAR REAR OF FUSE BLOCK C23X F32 18PK DB S2 8 8W 70 27 V30 Z l l V40 V32 L50 20DB 20BK 20WT 20YL 18WT RD WT PK RD TN C214 C214 C214 F32 V30 Z l l 18PK 20DB 20BK DB RD W T V40 V32 L5...

Page 642: ...l gauge in the instrument cluster Circuit F14 from fuse 12 in the fuse block supplies voltage to the fuel page Manual Transmission Up Shift Lamp 2 Oil Pressure Gauge 1 Oil Pressure Warning Lamp 1 Park...

Page 643: ...ning lamp MALFUNCTION INDICATOR LAMP MIL The Powertrain Control Module PCM provides ground for the MIL on circuit G3 Circuit G3 con nects to cavity 32 of the PCM When illuminated the MIL displays the...

Page 644: ...ing Lamp 8W 40 67 Brake Warning Switch 8W 40 7 Buzzer Module JW 4Q 10 Check Anti Lock Lamp 8W 40 9 Check Engine Lamp JW 40 6 Daytime Running Lamps Module 8W 40 7 11 Engine Coolant Temperature Gauge 8W...

Page 645: ...CENTER f FUSED 1 IGN SW I OUTPUT I I START RUN j i C224 F14 20L6 YL 8 J L AIRBAG CONTROL Mjfiar CENTER Of I P f FUSED 1 IGN SW 1 I OUTPUT I 1 START RUN j C232 f 14 18LG YL J S209 ACC START SWITCH C21...

Page 646: ...4BR TN 8 0L ONLY G U I 8W 15 5 ENGINE COOLANT TEMPERATURE SENSOR FRONT OF ENGINE G60 18GY DIESEL YL ENGINE ENGINE FUEL TANK LEVEL GAUGE SENDING UNIT 2 C328 3 Z l l 20BK WT Zll 16BK WT C128 Z l l 20BK...

Page 647: ...N CONTROL MODULE RIGHT SIDE OF DASH PANEL r i 32 MIL i G3 20BK PK CI2S REAR WHEEL ANTI LOCK CONTROL MODULE CENTER OF I P rBRAKE 1 warning 1 LAMP DRIVER j L 6 J J C228 G9 22GY BK 5 C212 1 I G N I T I O...

Page 648: ...SWITCH INSTRUMENT CLUSTER DAYTIME RUNNING LAMPS M O D U L E LEFT FENDER SIDE SHIELD T PARK BRAKE SWITCH SENSE I 3 1 t r C131 611 20WT BK REAR W H E E L ANT I LOCK CONTROL M O D U L E CENTER OF I P T P...

Page 649: ...I B U T I O N C E N T E R 619 20L6 RD SI4S 81 70 20 A2 12PK BK Zl 12BK g i o i 13 WARNIN6 LAMP RELAY CONTROL 8W 15 2 24 WARNING LAMP I RELAY CONTROL I s t i o 8W 70 5 A N T I L O C K B R A K E S Y S...

Page 650: ...WITCH on TRANSFER CASE 619 20L6 RD Zl 20BK C407 1 S103 8W 70 2 6107 18BK 6Y C106 Zl 18BK mm 8W 15 3 6107 20BK 6Y CI33 T 4WD I SWITCH OUTPUT 4 WARN1N6 LAMP I DRIVER 2 n REAR WHEEL ANTI LOCK CONTROL MOD...

Page 651: ...F33 20PK RD fT v 1 ISA 13 f El 20TN 0R f U O 1 C241 A7 12RD BK 5 5A l l E2 220R C209 E2 2 2 0 R f HEATER SWITCH OR HVAC SWITCH 8 W 4 2 3 8 W 4 2 4 OVERHEAD CONSOLE RADIO 8W 47 8 8 W 4 7 4 E2 220R E2...

Page 652: ...N C 2 2 2 S 2 1 1 8W 70 28 v J t J L B I 85 i 634 18RD GY 634 IBRD GY L39 20LB 87A L _ _ _ j 30 Z3 18BK OR S 1 4 7 8W 70 21 T U R N S I G N A L A N D H A Z A R D F L A S H E R S W I T C H 8 W 5 2 3 S...

Page 653: ...S R I 1 S103 8 W 7 0 4 Zl 12BK S1 S 56 Zl 18BK 8 W 1 5 2 S208 8 W 7 0 2 7 C 624 206Y PK 13S F14 20LG YL T R A N S M I S S I O N OVERDRIVE SWITCH 8 W 3 1 2 654 220R BK C108 127 2 LOW WASHER F L U 1 P L...

Page 654: ...also a 20 amp fuse located in cavity 5 of the fuse block dedicated for the cigar lighter When the operator depresses the lighter contacts inside of the lighter element close and voltage flows through...

Page 655: ...50A S I 3 40A POWER DISTRIBUTION CENTER C18Q Al 12RD C133 C212 Al 12RD f 1 I G N I T I O N SWITCH A3 12BK WT CHAR LIGHTER C236 n ri s ts o s F30 18RD 0R S21S A7 12RD BK 2 8W 70 29 1 m i I O A A I FUS...

Page 656: ...2 6 L F 3 1 20VT 86 I f H I 87 85 HORN RELAY J C180 C211 HORN SWITCHES WITHOUT HIGH LINE CLUSTER X3 X2 22BK 1806 RD RD X2 18D6 RD 133 X3 22BK RD X3 20BK RD GROUND JOINT NEXT TO PDC C123 WITH POWER 6R0...

Page 657: ...e ries only two on the heater only vehicles 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 pas...

Page 658: ...r 8W 42 4 Blower Motor Heater Only 8W 42 3 Blower Motor Resistor Heater Only 8W 42 3 Blower Motor Resistor A C Heater 8W 42 4 Fuse 1 PDC 8W 42 5 Fuse 2 Fuse Block 8W 42 3 4 Component Page Fuse 2 PDC 8...

Page 659: ...Y P O S I T I V E TERMINAL JOINT CONNECTOR C BEHIND BOLSTER KNEE f FUSED 1 1 HEADLAMP1 1 SWITCH I OUTPUT i i i C2Q9 E2 220R C227 f FAN SWITCH OFF ILLUMINAT ION C227 6 3 4 7 HEATER SWITCH FUSE BLOCK J...

Page 660: ...5 C182 1 C 9 0 1 8 L 6 W T A C H I G H f 0 C112 C 2 0 1 8 B R P R E S S U R E S W I T C H N E A R A C C O M P R E S S O R 2 CJ35 A c L O W r i I 27 P O W E R T R A I N R E Q U E S T CONTROL I S I G N...

Page 661: ...220R OVERHEAD CONSOLE f FUSED 1 H I HEADLAMP1 1 I SWITCH J J OUTPUT E2 220R RADIO 8 W 4 7 2 m E2 220R 8 W 4 7 4 r TTjqT l C21S INSTRiMEWT H E A D L A H P 1 4 Uv E 2 2 2 0 R CLUSTER I SWITCH I t l f U...

Page 662: ...8W 42 6 BATTERY P O S I T I V E TERMINAL IW 42 AIR CONDmONINtyHEATER BR POWER C127 J958W 9...

Page 663: ...ovide 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 1 of the 13 way connector Cir...

Page 664: ...m 40A 1 CENTER A2 12PK IK S146 8W 70 20 A2 12PK BK CI33 A2 12PK BK C180 Al 12RD FUSE BLOCK C24I C241 C133 A21 12DB I Al 12RD C212 D 4 ACC OFF RUN I TART ACC OFF R U N S T A R T C 2 1 2 12 i 1 5 A I 1...

Page 665: ...8BK LB LB I I I A JL A I R B A G CONTROL MODULE CENTER OF I P CCD BUS 1 Dl I8VT BR i CCD BUS R 3 AIRBAG WARNING LAMP DRIVER 7 I 02 I8WT BK 4 I I K f 6 I f i C223 1 C223 i A I R B A G A B S DATA LINK C...

Page 666: ...Circuit M l from the IOD fuse fuse 17 in the fuse block powers the glove box lamp A case grounded switch in series after the lamp CLOSES when the glove box door is OPENED The switch completes a page H...

Page 667: ...lamps or headlamps are ON the headlamp switch connects circuit G16 from the driv ers side door jamb switch to circuit G26 Circuit G26 connects to the buzzer module and the key in switch Circuit G16 fr...

Page 668: ...01 8W 15 6 fen I G N I T I O N SWITCH C241 M50 22YL RD f j 54 53 TIME DELAY RELAY 17 55 C241 LAMP 1 FUSE BLOCK I C241 Ml 20PK Mi 18PK C 4 1 0 C 4 1 0 i v y 2 CARGO LAMP 1 Mi 18PK S205 M3 20PK OB M3 20...

Page 669: ...B WT FUSE BLOCK C 2 4 1 I s I I 24l r F12 22DB WT 20 F12 20DB WT F12 20DB WT G16 22BK LB 616 22BK LB 22 616 22BK LB 21 19 C2Q8 F12 22DB W T JOINT CONNECTOR C BEHIND KNEE BOLSTER 12 13 C209 1 14 C209 6...

Page 670: ...AD C206 5 K E Y I N SWITCH IGNITION SWITCH C213 C241 I 1 7 ISA FUSE BLOCK l C241 Ml 18PK S20S 626 G26 18LB 18LB F12 20DB WT 8W 70 25 Ml 20PK 1 218 SEAT BELT WARNING SW 7 1 KEY IN FUSED IGN SW BUZZER O...

Page 671: ...NNECTOR 8 W 3 2 1 1 S204 8M 70 24 A7 1 2 R D BK Ml 20PK RADIO 8 W 4 7 2 8 W 4 7 4 C231 r 1 Ml 20PK f f RADIO CHOKE 8 W 4 7 5 Ml 20PK 1 Ml 18PK f 10 17 ISA C241 1FUSE BLOCK C231 1 I C241 C231 Ml 18PK M...

Page 672: ...C212 A2 12PK BK 5 2 0 1 8W 70 22 4 m ACC OFF R U N START C212 3 A22 12BK 0R 15 FUSE BLOCK 10A A22 12BK 0R JOINT CONNECTOR C BEHIND KNEE BOLSTER LIO 22BR L6 1 LtO 22BR LG t LIO 22BR LG X SPLICE S117 8...

Page 673: ...ackages except for the 8 0L On the 8 0L the G14 circuit connects to cavity 36 of the PCM Circuit G85 is connected from the message center to the PCM and is used for the WAIT TO START lamp The WAIT TO...

Page 674: ...8TN OR G85 180R BK CX33 G86 20TN OR G85 20OR BK MESSAGE CENTER I 1 C241 AIRBAG r n I OUTPUT I I START RUN i MODULE CENTER OF I P I TRANS TRANS OD OD I LAMP LAMP l C232 31 I 36 C135 F14 18LG YL F14 18L...

Page 675: ...rcuit Ml This is the Ignition Off Draw IOD circuit and is protected by a 15 amp fuse located in cavity 17 of the fuse block Circuit Z2 provides ground for the radio choke When the radio supplies power...

Page 676: ...47 2 8W 47 AUDIO SYSTEM STANDARD RADIO BR BATTERY P O S I T I V E TERMINAL f AO 6RD 5 FUSED 1 HEADLAMP iSW OUTPUT 4 PARK LP SW OUTPUT 6 FUSED ION SW OUTPUT START RUN I J958W 9...

Page 677: ...56 20DB RD C240 X54 20VT C229 C230 X56 20DB RD C229 LEFT REAR SPEAKER 1 2 C306 X57 X51 18BR 18BR LB YL C202 X57 X51 20BR 20BR LB YL 4 5 6 2 RIGHT REAR SPEAKER gax4 CD 2 C302 X58 X52 18DB 18DB OR W T C...

Page 678: ...AUDIO SYSTEM BR PREMIUM STEREO RADIO BATTERY P O S I T I V E TERMINAL f AO 6RD POWER D I S T R I B U T I O N CENTER 5 FUSED HEADLAMP SW OUTPUT 4 PARK LP SW OUTPUT FUSED B 6 FUSED IGN SW OUTPUT START...

Page 679: ...R RD X56 18DB RD X57 X51 X58 X52 18BR 18BR 18DB 18DB LB YL OR WT C240 C202 X54 20VT C230 C229 X56 20DB RD X57 X51 X58 X52 20BR 20BR 20DB 20DB LB YL OR WT C230 C229 4 12V OUT 1 5 2 7 3 C330 n PREMIUM S...

Page 680: ...DOOR SPEAKER RADIO 8W 47 5 RIGHT DOOR SPEAKER C3 3 22 18BK LG 1 X53 18DG X55 18BR RD 22 18BK LG X13 18BK RD 8302 Xi3 18BK RD 8W 70 30 X13 18BK RD X51 X57 X52 X58 20BR 20BR 20DB 20DB YL LB WT OR T j C2...

Page 681: ...3 20DG T X53 1 801 C201 X53 180G 5 3 0 4 S305 8W 70 31 C240 X55 18BR RD 8W 70 31 X53 1806 2 314 22 18BK L6 fZor LEFT DOOR TWEETER 22 18BK L6 S2I2 8W 70 28 22 18BK L6 G202 8W 15 7 22 18BK L6 C202 X56 2...

Page 682: ...ground for the reading lamps and dome lamp The M2 circuit supplies ground for the overhead console lamp in two ways One way is through the door jamb switches Circuit M2 connects to the door jamb switc...

Page 683: ...0A 8W 70 21 C180 C133 Al 1 2 R D A7 12RD BK Al 12RD E2 200R JOINT CONNECTOR A NEAR REAR OF FUSE BLOCK t T a r k 1 I LAMP 6 Lv OUTPUT J L7 20BK YL C209 E2 220R C338 E2 220R JOINT CONNECTOR C BEHIND KNE...

Page 684: ...M50 22YL RD C241 M2 22YL W2 20YL 2 I 21 20BK OR I 5206 Ol8W 70 26 Z3 12BK OR C204 caoi 5 C206 C204 I CARGO OFF PARK HEADLAMP SWITCH HEAD C206 1 6 M2 22YL 54 53 TIME DELAY RELAY FUSE BLOCK Ml 20PK 241...

Page 685: ...TEMPERATURE SENSOR 2 C114 G31 18VT LG G32 18BK LB JOINT CONNECTOR A NEAR REAR OF FUSE BLOCK 217 C133 WITHOUT OVERHEAD CONSOLE Zll 20BK WT C208 631 22VT LG G32 22BK LB it L7 W 0 18BK CLEARANCE YL LAMPS...

Page 686: ...supplies power to the contact side of fog lamp 1 relay Circuit L7 supplies power to the coil side of fog lamp 1 relay Circuit L72 connects to the coil side of the relay and to ground on circuit Z3 thr...

Page 687: ...CENTER C131 A3 12RD LS S118 A3 12RD LG A3 12RD L6 A3 12RD L6 8W 70 8 133 A3 I2RD LG S203 DAYTIME RUNNING LAMPS ONLY L20 16LG WT HEADLAMP DIMMER SWITCH PART OF MULTI FUNCTION SWITCH C2I0 21 8W 70 23 L...

Page 688: ...W 7 0 2 S147 8W 70 21J S 2 i l RELAY 2 TOP OF BRAKE PEDAL ARM Z3 18BK OR SPLICE S215 8 W 7 0 2 9 8W 70 28 G34 18RD GY G34 18RD GY I H I G H K A M ii ffST ii fZ BMJim RUNNING INSTRUMENT CLUSTER r _ j...

Page 689: ...22BR LG REAR WHEEL ANTI LOCK CONTROL MODULE CENTER OF l P JOINT C209 CONNECTOR C BEHIND KNEE BOLSTER r i I PARK BRAKE I SWITCH I I SENSE C228 Gil 22WT BK r 1 PARK I SlKH 1 M i I SENSE CLUSTER 10 i z i...

Page 690: ...C2IB 634 18RD GY S2I1 8W 70 28 C113 C131 FUSED B HEADLAMP SW OUT LOW 5 PARK BRAKE SW SENSE 3 HEADLAMP SW OUT HIGH Gil 22WT BK T L4 16VT WT f SPLICE S107 8 W 5 0 3 T Gil 20WT BK FUSED IGN SW OUTPUT RU...

Page 691: ...7 18BK YL C338 12 l J OVERHEAD CONSOLE LEFT OUTBOARD CLEARANCE LAMP ROOF L7 18BK YL C335 2 C33S 1 LEFT OUTBOARD I D E N T I F I C A T I O N LAMP ROOF RIGHT OUTBOARD IDENTIFICATION LAMP L7 18BK YL RIGH...

Page 692: ...ed Stop Lamps CHMSL and multi func tion switch The multi function switch supplies power to the L62 and L63 circuits Circuit L62 powers the right stop lamp Circuit L63 powers the left stop lamp GROUND...

Page 693: ...8BK YL sy 70 3 C128 CONNECTOR A 111 r 1 C 2 M L I NEAR REAR O F FUSE BLOCK 17 I83K YL L7 1 8 B K YL 8 70 35 L7 J 8 B K Y L 1 2 C 4 1 7 LEFT LICENSE LAMP RIGHT LICENSE LAMP 417 L7 20BK YL L7 18BK YL L7...

Page 694: ...4 2 L62 18BR PK C331 C329 L62 18BR PK L7 18BK YL S315 8W 70 35 L62 18BR PK L62 18BR PK 0 Z 1 3 18BK S 4 i l 8W 70 37 ZI3 18BK Z13 188K Z13 18BK S312 8W 70 34 RIGHT T A I L STOP AND TURN SIGNAL LAMP L6...

Page 695: ...9 28 I I BEHIND KNEE BOLSTER A22 12BK 0R LIO 22BR LG B R S 2 0 1 8W 70 22 A22 12BK OR C 2 4 1 L i J C 2 4 1 l 5 F J M 10A PLOCK LI 18VT BK I S U 7 C126 8W 70 8 LI 18VT BK LI TRAILER 18VT TOM BK ONLY P...

Page 696: ...29 LI I8VT BK 1 4 C 4 i i LEFT BACK UP LAMP C416 419 RIGHT BACK UP LAMP C418 S312 S 4 0 1 C333 I Z13 1 8 B K Z13 18BK 8W 7G 34 8W 70 37 TRAILER TOW ONLY TRAILER TOW ONLY C329 Z13 18BK Z13 18BK S 4 0 2...

Page 697: ...S 2 0 3 8W 70 23 BR F32 20PK DB 13 C228 im CENTER B i OF I P i _i REAR WHEEL ANTI LOCK CONTROL MODULE A3 12RD LG C24X 20 Euai 15A BLOCK 241 F32 18PK DB C23JL f K C23I 4 JOINT CONNECTOR B NEAR REAR OF...

Page 698: ...EAR OF ROOF LINER C302 L50 18RT TN 13 18BK 0R G301 S207 8W 15 8 8H 70 26 L50 T8WT TN TURN SIGNAL AND HAZARD FLASHER SWITCH PART OF MULTI FUNCTION SWITCH 8 W 5 2 3 C30B 13 18BK OR SEAT BELT SWITCH 8 W...

Page 699: ...2RD BK C20B f 1 mm OFF PARK 9 HEADLAMP SWITCH C206 I JOINT CONNECTOR A I Cat i 1 C217 L7 18BK YL L7 18BK YL f f 6 L7 20BK YL i NEAR R E A R O F FUSE BLOCK C118 L7 I8BK YL L7 18BK YL L7 I8BK YL S3I4 8W...

Page 700: ...f L7 18BK YL f 1 2 C421 C403 Z l 3 18BK Z13 18BK 1 LEFT REAR FENDER LAMP C404 422 f L7 18BK YL 422 4 0 4 Zi3 18BK L7 18BK YL RIGHT REAR FENDER LAMP Z13 18BK C40S S406 L7 i 8 B K Y L f L 7 18BK YL 8W 7...

Page 701: ...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 batte...

Page 702: ...3 RIGHT PARK AND TURN SIGNAL LAMP S1Q8 LEFT PARK AND TURN SIGNAL LAMP 8W 70 4 C l i l f Q N D C123 C112 w o I Zl 12BK HIGH LINE CLUSTER Zl 12BKy f j4 3 j Z1 18BK Zl 1 J MBK GROUND JOINT L61 18LG TN C...

Page 703: ...241 L L61 20LG YL I LSI 18LG TN S123 L60 18TN BKH L60 18TN BK 1 16 1 L L61 20LG YL X LSI 18LG YL 11 L19 18BK WT 14 HAZARD SWITCH 2 1 0 j r A 1 L i _ jl r Ahazard Vjf i i q p J TURN RIGHT TURN LEFT 8W...

Page 704: ...l 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...

Page 705: ...T o f f J_Z DELAY 1 V3 18BR WT V9 18WT BK V3 18BR WT V3 18BR WT C O J V i 7 18DG V3 18BR WT 2 WASHER 1 v N I HI S W I T C V ty I D JJJY OFF 0 N J 2 4 3 V8 18VT V6 16DB B K S 2 0 2 ON J C210 V10 18BR 8...

Page 706: ...YL INTERMITTENT WIPER SWITCH 8W 53 2 PARK GND L _ _ 5 _ J C 2 i 9 INTERMITTENT I WIPER CONTROL I M O D U L E I TOP REAR CENTER OF I P O Q 7 INTERMITTENT WIPER M O T O R n Zl 18BK i B U S 8W 70 7 WIND...

Page 707: ...ARK or ON position Ground for the coil side of the relay is supplied on circuit Zl When the relay is energized the contacts in the re lay CLOSE connecting circuits A6 and L76 Circuit L76 connects from...

Page 708: ...W 70 8 Ct29 A6 14RD TN SPLICE SPLICE S316 S313 8 W 7 0 3 5 8 W 7 0 3 4 L63 18DG RD 176 14BK OR A6 14RD TN SPLICE S106 8 W 7 0 3 SPLICE S108 8 W 7 0 4 L76 14BK 0R SPLICE S315 S W 7 0 3 5 L63 18DG RD 33...

Page 709: ...switch to the Q26 circuit The Q26 circuit connects from the mas ter switch to the right window switch A bus bar in ternal to the right switch passes the voltage through the switch to circuit Q22 Circ...

Page 710: ...3 8W 70 29 F21 14TN S 2 0 1 BM 70 22 A22 12BK 0R F21 14TN A22 12BK OR FUSE BLOCK C241 I CB1 1 30A I 2 4 1 LEFT POWER WINDOW SWITCH F2I 14TN LEFT RIGHT UP DOWN UP DOWN C3IS V F2i 14TN LEFT POWER WINDO...

Page 711: ...INDOWS r C212 4 A2 12PK BK I G N I T I O N SWITCH ACC OFF RUN sM START S 2 I 4 8W 70 29 F21 14TN C212 3 8W 60 3 S20I 8W 70 22 A22 12BK 0R F21 14TN A22 12BK OR FUSE BLOCK C241 1 CB1 3QA S C241 QJ6 14BR...

Page 712: ...to the door mo tors on the unlock side Grounding for the UNLOCK function is provided by the P33 circuit The P33 circuit goes back to the right door switch LOCK side and passes through the internal bu...

Page 713: ...T I O N CENTER 8W 70 21 RIGHT DOOR LOCK SWITCH 8 W 6 1 3 F35 16RD c m F35 IBRD C207 F35 16RD F35 IBRD S21G F35 MRD 8W 70 30 3 C315 Z3 14BK 0R 5 i S306 8W 70 32 Z3 14BK 0R 2 C315 UNLOCK t LOCK C315 C2...

Page 714: ...5 MRD C207 F35 16RD 3 C325 P36 16PK YT 2 l f P35 160R VT F35 16RD C239 F35 16RD F35 IBRD S216 8W 70 30 C325 UNLOCK I LOCK S310 C32S P 3 4 16PK BK W 70 33 P 3 4 16PK BK P34 16PK BK S309 CT 70 33 y P33...

Page 715: ...ground is passed through circuit P73 When the left door mirror RIGHT movement is selected the power and ground are reversed When the switch is moved to the RIGHT position and mirror movement UP is se...

Page 716: ...4BK 0R i 1 G302 8W 15 8 P75 P72 20DB 20YL WT BK 20YL PK P70 20WT P72 20YL BK C201 P72 20YL BK f 5 20DB WT C240 VERTICAL A 3 P72 20YL BK O T I P71 20YL LT x RT HORIZONTAL C201 C310 P74 20DB C201 P70 20...

Page 717: ...its 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 P1...

Page 718: ...C431 f 23 14BK OR J C303 23 14BK m i 6301 8 W I 5 8 POWER SEAT SWITCH AFT f VERT UP VERT DOWN 4 4 Ifwd t L h X R AR UP HEAR DOWN FRTi UP FRT DOWN C431 P17 14DB RD P15 14YL LB P l l 14YL WT P13 14RD W...

Page 719: ...12 S130 8W 70 12 S131 8W 70 13 S132 8W 70 13 S133 8W 70 14 S134 8W 70 14 S135 8W 70 15 S136 8W 70 16 S137 8W 70 17 S138 8W 70 17 S139 8W 70 18 S140 8W 70 19 S141 8W 70 19 S142 8W 70 19 S143 8W 70 20...

Page 720: ...R SWITCH 8 W 5 2 3 PTO OR 4X4 SWITCH 8 W 3 1 3 SPLICE S409 8 W 7 0 3 9 C106 Zl 18BK Zl 20BK C1Q5 Zl 1 8 B K Zl 20BK I I GROUND GROUND jam L _ _ I fC123 Zl 18BK 5 1 0 3 Zl 18BK Zl 18BK Zl 20BK RIGHT PA...

Page 721: ...5 L7 18BK YL C128 SPLICE S314 L7 I8BK YL L 7 18BK YL 8 W 7 0 3 5 C133 FOG LAMP RELAY 1 L7 20BK YL L 7 20BK YL 8 W 5 0 6 JOINT CONNECTOR A PARK I L7 18BK YL L7 18BK YL 4 SWITCH C133 C217 S106 L7 20BK...

Page 722: ...8 W 1 1 4 8W 54 2 Zl 20BK Zi 18BK Zl 18BK S H I r 1 I I GND I _ J J DAYTIME RUNNING LAMPS MgPULE 1M b r 8W 15 21 VACUUM SENSOR 8W 32 5 8W 32 12 BRAKE WARNING SWITCH 8W 32 5 8W 32 12 G9 20GY BK HSfi G...

Page 723: ...18RD DB A20 18RD DB HOT AT ALL T I M E S 4 FUSE BLOCK s on 4 1 20A I C 2 4 I A20 18RD DB C133 A20 18RD DB A20 18RD DB A20 18RD DB VACUUM SENSOR 8 W 3 2 1 2 ABS PUMP RELAY 8 W U 6 8 W 3 2 9 C133 C2Q9...

Page 724: ...W 1 1 6 ENGINE STARTER MOTOR RELAY 8 W 1 1 7 C125 T 4 0 1 2 B R C119 T 4 0 1 2 B R S113 D I E S E L E N G I N E O N L Y T 4 0 1 2 B R T 4 0 1 2 B R T 4 0 1 2 B R FUEL SHUT DOWN RELAY 8 W 3 0 4 5 ENGI...

Page 725: ...Zl Zl 14BK 12BK 8W 15 4 G105 8W 15 4 Zl 18BK C183 NO CONNECTION Zl 18BK INTERMITTENT WIPER MOTOR 8 W 5 3 3 Z13 12BK Z13 16BK WITH TRAILER TOW Zl 16BK Zl Zl 16BK 12BK G106 8W 15 4 SPLICE S311 8 W 7 0 2...

Page 726: ...ER TOW ONLY DAY NIGHT MIRROR 8 W 4 4 7 SPLICE S313 8 W 7 0 3 4 SPLICE S203 8 W 7 0 2 3 DAYTIME RUNNING LAMPS MODULE FUSED e 1 B S C131 A3 12RD LG C133 A3 12RD LG A 3 12RD LG S118 HOT AT ALL TIMES I 1...

Page 727: ...c i a s PARK NEUTRAL POSITION SWITCH 8 W 3 1 5 BACK UP LAMP SWITCH 8W 31 S DRL ONLY MANUAL TRANSMISSION M Y T I M E RUNNING LAMPS MODULE HIGH BEAM INDICATOR LAMP HEADLAMP SWITCH 5 OUTPUT c m LEFT HEA...

Page 728: ...8W 15 7 LEFT PARK AND TURN SIGNAL LAMP 8 W 5 0 5 S123 L61 18LG TN CI33 L61 20LG YL L 6 1 18LG YL TURN SIGNAL AND HAZARD SWITCH 8 W 5 2 3 POWERTRAIN CONTROL MODULE INJECTOR 4 9 15 DRIVER INJECTOR 5 8...

Page 729: ...R COS S12G K158 20L6 BK 8 0 ENGINE ONLY S127 Kl14 20YL WT 8 0 ENGINE ONLY S128 Kl16 20WT DB 8 0 ENGINE ONLY K158 18LG BK K158 18LG BK Kl14 18YL WT Kl 14 18YL WT Kl16 18WT DB Kl16 18WT DB INJECTOR 7 8...

Page 730: ...8W 70 12 8W 70 SPLICE INFORMATION B R...

Page 731: ...GAS RECIRCULATION SOLENOID 8 W 3 0 1 7 8W 30 28 8W 30 36 EVAP PURGE SOLENOID 8 W 3 0 1 7 8 W 3 0 2 6 8 W 3 0 3 6 67 20WT 0R VEHICLE SPEED SENSOR I SIGNAL J INSTRUMENT CLUSTER VEHICLE SPEED SENSOR 8 W...

Page 732: ...9L 5 2L AND 5 9L ENGINES ONLY A142 14DG 0R 5 2L 5 9 AND 8 0L ENGINES ONLY A142 14DG 0R INJECTOR 8 8 W 3 0 3 2 8 0L ENGINE ONLY S133 GAS ENGINES ONLY A142 14DG 0R C125 SPLICE S135 8 W 7 0 1 5 A142 14D...

Page 733: ...42 16DG 0R A142 16DG 0R A142 16DG 0R A142 14DG 0R A142 14DG 0R 8 0L ENGINE ONLY INJECTOR 8 8 W 3 0 2 3 8 W 3 0 3 1 5 2L 5 9L AND 8 0L ENGINES ONLY A142 16DG 0R 3 9L 5 2L AND 5 9L ENGINES ONLY S135 GAS...

Page 734: ...N SENSOR 8 W 3 0 3 7 K4 18BK LB K4 18BK LB K4 18BK LB K4 16BK LB DIESEL ONLY K4 18BK LB K4 18BK LB K4 18BK LB GAS ENGINES ONLY K4 18BK LB C135 K4 20BK LB f 20BK LB DIESEL ENGINE ONLY 20BK LB K4 20BK L...

Page 735: ...K6 18VT WT K6 20YT WT cos POWERTRAIN CONTROL MODULE 5V S Q 7 GAS ENGINES ONLY S P L I C E S 1 3 3 8 W 7 0 1 4 S P L I C E S 1 3 5 8 W 7 0 1 5 A142 16DG 0R OUTPUT ASD 57 RELAY OUTPUT A142 14DG 0R A142...

Page 736: ...2 Zl2 16BK TN Z12 16BK TN ENGINE STARTER RELAY 8 W U 7 8 W 2 1 2 Z12 20BK TN T41 22BK WT MANUAL TRANSMISSION ONLY ZI2 20BK TN Z12 20BK TN DIESEL ENGINE ONLY Z12 18BK TN Z12 14BK TN Z12 20BK TN 8 0L EN...

Page 737: ...INES ONLY 1 RIGHT HEATED OXYGEN SENSOR 8 W 3 0 2 0 8W 3Q 29 8W 30 39 ENGINE STARTER MOTOR _ RELAY 8 W 1 1 7 8 W 2 1 2 POWERTRAIN CONTROL MODULE I PARK NEUTRAL I C135 I POSITION 0 I SWITCH 3 0 ri SENSE...

Page 738: ...ATER RELAY 8 W 3 0 4 5 A12 14RD TN AI2 200R DIESEL ONLY Q O HEATER W FEED FUEL SHUT DOWN RELAY 8 W 3 0 4 5 A18 10RD BK S 1 4 5 DIESEL ONLY AI8 16DB rrlFb FUEL SHUT DOWN FEED HOT AT ALL TIMES I 1 1 T U...

Page 739: ...ISTRIBUTION CENTER A7 I2R0 BK C180 C133 A7 12RD BK A7 12RD BK SPLICE S 2 0 4 8 W 7 0 2 4 S 1 4 8 AO 20BK A15 16BK C119 A 1 5 16BK C180 BATTERY P O S I T I V E TERMINAL 8 W 2 0 8 8 W 2 0 4 POWER DISTRI...

Page 740: ...0R S 2 0 1 A22 12BK 0R A22 12BK 0R FUSE BLOCK r i f C 2 4 1 F2 30A CB1 30A 14 20A 15 10A 16 15A J INTERMITTENT WIPER MOTOR 8 W 5 3 3 INTERMITTENT WIPER CONTROL MilULE IGNITION SWITCH OUTPUT ACC RUN C2...

Page 741: ...5 0 2 HOT AT ILL T I M E S 4 FUSE 8 I WER 4 0 A I DISTRIBUTION C180 A3 12RD LG C133 A3 12RD LG CENTER A3 12RD LG A3 12RD LG F32 18PK DB C241 1 L20 16LG WT L2 16LG P 20 FUSE BLOCK Q 5 A I 1 C241 A3 12...

Page 742: ...ON POWER OVERDRIVE SEAT SWITCH SWITCH 8 W 3 1 2 8 W 6 3 2 E2 200R HEADLAMP SWITCH L7 20BK YL C206 f 4 1 OFF PARK HEAD F33 20PK RD 18 ISA C241 SPLICE S 1 4 7 8 W 7 0 2 1 A7 12RD BK C206 9 El 20TN 0R 1...

Page 743: ...R SWITCH 8 W 6 2 2 U B 1 1 c FUSED 1 T j 6 B I I C231 J 8 FUSED B Ml 18PK Ml 20PK Ml 18PK Ml 20PK Ml 20PK S205 Ml 18PK Ml 20PK SPLICE S 3 2 0 8 W 7 0 3 7 Ml 20PK Ml 18PK Ml 20PK C133 Ml 20PK Ml 20PK C...

Page 744: ...S215 i 8W 70 29 FOG LAMP SWITCH 8 W 5 0 7 INTERMITTENT WIPER COOTiOL MOOilLE c m GND I Z3 20BK 0R Z3 20BK 0R Z3 12BK 0R Z3 20BK 0R Z3 20BK 0R Z3 20BK 0R L50 18WT TN C3Q8 L50 18WT TN L50 18WT TN C202 L...

Page 745: ...CONNECTOR 8 W 3 2 1 1 C133 f Zll 18BK WT SPLICE 5118 8W 70 7 AIRBAG CONTROL MODULE FUSED IGNITION SWITCH OUTPUT START RUN C232 MESSAGE CENTER FUSED IGNITION SWITCH OUTPUT START RUN 3p C224 FUSED IGNIT...

Page 746: ...7 20WT 0R SPLICE S131 8 W 7 0 1 3 G34 18RD 6Y SPLICE S121 8 W 7 0 9 634 634 18RD 18RD GY GY DAYTIME RUNNING LAMPS MODULE c m mm BEAM C133 G34 2 0 R D G Y f 2 1N0TcTT0R I I AMP I LAMP LEFT DOOR SPEAKER...

Page 747: ...POWER WINDOW SWITCH 8 W 6 0 3 F2I 14TN C207 C239 F21 14TN F21 14TN HOT I N RUN ONLY 4 FUSE BLOCK F21 14TN TC I m 3M i S 2 1 4 F2t 14TN I C 2 4 1 CIGAR LIGHTER i 8 W 4 1 2 POWER OUTLET PTO 8 W 4 1 2 S...

Page 748: ...12BK TN BLOWER MOTOR 8 W 4 2 3 8 W 4 2 4 BLOWER MOTOR RESISTOR 8 W 4 2 3 8 W 4 2 4 C183 NO CONNECTION f 1 2 18YL C133 M2 20YL S218 M2 20YL C202 M2 20YL M2 20YL DOME LAMP 8 W 4 4 3 JOINT CONNECTOR A I...

Page 749: ...PK CARGO LAMP 1 8 W 4 4 3 Ml 18PK CARGO LAMP 2 8 W 4 4 3 X53 18DG X53 18DG RADIO 8 W 4 7 5 C 2 0 1 X53 20DG S 3 0 4 X53 18DG X53 18DG LEFT DOOR TWEETER 8 W 4 7 7 LEFT DOOR SPEAKER 8 W 4 7 6 X55 18BR R...

Page 750: ...18BK 0R S306 POWER MIRROR SWITCH 8 W 6 2 2 Z3 14BK OR 0 3 0 2 8W 15 8 RADIO 8 W 4 7 5 X54 20VT C240 X54 18VT 5307 X54 18VT X54 18VT RIGHT DOOR TWEETER 8 W 4 7 7 RIGHT DOOR SPEAKER 8 W 4 7 6 RADIO 8 W...

Page 751: ...3 160R BK RIGHT FRONT DOOR LOCK MOTOR 8 W 6 1 3 C207 C239 P34 16PK BK P34 16PK BK LEFT FRONT DOOR LOCK MOTOR 8 W 6 1 3 P34 16PK BK RIGHT DOOR LOCK SWITCH 8 W 6 1 3 S310 P34 16PK BK P34 ISPK BK RIGHT F...

Page 752: ...3 12BK Z13 12BK C333 Z13 18BK C329 Z13 18BK TRAILER TOW I CONNECTOR 8 W 5 4 2 SPLICE 84 i 8 W 7 0 3 7 SPLICE S 4 0 2 8 W 7 0 3 7 SPLICE S I I 8W 70 8 WITH TRAILER TOW LI 18VT BK C331 LI I8VT BK CT2S L...

Page 753: ...W 5 1 2 LEFT LICEWS L7 18BK YL LANP 8 W 5 I 2 SPLICE S40S 8W 70 38 128 LS2 18BR PK TRAILER TOW CONNECTOR 8 W 5 4 2 C331 L82 18BR PK f L62 18BR PK C133 L62 18BR PK L62 18BR PK S315 C329 L62 18BR PK L 6...

Page 754: ...NTIFICATION LAMP 8 W 5 0 1 0 CENTER IDENTIFICATION LAMP 8 W 5 0 I O Z4 I8BK S318 Z4 18BK Z4 22BK Z4 18BK S319 A L7 18BK YL G304 Z4 18BK Z4 18BK JOINT CONNECTOR A r PARK LAMP I SWITCH OUTPUT I RIGHT OU...

Page 755: ...Z13 18BK S4 I Z13 18BK Z13 18BK LEFT T A I L STOP AND TURN SIGNAL LAMP 8 W 5 1 3 RIGHT BACK UP LAMP 8 W 5 1 5 Z13 18BK C329 Z13 18BK S 4 0 2 Zl3 18BK Z13 18BK SPLICE S312 8 W 7 0 3 4 RIGHT T A I L STO...

Page 756: ...7 18BK YL C405 L7 18BK YL Z13 18BK SPLICE S312 8 W 7 0 3 4 SPLICE S 3 1 4 8W 70 3S f L7 18BK YL Z13 18BK Z13 18BK i i LEFT FORWARD FENDER LAMP 8 W 5 1 9 I RIGHT FORWARD FENDER LAMP 8 W 5 1 9 C 4 0 4 L...

Page 757: ...BR 8W 70 SPLICE INFORMATION 8W 70 39 C105 Zl 20BK SPLICE S103 8 W 7 0 2 Zl 20BK LEFT FOG LAMP 8 W 5 0 7 S 4 0 9 Zl 20BK Zl 20BK RIGHT FOG LANP 8W 50 7 J958W 9...

Page 758: ...u v v u u a 8 W 8 0 P 4 C127 8W 80 9 C171 U V V U U T T 8 W 8 N P 4 C128 8W 80 10 C172 U V V O U a 8W 80 P5 C129 8W 80 10 C173 U V V U U CO C130 8W 80 10 C174 U V V U U CO C131 8W 80 10 C175 U V V U U...

Page 759: ...C417 awfin51 8W 80 40 C418 2tt C C Z 8 W 8 0 4 0 C419 2llt 308 Q A _Qn_ n r nn 8W 80 51 8W 80 37 C405 8W 80 37 C406 8W 80 37 C407 8W 80 37 C408 8W 80 38 C409 SW 80 38 C410 8W 80 38 C411 8W 80 38 C412...

Page 760: ...TPUT LOW BEAM 3 L3 16RD 0R HEAD LAMP SWITCH OUTPUT HIGH BEAM BLACK 103 CAV CIRCUIT FUNCTION 1 R46 18BR LB RIGHT IMPACT SENSOR LINE 1 2 R48 18TN RIGHT IMPACT SENSOR LINE 2 RIGHT AIRBAG SENSOR BLACK RIG...

Page 761: ...ACK LOW WASHER FLUID LEVEL SWITCH 108 CAV CIRCUIT FUNCTION 1 Zl 18BK GROUND 2 G29 18BK TN LOW WASHER FLUID INDICATOR LAMP BLACK C109 1 4 VEHICLE SPEED CONTROL SERVO CAV CIRCUIT FUNCTION 1 Zi 20BK GROU...

Page 762: ...CIO CAV CIRCUIT FUNCTION 1 Zl 20BK GROUND 2 L4 16VT WT HEADLAMP SWITCH OUTPUT LOW BEAM 3 L3 16RD 0R HEADLAMP SWITCH OUTPUT HIGH BEAM LEFT HEADLAMP JT BLACK 1 2 AMBIENT AIR TEMPERATURE SENSOR 114 CAV...

Page 763: ...ISOLATION SOLENOID CONTROL CAV CIRCUIT FUNCTION 1 B254 I6DG 0R REAR DECAY VALVE CONTROL 2 BI9 20LB REAR VALVE RESET SWITCH SENSE 3 B120 12BR WT PUMP MOTOR RELAY OUTPUT 4 B252 18BR TN REAR ISOLATION VA...

Page 764: ...WARNING LAMP RELAY CONTROL 14 Bl14 20WT VT REAR WHEEL SPEED SENSOR LOW 15 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR 16 B8 20RD 6Y LEFT FRONT WHEEL SPEED SENSOR 17 A20 18RD DB FUSED IGNITION SWITCH OUT...

Page 765: ...OLATION VALVE CONTROL 8 B243 16DG BK LEFT FRONT DECAY VALVE CONTROL 9 B5 20VT RD LEFT FRONT RESET SWITCH SENSE 10 B120 12BR WT PUMP MOTOR RELAY OUTPUT C123 BLACK GROUND JOINT CAV CIRCUIT FUNCTION 1 Zl...

Page 766: ...G20 22VT YL 7 C3 18DB BK 8 G14 18PK BK 9 G7 22WT 0R 10 G86 18TN 0R 11 D21 20PK DB 12 D20 20DG LT GRAY C126 DARK GRAY C127 INDICATES TWISTED PAIR CAV CIRCUIT 1 Z l l 16BK WT 2 Z12 20BK TN 2 T41 20BK WT...

Page 767: ...K CAV CIRCU 1 A6 14RD TN 2 B40 HLB 3 L76 14BK 0R 13 BLACK UNDERHOOD LAMP BLACK DAYTIME RUNNING LAMPS MODULE CAV CIRCUIT FUNCTION 1 Ml 20PK FUSED B 2 Zl 20BK GROUND C131 CAV CIRCUIT FUNCTION 1 L10 18BR...

Page 768: ...L9 18BK VT 45 V4 18RD YL 46 B108 18WT 47 A3 12RD LG 48 A7 12R0 BK 49 Z2 18BK LG 50 619 20LG RD BLACK J C Z L 1 2 4 J U U U U U U U U U U L J H i 2 4 O D 0 0 0 0 0 D D 0 D D I 3 36 H0DQDQ0 1 25 37 40...

Page 769: ...1 20BR RD 80 V32 20YL RD 81 V33 20WT L6 82 83 84 BLACK I 1 73 MUUUUUU UUUUUUI 84 6 1 D 7 2 49 6 0 45 41 37 o 2 5 a m r a d 3 6 13 ODDDDD 2 4 i H n n n n n n n n n n n n l 1 2 48 44 40 CAV CIRCUIT 51 B...

Page 770: ...NSMISSION TEMP LAMP DRIVER 32 63 20BK PK MALFUNCTION INDICATOR LAMP 33 V36 20TN RD VEHICLE SPEED CONTROL VACUUM SIGNAL 34 C13 200B 0R A C COMPRESSOR CLUTCH RELAY CONTROL 35 K35 206Y YL EGR SOLENOID CO...

Page 771: ...TCH SENSE 31 G14 18PK BK TRANSMISSION TEMP LAMP DRIVER 32 63 20BK PK MALFUCTION INDICATOR LAMP 33 V36 20TN RD VEHICLE SPEED CONTROL VACUUM SIGNAL 34 C13 20DB 0R A C COMPRESSOR CLUTCH RELAY CONTROL 35...

Page 772: ...ARK NEUTRAL POSITION SWITCH SENSE 31 T18 20L6 0R TRANSMISSION OVERDRIVE LAMP 32 63 20BK PK MALFUNCTION INDICATOR LAMP 33 V36 20TN RD VEHICLE SPEED CONTROL VACUUM SIGNAL 34 C13 20DB 0R A C COMPRESSOR C...

Page 773: ...V40 20WT PK STOP LAMP SWITCH OUTPUT 30 T41 20BK WT PARK NEUTRAL POSITION SW SENSE 30 Z12 20BK TN GROUND 31 614 18PK BK TRANSMISSION TEMP LAMP DRIVER 32 63 20BK PK MALFUNCTION INDICATOR LAMP 33 V36 20T...

Page 774: ...DWELL SIGNAL 8 K137 20WT BK DWELL SIGNAL 9 F18 20LG BK FUSED I6N SW OUTPUT START RUN 10 K7 180R 8V SUPPLY C138 CAV CIRCUIT FUNCTION 1 K24 20GY BK CRANKSHAFT POSITION SENSOR SIGNAL 2 K4 20BK LB SENSOR...

Page 775: ...OIL DRIVER C142 BLACK INJECTOR 8 CAV CIRCUIT FUNCTION 1 Kl13 18LB BR INJECTOR 8 DRIVER 2 A142 16DG 0R ASD RELAY OUTPUT CAV CIRCUIT FUNCTION 1 K18 18RD YL INJECTOR 8 DRIVER 2 A142 16DG 0R ASD RELAY OUT...

Page 776: ...PUT CAV CIRCUIT FUNCTION 1 K14 18LB BR INJECTOR 4 DRIVER 2 A142 16DG 0R ASD RELAY OUTPUT 8 0L ENGINE ONLY 3 9L 5 2L AND 5 9L ENGINES ONLY BLACK EXHAUST GAS RECIRCULATION SOLENOID 146 CAV CIRCUIT FUNCT...

Page 777: ...3 K6 18VT WT 5V OUTPUT C150 CAV CIRCUIT FUNCTION 1 K39 18GY RD IDLE AIR CONTROL MOTOR DRIVER 2 K60 18YL BK IDLE AIR CONTROL MOTOR DRIVER 3 K40 18BR WT IDLE AIR CONTROL MOTOR DRIVER 4 K59 18VT BK IDLE...

Page 778: ...CTOR M l DRIVER 2 A142 16DG 0R ASD RELAY OUTPUT ONLY 5 2L AND 5 9L ENGINES ONLY C1SS BLACK INJECTOR 5 CAV CIRCUIT FUNCTION 1 Kl13 18LB BR INJECTOR 5 DRIVER 2 A142 16DG 0R ASD RELAY OUTPUT CAV CIRCUIT...

Page 779: ...DB INJECTOR 1 DRIVER 2 A142 16DG 0R ASD RELAY OUTPUT CAV CIRCUIT FUNCTION 1 K l l 18WT DB INJECTOR 1 DRIVER 2 A142 16DG 0R ASD RELAY OUTPUT 8 0L ENGINE ONLY 3 9L 5 2L AND 5 9L ENGINES ONLY BLACK C I 6...

Page 780: ...CLE SPEED SENSOR SIGNAL 2 K4 18BK LB SENSOR GROUND 3 K7 180R 8V SUPPLY BLACK C164 LH i CAV CIRCUIT FUNCTION 1 C3 18DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 2 Z l l 18BK WT GROUND A C COMPRESSOR CLUTCH...

Page 781: ...L 2 K4 18BK LB SENSOR GROUND CAV CIRCUIT FUNCTION 1 T54 IGVT TRANSMISSION TEMPERATURE SENSOR SIGNAL 2 K4 16BK LB SENSOR GROUND cisi CAV CIRCUIT FUNCTION 1 LIO I8BR LG FUSED IGNITION SWITCH OUTPUT RUN...

Page 782: ...MOTOR RELAY OUTPUT 3 A123 10RD VT FUEL SHUT DOWN RELAY OUTPUT 4 Z12 18BK TN GROUND BLACK 1 2 WATER IN FUEL SENSOR C174 CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 2 Kl 20DG RD WATER IN FUEL SIGNAL...

Page 783: ...M 3 2 2 P K D B GROUND 4 F 3 3 2 0 P K R D F U S E D 8 4 5 G 2 6 1 8 L B K E Y I N I G N I T I O N S W I T C H S E N S E 6 G 1 6 2 2 B K L B D O O R J A M B S W I T C H S E N S E 7 L 2 0 1 6 L G W T F...

Page 784: ...WT F12 22DB WT G9 22GY BK G9 22GY BK G9 22GY BK G9 22GY BK LIO 22BR LG LIO 22BR LG LIO 22BR LG V40 22WT PK V40 20WT PK V40 22WT PK FUNCTION FUSED HEADLAMP SWITCH OUTPUT FUSED HEADLAMP SWITCH OUTPUT F...

Page 785: ...NAL 12 L63 18DG RD LEFT REAR TURN SIGNAL 13 L50 18WT TN STOP LAMP SWITCH OUTPUT 14 L19 18PK WT HAZARD FLASHER OUTPUT 15 L62 18BR PK RIGHT REAR TURN SIGNAL 16 L60 20TN BK RIGHT FRONT TURN SIGNAL 16 L60...

Page 786: ...WT PK STOP LAMP SWITCH OUTPUT C215 BLACK 1 i n 14 0 Li UUUUUL JULUUUULL 1 TEdJ INSTRUMENT CLUSTER CAV CIRCUIT FUNCTION 1 G19 22LG RD WARNING LAMP DRIVER 1 G19 22LG RD WARNING LAMP DRIVER 2 G107 22BK G...

Page 787: ...69 226Y BK BRAKE WARNING LAMP DRIVER 12 654 220R BK UP SHIFT LAMP DRIVER 13 14 613 20DB RD SEAT BELT LAMP DRIVER C217 CAV CIRCUIT FUNCTION 1 M2 20YL COURTESY LAMP DRIVER 2 M2 22YL COURTESY LAMP DRIVER...

Page 788: ...OUTPUT PARK 7 VI7 18DG WINDSHIELD WIPER SW OUTPUT DELAY 8 V8 18VT WINDSHIELD WIPER SW OUTPUT DELAY C220 CAV CIRCUIT FUNCTION 1 Bl13 22RD VT REAR WHEEL SPEED SENSOR HIGH I Bl13 22RD VT REAR WHEEL SPEE...

Page 789: ...FUSED ION SW OUTPUT START RUN 4 685 200R BK WAIT TO START 5 614 20PK BK TRANS WARNIN6 LAMP DRIVER 6 7 8 C225 CAV CIRCUIT FUNCTION 1 T6 220R WT TRANSMISSION OVERDRIVE SWITCH OUTPUT 2 Z3 20BK 0R 6R0UND...

Page 790: ...20 18RD DB FUSED 84 3 A20 18RD DB FUSED B4 4 G107 20BK GY 4WD SWITCH OUTPUT 4 G107 20BK GY 4WD SWITCH OUTPUT 5 Gil 22WT BK PARK BRAKE SWITCH SENSE 6 G9 22GY WT BRAKE WARNING LAMP DRIVER 7 V40 22WT PK...

Page 791: ...4 2 Ml 20PK FUSED B 4 3 4 F32 18PK DB FUSED B 5 F32 18PK DB FUSED B 6 7 F32 20PK DB FUSED B 8 Mi 18PK FUSED B 9 Ml 20PK FUSED B 10 Ml 18PK FUSED B f C 2 3 2 BLACK AIRBAG CONTROL MODULE CAV CIRCUIT FUN...

Page 792: ...XI3 I8BK RD INFINITY SPEAKER AMPLIFIER 4 Ml I8PK FUSED B POWER OUTLET C235 CAV CIRCUIT FUNCTION 1 F30 18RD 0R FUSED IGN SW OUTPUT ACC RUN 1 F30 18RD 0R FUSED IGN SW OUTPUT ACC RUN 2 Z3 18BK 0R GROUND...

Page 793: ...BK 9 P34 16PK BK 10 P35 160R VT 5 u n L BLACK 10 CAV CIRCUIT 1 026 14VT WT 2 016 14BR WT 3 F2 14TN 4 5 6 P36 16PK VT 7 F35 IBRD 8 P33 160R BK 9 P34 16PK BK 10 P35 160R VT C 2 4 Q L BLACK a CAV CIRCUIT...

Page 794: ...HT REAR SPEAKER 2 X52 18DB WT RIGHT REAR SPEAKER RIGHT REAR STANDARD SPEAKER BLACK C303 CAV CIRCUIT I Z3 HBK OR 2 F37 14RD LB BLACK 2 1 CAV CIRCUIT i Z3 14BK 0R 2 F37 14RD LB BLACK C3 4 DOME LAMP 4 BL...

Page 795: ...Ml 18PK 2 Z3 18BK 0R 2 Z3 18BK 0R 3 L50 18WT TN 3 L50 18WT TN 4 M3 18PK DB 4 M3 18PK DB 5 6 BLACK LEFT DOOR JAMB SWITCH C 3 0 9 CAV CIRCUIT F U N C T I O N 1 Z3 18BK 0R GROUND Z GIG 18BK LB DOOR JAMB...

Page 796: ...IT FUNCTION 1 X55 20BR RD LEFT DOOR SPEAKER 2 X53 20DG LEFT DOOR SPEAKER C313 CAV CIRCUIT FUNCTION 1 12 18BK LG GROUND 2 X55 18BR RD LEFT DOOR SPEAKER 3 X53 18DG LEFT DOOR SPEAKER 4 X13 I8BK RD AMPLIF...

Page 797: ...SW RIGHT UP DOWN CONTROL B R BLACK 317 CAV CIRCUIT FUNCTION 1 P33 160R BK DOOR LOCK DRIVER 2 P34 16PK BK DOOR UNLOCK DRIVER LEFT DOOR LOCK MOTOR 318 BLACK CAV CIRCUIT FUNCTION 1 Oil HLB LEFT PWR WIND...

Page 798: ...DOWN CONTROL 3 P72 20YL BK POWER MIRROR LEFT RIGHT CONTROL C323 CAV CIRCUIT FUNCTION I 12 I8BK LG GROUND 2 X56 18DB RD RIGHT DOOR SPEAKER R 3 X54 18VT RIGHT DOOR SPEAKER 4 X13 18BK RD AMPLIFIED SPEAKE...

Page 799: ...DOOR LOCK MOTOR CAV CIRCUIT FUNCTION 1 P33 160R BK DOOR LOCK DRIVER 2 P34 16PK BK DOOR UNLOCK DRIVER C328 BLACK FUEL TANK LEVEL GAUGE SENDING UNIT CAV CIRCUIT FUNCTION 1 A61 16D6 BK FUEL PUMP RELAY OU...

Page 800: ...7B 14BK 0R 3 4 3 L76 HBK OR 4 ZI3 12BK M 4 ZI3 I2BK C333 BLACK CAV CIRCUIT i L7 18BK YL 2 Z13 18BK 3 Li 18VT BK 4 L63 18DG RD BLACK CAV CIRCUIT I L7 183K YL 2 Z13 18BK 3 LI 18VT V 4 L63 18DG BR C334 B...

Page 801: ...K q a a o q OVERHEAD CONSOLE CAV CIRCUIT FUNCTION 1 2 Z l l 20BK WT GROUND 3 4 1A 18BK 6R0UND 5 Ml 18PK FUSED B 8 Mi 18PK FUSED B 7 F12 22DB WT FUSED IGN SWITCH OUTPUT START RUN 8 M2 22YL COURTESY LAM...

Page 802: ...PARK LAMP SWITCH OUTPUT BLACK C342 CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL 2 I BLACK CAV CIRCUIT 1 Z13 18BK 2 L7 1 8BK YL C343 1 2 BLACK CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL BLACK CAV CIRCUIT 1 Z13 18BK 2...

Page 803: ...3 BLACK H 2 BLACK CAV CIRCUIT 1 113 IBBK 2 L7 I8BK YL CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL C 4 0 4 BLACK u n i 2 BLACK CAV CIRCUIT 1 111 18BK 2 17 18BK YL i u r n I CAV CIRCUIT 1 Z13 18BK 2 L7 18BK YL...

Page 804: ...SWITCH C409 CAV CIRCUIT FUNCTION 1 Bl14 20WT VT REAR WHEEL SPEED SENSOR LOW 2 Bl13 20RD WT REAR WHEEL SPEED SENSOR HIGH REAR WHEEL ANTI LOCK BRAKE SENSOR BLACK C410 CAV CIRCUIT FUNCTION 1 13 18PK DB G...

Page 805: ...SWITCH OUTPUT CENTER HIGH MOUNTED STOP LAMP 2 I 2 BLACK RIGHT LICENSE LAMP BLACK 3 H RIGHT TAIL STOP AND TURN SIGNAL LAMP C414 CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTP...

Page 806: ...P SWITCH OUTPUT 3 Z13 I8BK GROUND LEFT TAIL STOP AND TURN SIGNAL LAMP GRAY 4 1 9 CAV CIRCUIT FUNCTION I LI 18VT BK BACK UP LAMPS SWITCH OUTPUT 2 Zl3 18BK GROUND LEFT BACK UP LAMP BLACK C420 CAV CIRCUI...

Page 807: ...RK LAMP SWITCH OUTPUT DUAL REAR WHEELS C423 CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK LAMP SWITCH OUTPUT DUAL REAR WHEELS C424 CAV CIRCUIT FUNCTION 1 Z13 18BK GROUND 2 L7 18BK YL PARK L...

Page 808: ...TION 1 P15 14YL LB LEFT POWER SEAT HORIZONTAL FORWARD 2 P17 HDB RD LEFT POWER SEAT HORIZONTAL REARWARD C429 CAV CIRCUIT FUNCTION 1 P i l 14YL WT LEFT POWER SEAT REAR UP 2 Pi3 14RD WT LEFT POWER SEAT R...

Page 809: ...TOR PIN OUTS BR BLACK C431 CAV CIRCUIT FUNCTION 1 L39 20LB FOG LAMP RELAY 2 OUTPUT 2 Zl 20BK GROUND RIGHT FOG LAMP BLACK C433 CAV CIRCUIT FUNCTION 1 L39 20LB FOG LAMP RELAY 2 OUTPUT 2 Zl 20BK GROUND L...

Page 810: ...ock 6 7 V 10 Right Side of Block 8 V 6 V 8 Near Distributor 6 7 V 10 Near Oil Filter 8 Diesel Left Side of Engine 9 V 10 Injector 10 7 8 V 10 Right Side of Engine 8 Injector 8 7 8 Injector 6 6 7 8 V 1...

Page 811: ...Rear Speaker 17 18 At Left Rear Speaker 17 18 In Body Behind LT Door Opening 17 18 Center Rear of Headliner 17 18 Rear of Left Door Jamb Switch Left Door 19 Left Door 19 Left Door 19 Left Door 19 Con...

Page 812: ...10 Below A C Compressor 8 G111 V 6 V 8 V 10 Below A C Compressor 6 7 8 G111 Diesel Front Top of Cylinder Head 9 Fig Connector Color Location Fig G112 Diesel Front of Cylinder Head 9 G113 Below A C Com...

Page 813: ......

Page 814: ...INTAKE AIR TEMPERATURE SENSOR CI39 BLACK ENGINE OIL PRESSURE SENDING UNIT SWITCH EVAP PURGE SOLENOID C153 BLACK CI 71 BLACK CAMSHAFT POSITION SENSOR CI52 BLACK ENGINE COOLANT TEMPERATURE SENSOR A C CO...

Page 815: ...IDLE AIR CONTROL MOTOR CI46 RED EGR SOLENOID TRANSDUCER ASSEMBLY CI45 BLACK FUEL INJECTOR 4 CI47 BLACK FUEL INJECTOR 2 CI39 BLACK ENGINE OIL PRESSURE SENDING UNIT SWITCH EGR TUBE GO O o z m o o o o m...

Page 816: ...TCH CI55 BLACK INJECTOR 7 CI54 BLACK INJECTOR 9 C I 3 9 BLACK OIL PRESSURE SENDING UNIT C I 6 6 BLACK CAMSHAFT POSITION SENSOR SEE VIEW C SEE VIEW C CI38 BLACK CRANKSHAFT POSITION SENSOR C I 5 8 BLACK...

Page 817: ...C I 7 7 BLACK CI74 BLACK WATER IN FUEL SENSOR CI57 GRAY INTAKE AIR TEMPERATURE SENSOR CI78 BLACK ENGINE SPEED SENSOR CONNECTOR VIEW IN DIRECTION OF ARROW T CI76 BLACK THROTTLE POSITION SENSOR VIEW IN...

Page 818: ...SFER CASE 3 9L5 2L AND 5 91 TO ENGINE WIRING CI60 BLACK CI63 BLACK VEHICLE SPEED SENSOR TO ENGINE WIRING n Cl63 BLACK VEHICLE SPEED SENSOR C161 BLACK BACK UP LAMP SWITCH C163 BLACK VEHICLE SPEED SENSO...

Page 819: ...AL P O S I T I O N S W I T C H HEATED O X Y G E N S E N S O R C I 6 3 BLACK VEHICLE SPEED S E N S O R 3 9L 5 2 L A N D 5 9 L HEATED O X Y G E N S E N S O R HEATED O X Y G E N S E N S O R C I 6 9 BLACK...

Page 820: ...GHTER C 2 3 3 YELLOW A I R B A G C O N T R O L MODULE T O RWAL MODULE SEE V I E W Y C 2 3 2 YELLOW A I R B A G C O N T R O L MODULE C 2 1 9 BLACK INTERMITTENT WIPER MODULE INSTRUMENT PANEL ASSEMBLY V...

Page 821: ...ARK BRAKE S W I T C H C 2 1 4 BLACK STOP LAMP S W I T C H C 2 1 0 BLACK MULTI FUNCTION S W I T C H V I E W IN DIRECTION O F A R R O W Y C 2 2 3 BLACK A I R B A G A B S DATA LINK C O N N E C T O R INST...

Page 822: ...Fig 14 instrument Panel Ground Connections...

Page 823: ......

Page 824: ......

Page 825: ...C308 BLACK CHMSL C301 BLACK OR C302 BLACK REAR SPEAKER VIEW IN DIRECTION OF ARROW X Fig 17 Cab Connectors J958W 18...

Page 826: ......

Page 827: ...EFT DOOR C326 BLACK RIGHT DOOR POWER MIRROR SWITCH C310 BLACK TO INSTRUMENT PANEL WIRING DOOR SPEAKER LEFT DOOR C312 BLACK OR C313 BLACK RIGHT DOOR C320 BLACK OR C323 BLACK POWER WINDOW MOTOR C318 BLA...

Page 828: ...1 BLACK OR C332 BLACK C330 BLACK REAR WHEEL SPEED SENSOR TO C409 BLACK FRAME ASSEMBLY C333 BLACK LEFT TAIL LAMP CI28 BLACK C328 BLACK FUEL TANK MODULE FUEL TANK X MEMBER CHASSIS WIRING HARNESS J958W 1...

Page 829: ...90 24 8W 90 CONNECTOR LOCATIONS J958W 236 Fig 21 Center High Mounted Stop Lamps and Cargo Lamps...

Page 830: ...C414 BLACK RIGHT C417 BLACK LEFT LICENSE LAMPS C416 BLACK RIGHT i CO o Fig 22 Rear Lamps m...

Page 831: ......

Page 832: ...2 5132 After Branch to Injectors 2 4 6 8 10 V 10 2 S132 Rear of Engine In Branch to PCM Diesel 5 5133 After T 0 for Idle Air Control Motor V 6 V 8 3 S133 After T 0 for Injector 10 V 10 4 5134 Between...

Page 833: ...312 After Branch to Right Rear Lamps 11 S313 After Branch to Right Rear Lamps 11 S314 After Branch to Right Rear Lamps 11 Splice lumber Locations Fig S315 In T O to Trailer Tow Harness Connectors 11 S...

Page 834: ......

Page 835: ...2 VIEW IN DIRECTION OF ARROW Y VIEW IN DIRECTION OF ARROW Z SEE to cn oo SI36 V 10 VIEW IN DIRECTION OF ARROW W SI 3 V 6 V 8 140 CO cn SI 31 DIESEL J958W 245 Fig 2 Engine Compartment Wiring Splices m...

Page 836: ...Fig 3 V 6 V 8 Engine Wiring Splices...

Page 837: ......

Page 838: ...S134 m VIEW IN DIRECTION OF ARROW X S132 CO m m o m o m VIEW IN DIRECTION OF ARROW Y J958W 243 CO cn Fig 5 Diesel Engine Wiring Splices...

Page 839: ...8W 95 8 8W 95 SPLICE LOCATIONS Fig 6 Transmission Wiring Splices J958W 237...

Page 840: ......

Page 841: ......

Page 842: ......

Page 843: ...S309 RT DOOR Fig 10 Door Wiring Splices J958W 240...

Page 844: ......

Page 845: ...in color is available in 3 ounce tubes Moisture in the air causes the sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of 1 year and will not prop...

Page 846: ...rt compression gage adaptor into the No l spark plug hole Crank engine until maximum pressure is reached on gauge Record this pressure as No l cylinder pressure h Repeat Step 3g for all remaining cyli...

Page 847: ...f the main bearings can only be determined by removing the weight of the crankshaft This can be accomplished by either of two methods METHOD 1 PREFERRED Shim the bear ings adjacent to the bearing to b...

Page 848: ...e for checking engine bearing clearances REPAIR DAMAGED OR WORM THREADS Damaged or worn threads can be repaired Essen tially this repair consists of Drilling out worn or damaged threads Tapping the ho...

Page 849: ...E TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good ope...

Page 850: ...d by manufacturer Start the engine and let idle for ap proximately 15 minutes Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black ligh...

Page 851: ...e seal area on the crank shaft could have minor nicks or scratches that can be polished out with emery cloth _ ENGINES I 7 scratches The crankshaft sea flange is especially machined to complement the...

Page 852: ...ly 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 11 Plugged or restrict...

Page 853: ...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 Maint...

Page 854: ...vibration d Minor damage can be polished out damper hub otherwise replace the part OIL PRESSURE DROP 1 Low oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending...

Page 855: ...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 i...

Page 856: ...or corroded wiring connections C Rotate the engine with barring tool Snap on Tool SP371 MTE No 3377462 or equivalent to check for external rotational resistance 3 Verify system is working Repair repla...

Page 857: ...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 defectiv...

Page 858: ...red 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 require...

Page 859: ...ste gate operation 14 Check for bent push rod replace if necessary 15 Check replace injectors 16 Verify injection pump timing see Group 14 Fuel System 17 Repair or replace injection pump EXCESSIVE EXH...

Page 860: ...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 pu...

Page 861: ...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 not being exceeded COOLANT TEMPERATURE B...

Page 862: ...od or main bearings Check and replace piston cooling nozzles 11 Check oil jet position LUBRICATING OIL PRESSURE TOO HIGH 1 Pressure switch gauge not operating properly 2 Engine running to cold 3 Oil v...

Page 863: ...n 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 compo...

Page 864: ...orged Ste J9409 9 Fig 1 Engine Description This engine is designed for unleaded fuel Engine lubrication system consists of a rotor type oil pump and a full flow oil filter The cylinders are numbered f...

Page 865: ...ngine SLIGHTLY 5 Remove the bolts holding the support cushion to the transmission support bracket Remove the sup port cushion 6 If necessary remove the bolts holding the transmission support bracket t...

Page 866: ...9 22 3 9L ENGINE Fig 6 Engine Rear Support Cushion Assemblies J9509 126...

Page 867: ...n 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 st...

Page 868: ...the same order as removed B R ROCKER ARMS J9209 66 Fig 2 Rocker Arms INSTALLATION 1 Rotate the crankshaft until the V6 mark lines up with the TDC mark on the timing chain case cover This mark is locat...

Page 869: ...0 Remove the return spring 11 Remove distributor cap and wires 12 Disconnect the coil wires 13 Disconnect heat indicator sending unit wire 14 Disconnect heater hoses and bypass hose 15 Remove cylinder...

Page 870: ...l cooling system refer to Group 7 Cooling System for proper procedure 23 Connect the negative cable to the battery B R ALVES AND VALVE SPRINGS The valves are arranged in line and inclined 18 The rocke...

Page 871: ...at the correct size valve guide pilot be used for reseat ing stones A true and complete surface must be ob tained 3J L ENGINE I 27 CONTACT i A SEAT WIDTH INTAKE 1 016 1 524 mm 0 040 0 060 in EXHAUST 1...

Page 872: ...s 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 head coun terbore This should bring spring height back to nor ma...

Page 873: ...If all tappets are to be removed identify tappets to ensure installation in original location 8 If the tappet or bore in cylinder block is scored scuffed or shows signs of sticking ream the bore to n...

Page 874: ...tion damper onto the crank shaft 2 Place installing tool part of Puller Tool Set C 3688 in position and press the vibration damper onto the crankshaft Fig 2 Fig 2 Installing Vibration Damper 3 Install...

Page 875: ...ft sprocket and in cam shaft sprocket 9 Lift sprockets and chain keep sprockets tight against the chain in position as described 10 Slide both sprockets evenly over their respec tive shafts and use a...

Page 876: ...ct the negative cable to the battery FROMT CRANKSHAFT OIL SEAL REPLACEMENT The oil seal can be replaced without removing the timing chain cover provided the cover is not mis aligned 1 Disconnect the n...

Page 877: ...bearing shell over proper adapter 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...

Page 878: ...d 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 from which it was removed When camshaf...

Page 879: ...mission strut 7 Loosen the right side engine support bracket cushion thru bolt nut and raise the engine slightly Remove oil pan by sliding backward and out 8 Remove the one piece gasket GLEAMING Clean...

Page 880: ...hten these bolts to 24 N m 215 In lbs torque 8 Lower the engine into the support cushion brackets and tighten the thru bolt nut to the proper torque 9 Install the drain plug Tighten drain plug to 34 N...

Page 881: ...crankshaft is drilled Internally to pass oil from the main bearing journals to the connecting rod journals Each connecting rod bearing has half a hole in it oil passes through the hole when the rods r...

Page 882: ...Fig 3 Oil Lubrication System...

Page 883: ...inner rotor with shaft Fig 5 4 Wash all parts In a suitable solvent and Inspect carefully for damage or wear INSPECTION Mating surface of the oil pump cover should be smooth Replace pump assembly If c...

Page 884: ...5 mm 1 95 Inches The spring should test between 19 5 and 20 5 pounds when compressed to 84 mm 1 11 82 inches Replace spring that fails to meet these specifications Fig 12 If oil pressure was low and p...

Page 885: ...the rings down to ensure positioning rings squarely In the cylinder bore before measur ing b Insert feeler gauge In the gap The top com pression ring gap should be between 0 254 0 508 mm 0 010 0 020 I...

Page 886: ...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 Li...

Page 887: ...e crankshaft rear oil seals 8 Remove and discard the front crankshaft oil seal INSPECTION OP JOUMMALS The crankshaft connecting rod and main journals should be checked for excessive wear taper and sco...

Page 888: ...dard and the following undersizes 0 25 mm 0 001 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 Never install an undersize bearing that will reduce clearance...

Page 889: ...and wipe excess sealant off the oil pan seal groove 13 Install new front crankshaft oil seal 14 Immediately install the oil pan 1 Remove the oil pan 2 Remove the oil pump from the rear main bear ing c...

Page 890: ...han 0 127 mm 0 005 Inch out of round The cylinder bores show a taper of more than 0 254 mm 0 010 inch The cylinder walls are badly scuffed or scored Boring and honing operation should be closely co or...

Page 891: ...into the casting as restricted coolant flow can result and cause se rious engine problems DRIFT 9209 41 Fig 3 Core Hole Plug Removal 2 Using proper plug driver drive cup plug into hole The sharp edge...

Page 892: ...e No 1 0 013 0 038 mm 0 0005 0 0015 in Nos 2 3 and 4 0 013 0 051 mm 0 0005 0 0020 in Max Allowable Nos 2 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 M...

Page 893: ...0 150 0 160 in Weight 592 6 596 6 grams 20 90 21 04 oz 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 00...

Page 894: ...CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R or 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 Steel stamped near notch on...

Page 895: ...al Oil Pan Bolts 23 N m 200 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 Mount Support Cushion to...

Page 896: ...uid Cooled Forced Circulation Cooling Canity 16 U 17 0 Qts Cylinder Block Gas to Crankshaft hbcbfar Iron Cylinder Heed Cost Smn Combustion Chambers Wedge High Swirl Valve Shrouding Camshaft Nodular Ca...

Page 897: ...ssion support bracket Remove the sup port cushion 6 If necessary remove the bolts holding the transmission support bracket to the transmission 5 2L ENGINE S 13 CUSHION BRACKET Jf409 54 Fig 5 Positioni...

Page 898: ...9 54 5 2L ENGINE Fig Engine Rear Support Cushion Assemblies...

Page 899: ...21 Transmissions for transmis sion installation 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 Insta...

Page 900: ...TION 1 Rotate the crankshaft until the V8 mark lines up with the TDC mark on the timing chain case cover This mark is located 147 ATDC from the No l firing position CAUTION DO NOT rotate or crank the...

Page 901: ...ve exhaust manifolds 17 Remove rocker arm assemblies and push rods Identify to ensure installation in original locations 18 Remove the head bolts from each cylinder head and remove cylinder heads Disc...

Page 902: ...der head REMOVAL 1 Remove the cylinder head 2 Compress valve springs using Valve Spring Compressor Tool MD 998772A 3 Remove valve retaining locks valve spring re tainers valve stem seals and valve spr...

Page 903: ...oat valve seat LIGHTLY with Prussian blue then set valve In place Rotate the valve with light pressure If the blue Is transferred to the center of valve face A SEAT WIDTH INTAKE 1 016 1 524 mm 0 040 0...

Page 904: ...tall a reliable gauge at the pressure sending unit The pressure should be between 207 552 kPa 80 80 psi at 8 000 RPM Check the oil level after the engine reaches normal operating temperature Allow 5 m...

Page 905: ...o avoid mixing of parts Mixed parts are noi compatible DO NOT dis assemble a tappet on a dirty work bench 1 Pry out plunger retainer spring clip Fig 12 2 Clean varnish deposits from inside of tappet b...

Page 906: ...and gasket using ex treme 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 crankshaft seal su...

Page 907: ...12 Check camshaft end play The end play should be 0 051 0 152 mm 0 002 0 006 inch with a new thrust plate and up to 0 254 mm 0 010 inch with a used thrust plate If not within these limits install a ne...

Page 908: ...minimum interference If tool does not fit the cover must be re moved and installed properly 4 Place a suitable tool behind the lips of the oil seal to pry the oil seal outward Be careful not to damage...

Page 909: ...t Be sure this plug does not leak 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 Wheneve...

Page 910: ...ool and bushing Into the bore 2 Drive bushing and tool into position using a hammer Fig 15 Fig 15 Distributor Dm shafi Bushing installation 3 As the burnisher is pulled through the bushing the bushing...

Page 911: ...d threads Repair as necessary Inspect oil pan mounting flange for bends or distor tion Straighten flange if necessary INSTALLATION 1 Fabricate 4 alignment dowels from 5 16 x 1 1 2 inch bolts Cut the h...

Page 912: ...JIL PUMP PRESSURE The MINIMUM oil pump pressure is 41 4 kPa 8 psi at curb idle The MAXIMUM oil pump pressure is 207 552 kPa 80 80 psi at 3 000 EPM or more CAUTION If oil pressure Is 2E30 at curb Idle...

Page 913: ...Fig 3 Oil Lubrication System...

Page 914: ...be between 0 508 0 762 mm 0 020 0 030 inch The oil ring gap should be 0 254 1 270 mm 0 010 0 050 inch c Rings with insufficient end gap may be prop erly filled to the correct dimension Rings with ex c...

Page 915: ...h the special wrench part of Tool 0 385 Be sure position f rings does not change during this operation 4 Install connecting rod bolt protectors on rod bolts the long protector should be installed on t...

Page 916: ...oil seal into the bearing cap with the yellow paint facing towards the rear of the engine 6 Apply 5 mm 0 20 in drop of Loctite 518 or equivalent on each side of the rear main bearing cap Fig 2 DO NOT...

Page 917: ...otate crankshaft counterclockwise slid ing the bearing into position Remove Tool C 3059 3 Install the bearing caps Clean and oil the bolts Tighten the capbolts to 115 N m 85 ft lbs torque 4 Install th...

Page 918: ...and cap bolts DO NOT remove excess material after assembly DO NOT strike rear cap more than 2 times for proper engagement 11 Install the rear main bearing cap with cleaned and oiled cap bolts Alternat...

Page 919: ...ck of block 2 Insert a 8 175 mm 1 8 inch finish wire or equivalent into passage 3 Plug should be 192 0 to 195 2 mm 7 1 2 to 7 11 16 inches from machined surface of block Fig 6 If plug is too high use...

Page 920: ...LE 1 Install the piston connecting rod assembly 2 Install the oil pan 3 Install the cylinder head 4 Install the engine into the vehicle CLEftliNG Thoroughly clean inside of cup plug hole in cylinder b...

Page 921: ...in 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 All...

Page 922: ...064 mm 0 150 0 160 in Weight 592 6 596 6 grams 20 90 21 04 oz Piston Pins Clearance In Piston 0 00635 0 01905 m m 0 00025 0 00075 in In Rod Interference 0 0178 0 0356 mm 0 0007 0 0014 in Diameter 24 9...

Page 923: ...0 Duration 250 Valve Overlap 31 J9409 99 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R or M M...

Page 924: ...Service Manual Oil Pan Bolts 23 N m 200 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 Mount Suppor...

Page 925: ...escription This engine is designed for unleaded fuel Engine lubrication system consists of a rotor type oil pump and a full flow oil filter The cylinders are numbered from front to rear 1 3 5 7 on the...

Page 926: ...ion to the transmission support bracket Remove the sup port cushion 6 If necessary remove the bolts holding the transmission support bracket to the transmission CUSHION BRACKET J9409 54 Fig 5 Position...

Page 927: ...5 9L ENGINE 9...

Page 928: ...a hoist 4 Refer to Group 21 Transmissions for transmis sion installation 5 Install rear transmission support j Install the prop shaft refer to Group 16 Pro peller Shaft 6 Install the dust shield and...

Page 929: ...ALLATION 1 Rotate the crankshaft until the V8 mark lines up with the TDC mark on the timing chain case cover This mark is located 147 ATDC from the No l firing position CAUTION DO NOT rotate or crank...

Page 930: ...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 rock...

Page 931: ...em 21 Install the air cleaner 22 Install the heat shields Tighten the bolts to 41 N m 30 ft lbs torque 23 Fill cooling system refer to Group 7 Cooling System for proper procedure 24 Connect the negati...

Page 932: ...Valve Face and Seat Angles WftlWES Inspect the remaining margin after the valves are refaced Fig 9 Valves with less than 1 190 mm 0 047 inch margin should be discarded INTAKE VALVE VALVE SPRING RETAI...

Page 933: ...to cor rect tappet noise check the oil pressure If vehicle has no oil pressure gauge install a reliable gauge at the pressure sending unit The pressure should be between 207 552 kPa 30 80 psi at 3 000...

Page 934: ...plunger cap 8 Invert tappet body and remove plunger cap plunger check valve check valve spring check valve retainer and plunger spring Fig 12 Check valve could be flat or ball ASSEMBLE 1 Clean all tap...

Page 935: ...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...

Page 936: ...end play should be 0 051 0 152 mm 0 002 0 006 inch with a new thrust plate and up to 0 254 mm 0 010 inch with a used thrust plate If not within these limits install a new thrust plate CLEANING Be sure...

Page 937: ...terference If tool does not fit the cover must be re moved and installed properly 4 Place a suitable tool behind the lips of the oil seal to pry the oil seal outward Be careful not to damage the crank...

Page 938: ...a minimum of 805 km 500 miles Drain at the next normal oil change 2 Install Camshaft Gear Installer Tool C 3509 with tongue back of distributor drive gear Fig 12 Fig 12 Camshaft Holding Tool C 3509 I...

Page 939: ...N This procedure MUST be followed when installing a new bushing or seizure to shaft may oc cur Fig 16 Burnishing Distributor Driveshaft Bushing 4 Install the intake manifold refer to Group 11 Exhaust...

Page 940: ...sary INSTALLATION 1 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 in stallation and removal with...

Page 941: ...e crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals Each connecting rod bearing has half a hole in it oil passes through the hole when the rods...

Page 942: ...CO Fig 3 Oil Lubrication System...

Page 943: ...all parts in a suitable solvent and inspect carefully for damage or wear INSPECTION Mating surface of the oil pump cover should be smooth Replace pump assembly if cover is scratched or grooved Lay a s...

Page 944: ...sandpaper The relief valve spring has a free length of approx imately 49 5 mm 1 95 inches The spring should test between 19 5 and 20 5 pounds when compressed to 34 mm 1 11 32 inches Replace spring th...

Page 945: ...STONS Piston 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 inch Piston diameter should be measured at the top of...

Page 946: ...ther because connecting rods and pistons are not interchangeable from one bank to another The bearing caps are not interchangeable and should be marked at removal to ensure correct as sembly Each bear...

Page 947: ...e the oil pan 2 Remove the oil pump from the rear main bear ing cap 3 Remove the vibration damper 4 Remove the timing chain cover 5 Identify bearing caps before removal Remove bearing caps and bearing...

Page 948: ...are interchangeable Upper and lower No 3 bearing halves are flanged to carry the crankshaft thrust loads They are NOT interchangeable with any other bearing halves in the engine Fig 9 Bearing shells a...

Page 949: ...squeezed out Withdraw nozzle and wipe excess sealant off the oil pan seal groove 13 Install new front crankshaft oil seal 14 Immediately install the oil pan UPPER SEAL REPLACEMENT CRANKSHAFT INSTALLED...

Page 950: ...show a taper of more than 0 254 mm 0 010 inch The cylinder walls are badly scuffed or scored Boring and honing operation should be closely co ordinated with the fitting of pistons and rings so specifi...

Page 951: ...sing proper plug driver drive cup plug into hole The sharp edge of the plug should be at least 0 50 mm 0 020 inch inside the lead in chamfer It is not necessary to wait for curing of the sealant The c...

Page 952: ...5 J9509 97 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS C O N D I T I O N I D E N T I F I C A T I O N m mmm O F mmiwmmmm 0 025 mm 0 001 inch U S Crankshaft R or M M 2 3 etc Indicating No 2 3 main...

Page 953: ...Pan Bolts 23 N m 200 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 Belts 11 N m 95 in lbs DESCRIPTION T O f t O J i Rear Mount Support Cushion to...

Page 954: ...low Filtration Direct Crankshaft Driven Pump Engine Oil Capacity 6 6L 7 0 Qts w filter Cooling System Liquid Cooled Forced Circulation Cooling Capacity 20 5L 21 75 Qts Cylinder Block Cast Iron Cranksh...

Page 955: ...09 93 INSTALLATION 1 With engine raised SLIGHTLY position the en gine support bracket cushion and heat shields to the block Install new bolts and tighten to 81 N m 60 ft lbs torque 2 Install the thru...

Page 956: ...e 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...

Page 957: ...4X4 4X2 3500 MANUAL 4X2 4X4 3500 MANUAL 4500 ALL AUTOMATICS AUTOMATICS J9509 126 Fig 6 Engine Rear Support Cushion Assembly...

Page 958: ...Cooling Sys tem 25 Connect the lower radiator hose 26 Install the transmission oil cooler 27 Connect the transmission cooler lines 28 Connect the power steering hoses if equipped 29 Install the fan s...

Page 959: ...assembly Fig 3 Place rocker arm assemblies on a bench in the same order as removed 4 Remove the push rods and place them on a bench in the same order as removed INSTALLATION CAUTION DO NOT rotate or c...

Page 960: ...alloy cast iron cylinder heads Fig 4 are held in place by 12 bolts The spark plugs are located in the peak of the wedge between the valves INTAKE VALVES INTAKE VALVES INTAKE VALVE EXHAUST EXHAUST VALV...

Page 961: ...s head If ex ceeded either replace head or lightly machine the head surface The cylinder head surface finish should be 1 78 4 57 microns 15 80 microinches Inspect push rods Replace worn or bent rods I...

Page 962: ...bypass hose 21 Connect the accelerator linkage and if so equipped the speed control and transmission kick down cables 22 Install the fuel line 23 Install the generator and drive belt Tighten generato...

Page 963: ...leaner VALVE INSPECTION Measure valve stems for wear If wear exceeds 0 051 mm 0 002 inch replace the valve VALVE GUIDES Measure valve stem guide clearance as follows A Install Black Valve Guide Sleeve...

Page 964: ...entricity of valve seat using a dial indicator Total runout should not exceed 0 038 mm 0 0015 inch total indicator reading 3 Inspect the valve seat with Prussian blue to de termine where the valve con...

Page 965: ...em to lose length and allow valves to seat noisily LOW Low oil level may allow oil pump to take in air When air is fed to the tappets causes them to lose length and allows valves to seat noisily Any l...

Page 966: ...e with the number up For the right side the mnsber tab is at the rear of engine with the number up CAUTION The cylinder head cower fasteners have a special plating DO NOT use alternative fasteners 9 P...

Page 967: ...t refer to Group 7 Cooling System 4 Install the cooling system fan Tighten the bolts to 28 N m 17 ft lbs torque 6 Position the fan shroud and install the bolts Tighten the bolts to 11 N m 95 in lbs to...

Page 968: ...ote the amount of chain movement Fig 5 J9409 96 Fig 5 Measuring Timing Chain Wear and Stretch 4 Install a new timing chain if its movement ex ceeds 3 175 mm 1 8 inch 5 If chain is not satisfactory ali...

Page 969: ...l C 3688 Fig 10 SPECIAL TOOL C 3688 J9409 142 Fig 10 Installing Crankshaft Pulley Damper 5 Prime oil pump by squirt oil in the oil filter mounting hole and filling the J trap of the front tim ing cove...

Page 970: ...cylinder heads and gaskets They can be lifted and retained for camshaft removal 4 Remove upper and lower intake manifold refer to Group 11 Intake and Exhaust Systems 5 Remove timing chain cover and ti...

Page 971: ...e main bearing If the camshaft bearing shell oil holes are not in exact alignment remove and install them cor rectly Install a new core hole plug at the rear of camshaft Be sure this plug does not lea...

Page 972: ...anifolds refer to Group 11 Intake and Exhaust Systems OIL PAN REMOVAL 1 Disconnect the negative cable from the battery 2 Raise vehicle 3 Drain engine oil 4 Remove left engine to transmission strut 5 R...

Page 973: ...TS J9409 74 Fig 3 Oil Pan Bolt Location 8 Install the drain plug Tighten drain plug to 84 N m 25 ft lbs torque 9 Install the engine to transmission strut 10 Lower vehicle 11 Connect the negative cable...

Page 974: ...OIL G A L L E R Y FOR T A P P E T S T A P P E T OIL PRESSURE RELIEF VALVE CAMSHAFT HYDRAULIC T A P P E T FRTOF B L O C K OIL PICKUP J9509 144 FIG 4 ENGINE LUBRICATION SYSTEM...

Page 975: ...l Pump Cover Flatness Measure thickness Figs 7 and 8 and diameter of rotors If either rotor thickness measures 18 92 mm 0 744 inch or less or if the diameter is 82 45 mm 3 246 inches or less replace r...

Page 976: ...mall marks may be removed with 400 grit wet or dry sandpaper The relief valve spring has a free length of approx imately 49 5 mm 1 95 inches The spring should test between 100 and 109 N 22 5 and 24 5...

Page 977: ...rod cap are identified with the cylinder number Remove connecting rod cap Install connecting rod bolt guide set on connecting rod bolts 6 Pistons and connecting rods must be removed from top of cylind...

Page 978: ...on or the word TOP Figs 15 and 17 SECOND COMPRESSION RING BLACK CAST IRON CHAMFER TWO DOTS J9009 46 m Fig 15 Second Compression Ring Identification Typical c Using a ring installer install the top com...

Page 979: ...rrow on top of piston must be pointing toward front of engine The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet 7 While tapping the piston down in cylind...

Page 980: ...Upper Main Bearing Removal and Installation with Tool C 3059 thrust bearing against No 3 bulkhead Repeat proce dure driving crankshaft forward to align rear flange of thrust bearings in a common plan...

Page 981: ...the rear seal in the retainer 2 Using Special Tool 6687 position the retainer and oil seal over the crankshaft Install the bolts and tighten to 22 N m 16 ft lbs torque 3 The seal face surface must be...

Page 982: ...Mopar Gasket Maker or equivalent CAUTION DO NOT drive cup plug into the casting as restricted coolant flow can result and cause se rious engine problems 2 Using proper plug driver drive cup plug into...

Page 983: ...24 oz Crankshaft Connecting Rod Journal Diameter 53 950 53 975 mm 2 124 2 125 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Crankshaft Cont Main Bearing Diametrical Clearance No...

Page 984: ...m 0 0098 0 0218 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...

Page 985: ...TION IDENTIFICATION LOCATION O F 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 con...

Page 986: ...68 N m 50ft lbs 47 N m 35ft lbs 22 N m 75N m 41 N m 41 Hm 20 N m 22 N m 54 N m 16ft lbs 55ft lbs 30ft lbs 30ft lbs 175 in lbs 16ft lbs 40ft lbs Intake Manifold Bolts Upper 22 N m 16ft lbs Oil Filter...

Page 987: ...Aluminum Connecting Rods Forged Steel J9409 12 Fig 1 Diesel Engine Description This engine is designed for No 2 Diesel Fuel Only use No l Diesel Fuel where extended arctic condi tions exist below 23...

Page 988: ...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...

Page 989: ...9 148 5 9L DIESEL ENGINE B R 0 4 X 2 3500 MANUAL 4 X 4 3500 MANUAL 4500 ALL 4 X 2 AUTOMATICS 4 X 4 AUTOMATICS...

Page 990: ...Install the engine on a suitable stand 41 Remove all accessories and brackets not previ ously removed for use with the replacement engine INSTALLATION 1 Check the data plate to verify that the replace...

Page 991: ...gine with the required amount of clean engine lubricating oil refer to Group 0 Lubri cation and Maintenance 42 Install the battery and connect the battery ca bles 43 Check the oil level after the engi...

Page 992: ...N m 18 ft lbs torque CYLINDER HEAD These cylinder heads can only be used on engines with an intercooler DO NOT interchange with ear lier models REMOVAL 1 Drain the coolant DO NOT waste reusable coolan...

Page 993: ...combined total of stock removed must not exceed 1 00 m m 0 03937 inch The amount of MIN 102 0 mm 4 0157 inch MAX 102 116 m m 4 0203 inch Out of Round 0 038 mm 0 0015 inch Taper 0 76 mm 0 003 inch Over...

Page 994: ...lower lbs tighten to this torque all long 12 mm bolts Nos 4 5 in sequence Fig 10 to 120 N m Check the torque If lower than tighten to this torque all bolts in sequence Fig 10 an t l 3T b a J9109 36 Fi...

Page 995: ...e the valve end VALWE GR1N01NG The valve seat angle should be 30 Intake Valve and 45 Exhaust Valve Fig 3 Measure the rim thickness Fig 4 The minimum valve rim thickness is 0 79 mm 0 031 inch Grind the...

Page 996: ...Valve guides must also be square with the combustion face within 0 10 m m 0 004 inch at 50 0 m m 2 0 inch radius Lubricate the valve guides with oil and press in the guides to 12 25 0 50 m m 0 4823 0...

Page 997: ...d the depth of each valve CYLINDER HEAD DECK VALVE FACE VALVE DEPTH J9109 140 Fig 9 Cylinder Head Height Fig 10 Valve Depth Grind the valve seats to remove scores scratches and burns The seat angle sh...

Page 998: ...crometers 128 0 microinch J9409 116 Fig 13 Machining for Service Valve Seats Exhaust Valve SERWiCI WilWE SEAT GRINDING Install the valves in their designated location and measure the valve depth The v...

Page 999: ...D IN LINE WITH THE VALVE STEM WHEN TAPPING THE VALVES BR Fig 16 Valve Stem Seal Installation COLLETS VALVE Fig 17 Waive Valve Spring and Collet Installation 6 Tap the ends of the valve stems with a ma...

Page 1000: ...ve the following Camshaft Gear driven accessories Fuel injection pump refer to Group 14 Fuel Sys tem Fan hub assembly refer to Group 7 Cooling Sys tem 4 Remove the gear housing and gasket Fig 1 5 Clea...

Page 1001: ...ION 1 Lubricate the front gear train with clean en gine oil 2 Thoroughly clean the front seal area of the crankshaft The seal lip and the sealing surface on the crankshaft must be free from all oil re...

Page 1002: ...emoved from gear housing it must be precisely reset to obtain exact TDC 3 Install a new O Ring lubricate the pin and po sition in the housing Fig 7 Install the new retain ing ring to 1 5 mm 0 059 inch...

Page 1003: ...t be rotated one revo lution in the direction of engine rotation 15 Apply a coat of Loctite 59241 Liquid Te flon or equivalent to the threads of the Torx head bolts Install the timing pin assembly and...

Page 1004: ...l 3822513 is available for this job 3 Make sure the trough is positioned so it will catch the tappet when the wooden dowel is removed 4 Identify the location of each tappet as it is re moved The tappe...

Page 1005: ...m bore Fig 4 Fig 4 Insert Installation Tool into Tappet 7 Pull the tool tappet through the cam bore and up into the tappet bore Fig 5 Fig 5 Pull Tappet Tool into Position 8 Difficulty could be experie...

Page 1006: ...kshaft to camshaft timing marks Fig 7 J9109 51 Fig 7 Align Crankshaft to Camshaft 5 Remove the bolts from the thrust plate Fig 8 6 Remove the camshaft gear and thrust plate Fig 8 Thrust Plate Bolt Loc...

Page 1007: ...h any rough sur faces caused by removing the gear 3 Install the camshaft key 4 Lubricate the camshaft surface with Lubriplate 105 or equivalent CAUTION The camshaft gear will be permanently distorted...

Page 1008: ...Inspect the tappet bores for scoring or excessive wear Fig 4 If out of limits replace the cylinder block CYLINDER BORES DE GLAZE 1 New piston rings may not seat in glazed cylin der bores 2 De glazing...

Page 1009: ...e CYLINDER BLOCK REFACING 1 The combustion deck can be refaced twice The first reface should be 0 25 m m 0 0098 inch I f addi tional refacing is required an additional 0 25 m m 0 0098 inch can be remo...

Page 1010: ...80 grit honing stones To finish hone use 280 grit honing stones A maximum of 1 2 micrometer 48 microinch sur face finish must be obtained After finish honing is complete immediately clean the cylinder...

Page 1011: ...ear protective gloves to push the cold sleeve into the bore as far as possible Using a sleeve driver drive the sleeve downward until it contacts the step at the bottom of the bore Fig 12 Fig 12 Sleeve...

Page 1012: ...15 Fig 15 Oii Hole Alignment CUP PLUG REPLACEMENT 1 Remove the cup plugs from the oil passages Fig 16 2 Apply a bead of Loctite 277 around the outside diameter of the oil passage cup plugs 3 Drive the...

Page 1013: ...damage Inspect the pistons for damage and excessive wear Check top of the piston ring grooves skirt and pin bore Measure the piston skirt diameter Fig 2 If the piston is out of limits replace the pis...

Page 1014: ...earing Clearance Max 0 089 mm 0 0035 Inch J 9 1 0 9 9 1 Fig 7 Connecting Rod Journal Diameter Limits PISTON GRADING When rebuilding an engine with the original cylin der block crankshaft and pistons m...

Page 1015: ...l the top of the piston is approximately 50 mm 2 inch below the J9109 84 Fig 20 Piston Rod Assembly at BDC top of the block Carefully pull the connecting rod onto the crankshaft journal 8 Use clean en...

Page 1016: ...rom the cylinder block 5 Use two of the main bearing cap bolts to wiggle the main cap loose being careful not to damage the bolt threads Fig 2 Remove the caps WARNING USE A HOIST TO AVOID INJURY 6 Lif...

Page 1017: ...0005 inch 0 50 mm 0 0197 inch 82 500 0 013 mm 3 2480 0 0005 inch 0 75 mm 0 0295 inch 82 250 0 013 mm 3 2381 0 0005 inch 1 00 mm 0 0394 inch 82 000 0 013 mm 3 2283 0 0005 inch OUT OF ROUND TAPER MAX 0...

Page 1018: ...al 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 ORIGINAL RADIUS NEW UNDERCUT RADIUS JOURNAL SURFACEs SURFACE FINISH 0 8 micr...

Page 1019: ...Install the pilot from the seal kit onto the crankshaft 5 Install the seal onto the pilot and start it into the gear housing cover seal bore 6 Remove the pilot 7 Use the alignment installation tool an...

Page 1020: ...eal pilot SEAL PILOT J9109 101 Fig 15 Crankshaft Rear Seal Pilot 8 Use alignment and installation tool packaged in the seal kit Fig 16 Alternately drive the seal at the 12 3 6 and 9 o clock positions...

Page 1021: ...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 127 C 250 F WARNING YOU INST WEAR PROTECTIVE LL THE HEATED G E A F GLOVES...

Page 1022: ...oulder INSTALLATION CAUTION Use only hand force to push the nozzle in place If driven with a hammer the nozzle will be damaged 1 Use a center punch to push the piston cooling nozzle into place Install...

Page 1023: ...ust and place a dial indicator as shown Fig 25 DIAL INDICATOR CYLINDER BLOCK J9109 97 Fig 25 Position of Dial Indicator 15 Zero the indicator needle and push the crank shaft towards the other end of i...

Page 1024: ...ged filter The valve is designed to open when the pressure drop across the filter is more than 138 kPa 20 PSI as with a plugged filter and lets the lu bricating oil continue on through the engine When...

Page 1025: ......

Page 1026: ...he crankshaft vibration damper and re move the drive belt 8 Remove the fan clutch assembly 4 Remove the fan hub Remove the oil fill tube Remove the crankshaft vibration damper Remove the gear housing...

Page 1027: ...the pump Measure the gears backlash Fig 9 The limits of a used pump is 0 080 0 380 mm 0 003 0 015 inch If the backlash is out of limits replace the oil pump Install the back plate PORT PLATE GEROTOR...

Page 1028: ...filter element with clean oil before installation Use the same type oil that will be used in the engine 2 Apply a light film of lubricating oil to the seal ing surface before installing the filter CA...

Page 1029: ...lve bore 2 Install the valve spring gasket and plug VALVE OPEN HEIGHT 41 25mm 1 62 inch LOAD 126 N 28 4 lb FREE LENGTH 66mm 2 6 inch J9509 161 Fig 14 Oil Pressure Regulator Spring Check Tighten the pl...

Page 1030: ...to 24 N m 18 ft lbs torque 3 Connect the turbocharger oil supply line Tighten the nut to 15 N m 11 ft lbs torque 4 Fill the filter with clean lubricating oil and ap ply a light coat of oil to the seal...

Page 1031: ...0 50 mm 68 462 mm 0 0197 in 2 6954 in Machined 0 75 mm 68 212 mm 0 0295 in 2 6855 in Machined 1 00 m m 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 Oi...

Page 1032: ...3 kPa 25 psi Pistons Skirt Diameter 101 880 101 823 mm 4 0110 4 0088 in Ring Groove Depth I n t e r m e d i a t e 0 150 mm 0 006 in Oil Control 0 130 mm 0 005 in Piston Pins Diameter Min Bore Diameter...

Page 1033: ...6 N m 1 4 0 ft lbs Generator Mounting Bolts 4 1 N m 3 0 ft lbs Generator Pulley 8 0 N m 5 9 ft lbs Generator Support Upper 2 4 N m 1 8 ft lbs Gear Cover 24 N m 18 ft lbs Gear Housing Bolts 2 4 N m 1 8...

Page 1034: ...talytic converter body Excessive heat can result in bulging or other distor tion but excessive heat will not be the fault of the converter If unburned fuel enters the converter over heating may occur...

Page 1035: ...muffler assembly Check exhaust system 3 Replace exhaust pipe 4 Tighten connection attaching nuts 5 Replace exhaust manifold 6 Tighten exhaust manifold to cylinder head stud nuts or bolts 7 Remove rest...

Page 1036: ...pe from the support hangers on the 5 9L Heavy Duty and the 8 0L en gines Fig 2 6 Remove the exhaust pipe CLEANING Clean ends of pipes to assure mating of all parts INSPECTION Discard rusted clamps bro...

Page 1037: ...ent with orig inal equipment parts or equivalent This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels INSTALLATION 1 Connect the support hanger...

Page 1038: ...used to permit proper alignment of all parts 2 Connect the support hangers Fig 6 and 7 3 Position the exhaust tailpipe and extension pipe if used for proper clearance with the underbody parts 4 Tight...

Page 1039: ...lenum pan rail must be clean and dry free of all foreign material INSPECTION Inspect manifold for cracks Inspect mating surfaces of manifold for flatness with a straightedge INSTALLATION 1 Install the...

Page 1040: ...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 s...

Page 1041: ...em refer to 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...

Page 1042: ...lent into the four corner pockets Fig 11 Fill the pocket but DO NOT overfill J9409 65 f er intah LOCATOR DOWELS LOCATOR DOWELS J9409 64 Fig 12 intake Manifold Flange Gasket Alignment 4 The lower intak...

Page 1043: ...fold to cylinder head 7 Remove manifold from the cylinder head CLEANING Clean mating surfaces on cylinder head and mani fold Wash with solvent and blow dry with com pressed air INSPECTION Inspect mani...

Page 1044: ...air SHIELD J94H 14 Fig 17 Left Engine Exhaust Manifold INSPECTION Inspect manifold for cracks Inspect mating surfaces of manifold for flatness with a straight edge Gasket surfaces must be flat within...

Page 1045: ...gers Fig 1 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 page Exhaust Tailpipe 15 Intak...

Page 1046: ...d provide acceptable exhaust noise levels INSTALLATION 1 Connect the support hanger Fig 3 2 Install the clamps and nuts Tighten the nuts to 43 N m 32 ft lbs torque 3 Lower the vehicle 4 Start the engi...

Page 1047: ...upply line and the oil drain tube from the turbocharger Fig 7 3 Disconnect the charge air cooler Intercooler inlet duct from the turbocharger Fig 7 4 Remove the turbocharger and gasket 5 Remove the ca...

Page 1048: ...nect the charge air temperature sensor from the intake manifold cover Fig 12 6 Disconnect the air temperature switch from the intake manifold cover Fig 12 7 Disconnect the fuel heater ground wire from...

Page 1049: ...l and bleed the high pressure fuel lines Tighten the high pressure fuel line nuts to 24 N m 18 ft lbs torque TURBOCHARGER REMOVAL 1 Disconnect the negative cable from the battery 2 Disconnect the air...

Page 1050: ...the negative cable to the battery 10 Operate the engine and check for leaks WASTEGATE ADJUSTMENT The wastegate turbocharger provides additional low speed boost without over boost at high speeds This i...

Page 1051: ...ne efficiency and power REMOVAL WARNING IF THE ENGINE WAS JUST TURNED OFF THE INTAKE AND OUTLET DUCTS MAY B E HOT 1 Remove the grille refer to Group 23 Body for the proper procedure 2 Remove the front...

Page 1052: ...If any damage causes the charge air cooler to fail the charge air cooler must replaced INSTALLATION 1 Position the charge air cooler intercooler Fig 4 Install the bolts and tighten to 2 N m 17 in lbs...

Page 1053: ...32 ft lbs Exhaust Pipe to Catalytic Converter Clamp Nuts 43 N m 32 ft lbs Exhaust Pipe to Exnaust Manifold Bolts Nuts 26 N m 19 ft lbs Fuel Heater Ground Bolt 12 N m 110 in lbs Fuel Line Nuts 24 N m 1...

Page 1054: ...rs from horns 5 Disengage wire connectors from fog lamps if equipped 6 Separate front bumper from vehicle INSTALLATION Reverse the preceding operation FRONT BUMPER UPPER FASCIA REMOVAL FIG 2 1 Remove...

Page 1055: ...air dam from vehicle INSTALLATION Reverse the preceding operation Fig 4 Front Bumper Air Dam SKID PLATE MEMOWAL FIG 5 1 Hoist and support vehicle on safety stands 2 Remove bolts holding skid plate to...

Page 1056: ...R REMOVAL FIG 7 1 Support rear bumper on a suitable lifting de vice 2 Remove bolts holding rear bumper braces to frame rails 3 Disengage license plate lamp wire connector from body wire harness if equ...

Page 1057: ...ch on a suitable lifting de vice 2 Remove fasteners holding trailer wiring connec tor to trailer hitch if equipped 3 Remove bolts holding trailer hitch to frame rails 4 Separate trailer hitch from veh...

Page 1058: ...moldboard either straight ahead or to the side Hinge Pins Allows the A Frame to pivot up and down The pins act as moldboard attaching points Cutting Edge Replaceable blade edge extends the life of the...

Page 1059: ...ated between solenoid valve B and the lift cylinder It prevents fluid in the lift cylinder from leaking back through solenoid valve B If fluid leaks back it could angle the blade to the left This woul...

Page 1060: ...ITION SWITCH ANGLE LIGHT GREEN ORANGE WITH WHITE TRACER FUSE BATTERY O SOLENOID SWITCH MOTOR ENERGIZED MOTOR AND B COIL PRESSURE RELIEF B SOLENOID _ J T T L SOLENOID ANGLING CYLINDER l m OPERATING PRE...

Page 1061: ...ZED A COIL B SOLENOID C SOLENOID PRESSURE RELIEF CHECK CHECK POWER ANGLING CYLINDER LOWER AND FLOAT FORCE APPLIED AGAINST LIFT RAM OPERATING PRESSURE EXHAUST INTAKE OR DRAIN METERED FLOW RB526 Fig 3 L...

Page 1062: ...R 0 7 TAN ORANGE WITH WHITE TRACER TAN RED E 4 3 IGNITION SWITCH t SWITCH I ANGLE ORANGE WITH FUSE WHITE TRACER f 4 LIGHT GREEN MOTOR SOLENOID SWITCH BATTERY o ENERGIZED MOTOR AND C COIL Fig 4 Angle B...

Page 1063: ...E TRACER 6 SWITCH O ORANGE WITH WHITE TRACER TAN RED ANGLE FUSE i LIGHT GREEN IGNITION SWITCH BATTERY o MOTOR SOLENOID SWITCH ENERGIZED MOTOR C SOLENOID wsmrn OPERATING PRESSURE EXHAUST INTAKE OR DRAI...

Page 1064: ...o voltage at A coil b A cartridge jammed in closed position c Inoperative A coil a Leaking A cartridge b Leaking A cartridge O ring seal c Leaking B Check Valve d Leaking Ram Packing Cup e Leaking O r...

Page 1065: ...YL SP4 18WT BR f DOWN DOWN PLOW CONTROL SWITCH UP DOWN L Dl 18RD YL PLOW CONTROL j SWITCH 1 LEFT TO RIGHT SP4 18WT BR Dl 18RD YL TRANSMISSION OIL TEMPERATURE LAMP SP4 18WT BR SP4 18WT BR SP4 18WT BR S...

Page 1066: ...D YL SP5 18WT LG SP5 18WT LG Dl 18RD YL TRANSMISSION OIL TEMPERATURE LAMP T2 18LG RD BLUE SP4 18WT BR SNOW PLOW MOTOR SOLENOID LEFT WHEELHOUSE Ml 6RD BODY GROUND FRONT SNOW PLOW FRAME i Ml 6RD SNOW PL...

Page 1067: ...SH 25 y L2 14LG TO FRONT END WIRING SEE SH 22 RIGHT SIDE RADIATOR YOKE PANEL BLACK BLACK BLACK BLACK LEFT AUXILIARY PARK AND TURN SIGNAL LAMP LEFT AUXILIARY HEADLAMP RIGHT AUXILIARY HEADLAMP RIGHT AU...

Page 1068: ...id valve Inspect it for external damage BUMPERS AND FRAME 13 15 23 Disassemble the three way valve Fig 9 Dis card the O ring seal 24 Remove and clean solenoid valve C with spe cial tool J 25399 Fig 9...

Page 1069: ...Fig 9 Power Unit Exploded View...

Page 1070: ...Way Valve 43 4 Way Coil 44 3 Way Solenoid 45 3 Way Valve 46 3 Way Coil 47 Cap Plug 48 Check Spring 49 Cylinder Tank 50 Valve Block 51 Cage 52 O Ring Seal Glide Ring 53 Crossover Valve 54 Pilot Check V...

Page 1071: ...rt straps to the snow plow frame Fig 15 4 Remove the nuts washers and bolts that attach the snow plow frame to the vehicle frame side rails and front crossmember Fig 15 5 Remove the snow plow frame an...

Page 1072: ...ls with the bolt holes aligned Fig 16 2 Install the pivot bracket attaching bolts wash ers and nuts finger tight Fig 16 3 Install the support strap attaching bolts and nuts Fig 15 Tighten the nuts to...

Page 1073: ...e switch cover openings Connect the wire harness connectors to the switches Fig 18 4 Mate the switch cover with the module hous ing Install the housing attaching screws Fig 18 Tighten the screws until...

Page 1074: ...es H Y D R A U L I C SPICIPICATIONS mmp C R O S S O V E R RELIEF V A L V E SOLEWOIP VALVES A B AMP C SPE 8F2CATiONS A Coll Applied Voltage 12 Volts DC Current 0 83 Amperes Nominal resistance one ohmme...

Page 1075: ...es frame rail failure can result Do Not use softer than Grade 3 bolts to replace production fasteners loosening or failure can re sult When using heat to straighten frame components do not exceed 566...

Page 1076: ...the following procedures 1 Drill a hole at each end of the crack with a 3 mm 0 125 in diameter drill bit 2 Using a suitable die grinder with 3 inch cut off wheel V groove the crack to allow 100 weld p...

Page 1077: ...99 76 WB 134 7 SHOWN ALL DIMENSIONS ARE SHOWN IN INCHES CAB HOLD D O W N BRKT REAR TRANS C MEMBER FRONT SPRING HANGER REAR SPRING HANGER BR 1500 and 2500 119 and 135 WHEEL BASE REAR WHEEL DRIVE REAR F...

Page 1078: ...B 134 7 S H O W N ALL DIMENSIONS ARE SHOWN IN INCHES 0 6 3 2 HOLES CAB HOLD F R O N T D O W N BRKT SPRING HANGER REAR TRANS C MEMBER REAR SPRING HANGER BR 1500 and 2500 119 and 135 WHEEL BASE FOUR WHE...

Page 1079: ...13 26 BUMPERS AID FRAME ALL DIMENSIONS ARE SHOWN IN INCHES REAR FRAME SECTION Fig 6 BR 3500 Rear Wheel Drive J9413 17...

Page 1080: ...7 59 66 103 76 162 7 83 66 127 76 WB 134 7 SHOWN ALL DIMENSIONS ARE SHOWN IN INCHES CAB H O L D FRONT DOWN BRKT SPRING HANGER REAR TRANS C MEMBER REAR SPRING HANGER BR 3500 135 139 and 163 WHEEL BASE...

Page 1081: ...13 28 BUMPERS AND FRAME B R REAR TRANS C MEMBER BOX TIE DOWN BRKTS FRONT SPRING HANGER REAR SPRING HANGER Pig 8 BR 1500 Club Cab Rear Wheel Drive J9513 31...

Page 1082: ...20 59 35 51 37 63 58 97 34 9 0 2 5 1 5 J 5 0 9 0 41 02 REAR AXLE 3 6 6 18 84 i L E I FRONT SPRING HANGER REAR TRANS C MEMBER BOX TIE DOWN BRKTS REAR SPRING HANGER Fig 9 BR 1500 Club Cab Rear Wheel Dri...

Page 1083: ...L 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 injecti...

Page 1084: ...Electric fuel pump o Fuel pump reservoir o A separate in tank fuel filter Pressure relief rollover valve Fuel gauge sending unit Fuel supply line connection o Auxiliary fuel supply fitting not all eng...

Page 1085: ...egulator the pressure relief rollover valve and the fuel pump electrical connector should all be pointed to the drivers side of the vehicle before tightening locknut 2 Position new locknut over top of...

Page 1086: ...nk Refer to Fuel Tanks in this group 2 The fuel filter regulator is pressed into a rubber grommet Remove by twisting and pulling straight up Fig 5 CAUTION D not pull the filter regulator more than thr...

Page 1087: ...otective plastic cap from the pressure test port on the fuel rail Fig 9 On the 8 0L V 10 engine this test port is located at the front of the engine Fig 9 Typical Fuel Pressure Test Port W A R N I N G...

Page 1088: ...before tool connection 3 Connect Fuel Line Pressure Test Adapter Tool number 6631 3 8 in or number 6539 5 16 in into the disconnected fuel supply line tube Insert the other end of Adapter Tool 6631 o...

Page 1089: ...iately if there is any evidence of degra dation that could result in failure Never attempt to repair a plastic fuel line tube Re place as necessary Avoid contact of any fuel tubes hoses with other veh...

Page 1090: ...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 Fig 15 Removing Pull Tab 9 Prior to co...

Page 1091: ...ain 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...

Page 1092: ...to battery 15 Start engine and check for leaks pressed squarely into the fitting body if this re tainer is cocked during removal it may be dif ficult to disconnect fitting Use an open end wrench on th...

Page 1093: ...d air heater relays is not directly regulated by the PCM The fuel delivery system of the 5 9L turbo diesel engine consists of the Fuel tank Fuel tank module Low and high pressure fuel supply lines pag...

Page 1094: ...CTION PUMP HIGH PRESSURE FUEL LINES NTAKE MANIFOLD HIGH PRESSURE FUEL INJECTION PUMP THROTTLE POSITION SENSOR AUTO TRANS ONLY FUEL SHUTDOWN SOLENOID WATER TEMPERATURE SENSOR FOR I P GAUGE FUEL FILTER...

Page 1095: ...ing 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 Note the direction of the fuel line connectors the pressure relief rollover valv...

Page 1096: ...he Fuel Tank section of this group for in formation FUEL TRANSFER PUMP The fuel transfer pump fuel lift pump is located on the left rear side of the engine cylinder block above the starter motor Fig 1...

Page 1097: ...system up to the fuel injec tor pump continually press on the button Fig 8 un til resistance is felt This resistance will indicate that priming is completed and air has been removed If the primer butt...

Page 1098: ...e Diesel Engine sections of this group for an operational description diagnosis and removal instal lation procedures FUEL INJECTION PUMP The fuel injection pump is a Bosch P7100 series in line type Fi...

Page 1099: ...rns to the engine through an opening at the front of pump A KSB cold start solenoid is not used The injection pump high idle speed is factory sealed and is not adjustable The low idle speed is P7100 I...

Page 1100: ...lenoid and a three wire pigtail wire harness is attached to the solenoid When the ignition switch is turned to the CRANK starter engaged position high amperage current approximately 40 amps at 12 volt...

Page 1101: ...fuel is continually vented from the fuel injec tion pump to cool the pump and the fuel injectors During injection a small amount of fuel flows past the injector nozzle and is not injected into the co...

Page 1102: ...be replaced immediately if there is any evidence of degradation that could result in failure Avoid contact with clamps or other components that cause abrasions or scuffing Be sure that the rubber hose...

Page 1103: ...s While working over the left rear tire wheel a Disconnect the electrical connector from the fuel tank module Fig 3 b Disconnect the fuel supply and fuel return lines at the fuel tank module Fig 3 Ref...

Page 1104: ...e removed when servicing the fuel tank fuel tubes lines or va por vent line it is very important that these heat shields be reinstalled after service They are used to protect lines and tank from heat...

Page 1105: ...n removal 3 Use a second screwdriver as a support to pry valve and grommet assembly from tank 4 To remove grommet from valve place valve up right on a flat surface Push down on the grommet Peel the gr...

Page 1106: ...plastic cable retainer and throttle cable core wire from upper end of pedal arm Fig 3 The plastic cable retainer snaps into pedal the arm PEDAL RETURN SPRING MANUAL TRANS ONLY THROTTLE BODY CABLE PIN...

Page 1107: ...tabs at the dash panel Fig 3 5 Remove cable housing from dash panel and pull the cable into the engine compartment 6 3 9L 5 2L 5 9L Gas Powered Engines Dis connect the cable from the routing holddown...

Page 1108: ...bber plastic grom met locks into position on the bracket b Connect cable end socket to the fuel injection pump lever ball snaps on 4 Install the remaining cable housing end into and through the dash p...

Page 1109: ...erator pedal is pressed to the floor This is checked by observing throttle lever breakover position Pro ceed to the following a Key OFF and engine OFF for this test b Two people are needed for this te...

Page 1110: ...formation The 3 9L V 6 and 5 2L V 8 engines will be referred to in this group as LDC Light Duty Cycle engines The 5 9L V 8 gas powered engine will be referred to as either LDC Light Duty Cycle or HDC...

Page 1111: ...is con verts battery voltage to a regulated 8 0 volts It is used to power the crankshaft position sensor cam shaft position sensor and vehicle speed sensor The PCM also provides a five 5 volt supply f...

Page 1112: ...coil s and ignition timing Malfunction indicator lamp check engine lamp Overdrive solenoid electrical operation auto trans only Overdrive warning lamp auto trans only SCI transmit DRB scan tool connec...

Page 1113: ...GENERATOR J9414 49 Fig 2 System Schematic 3 9L V 6 Engine...

Page 1114: ...GENERATOR J9414 50 Fig 3 System Schematic 5 2L 5 9L LDC V 8 Engine...

Page 1115: ......

Page 1116: ...THROTTLE POSITION SENSOR o o S o o 0 o z 00 o m ZD X O GENERATOR J9414 52 Fig 5 System Schematic S OL HDC V 10 Engine m...

Page 1117: ...Engine Typical changes At cold coolant temperatures its resistance is high As temperatures increase its resistance will decrease The coolant sensor provides an input voltage to the powertrain control...

Page 1118: ...nsmission An overdrive override push button switch is located on the instrument panel The PCM circuit for overdrive is controlled by in puts from the engine coolant temperature sensor and vehicle spee...

Page 1119: ...FUEL INJECTORS PCM PIN 14 PCM OUTPUT 3 9L 5 2L 5 9L ENGINES Pin 14 is used as the ground control circuit for the fuel injector on cylinder 3 on 3 9L 5 2L 5 9L engines Refer to Fuel Injectors PCM Pin 1...

Page 1120: ...as the ground control circuit for the fuel injector on cylinder 8 on 5 2L 5 9L engines Re fer to Fuel Injectors PCM Pin 13 PCM Output for information IGNITION COIL DRIVER PCM PIN 18 PCM OUTPUT 8 0L V...

Page 1121: ...f the throttle body Fig 17 Fig 15 Sensor Location 3 9L V 6 Engine Typical THROTTLE POSITION SENSOR PCM PIN 22 PCM INPUT The throttle position sensor TPS is located on the left side of the throttle bod...

Page 1122: ...g ele ment that keeps the sensor at proper operating tem perature during all operating modes Maintaining correct sensor temperature at all times allows the system to enter into Closed Loop operation s...

Page 1123: ...CONTROL MODULE PCM J9414 11 Fig 22 PCM and Data Link Connector Typical is in the proper range for A C application The PCM uses this input to cycle the A C compressor clutch through the A C relay It w...

Page 1124: ...32 PCM OUTPUT The malfunction indicator lamp illuminates on the instrument panel each time the ignition key is turned on This lamp is displayed on the instrument panel as the CHECK ENGINE lamp Fig 24...

Page 1125: ...e operation of the instrument panel mounted overdrive lamp On the 8 0L V 10 engine this circuit is controlled by pin 31 When the lamp is illuminated the overdrive is engaged 8 0L V 10 ENGINE Pin 37 is...

Page 1126: ...CM PIN 42 PCM INPUT CERTAIN HEAWY DUTY ENGINES WITH AUTOMATIC TRANSMISSIONS ONLY The transmission temperature sensor is a variable thermistor type It reacts to temperature changes At cold transmission...

Page 1127: ...to Data Link Connector PCM PIN 25 PCM Output for information CCD BUS PCM PIN 46 PCM OUTPUT Various modules exchange information through a communications port called the CCD BUS VEHICLE SPEED SENSOR P...

Page 1128: ...voltage to the fuel injectors ignition coil s and generator field winding If these signals are not Fig 34 Power Distribution Center PDC Location received by the PCM after approximately one second of...

Page 1129: ...ng and is brought back to range of up shift lamp operation This will also happen if vehicle is shifted into fifth gear The indicator lamp is normally illuminated when the ignition switch is turned on...

Page 1130: ...ut for information FUEL FILTER A fuel tank mounted combination fuel filter fuel pressure regulator is used for all gasoline powered engines For information refer to Fuel Filter Fuel Pressure Regulator...

Page 1131: ...1 or 42 The fuel pressure regulator is not mounted to the fuel rail on any gas powered engines It is located on the fuel tank mounted fuel VACUUM FITTING IDLE AIR IDLE AIR PASSAGE CONTROL IAC MOTOR VI...

Page 1132: ...idle and cruise modes with the engine at operating tem perature are Closed Loop modes IGNITION SWITCH MODE KEY ON ENGINE OFF This is an Open Loop mode When the fuel system is activated by the ignition...

Page 1133: ...te 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 o Oxygen sensor Based...

Page 1134: ...rcuit to the A C clutch relay to disengage the A C compressor clutch This is done until the vehicle is no longer under de celeration if the A C system is operating WIDE OPEN THROTTLE MODE This is an O...

Page 1135: ...NG BOLT J9414 9 Fig 1 Powertrain Control Module PCM page Oxygen 02S Sensor Heating Element Test 62 Powertrain Control Module PCM 60 Way Connector 57 Powertrain Control Module Testing 65 Relays Operati...

Page 1136: ...I4 7 Fig 3 Ignition CoU 3 9U5 2U5 9L LDC Gas Engine COIL CONNECTOR Fig 4 ignition Coil 5 9L HDC Gas Engine 3 Fig 6 PCV Valve and Hose Connections 3 9U5 2U 5 9L Engines Typical VACUUM HE ENGINE C Y L I...

Page 1137: ...ser for restrictions 16 Verify that the intake manifold air tempera ture sensor wire connector is firmly connected to har ness connector Figs 8 9 or 10 Fig 8 Sensor Location 3 9L V 6 Engine Typical Fi...

Page 1138: ...r pinched or leaking fuel lines tubes Inspect for pinched cracked or leaking fuel hoses 24 Inspect for exhaust system restrictions such as pinched exhaust pipes collapsed muffler or plugged catalytic...

Page 1139: ...ION SENSOR TEST Refer to Group 8D Ignition Systems for Camshaft Position Sensor testing CRANKSHAFT POSITION SENSOR TEST Refer to Group 8D Ignition Systems for Crank shaft Position Sensor testing iNGIN...

Page 1140: ...orce a 4 3 downshift Once transmission temperature has cooled below mm SENSOR RESISTANCE ONMS ENGINE GOOLANT IMTAKE AIR AND TRANSMISSION TEMPERATURE SENSORS TEMPERATURI RESISTANCE OHMS C F mm MAX 40 4...

Page 1141: ...R TEMPERATURE SENSOR J9414 12 J9314 162 Fig 24 Sensor Location 5 2L 5 9L V 8 Engines Typical INTAKE MANIFOLD AIR TEMP SENSOR VI K I Fig 23 Sensor Location 3 9L V 6 Engine Typical J948D 10 Fig 25 Senso...

Page 1142: ...BBER FITTING J9314 87 Fig 28 Rubber Fitting MAP Sensor to Throttle Body Except S OL V 10 Engine Typical 2 3 9L V 6 or 5 2 5 9L V 8 Engines Test the MAP sensor output voltage at the MAP sensor connecto...

Page 1143: ...Attach the negative lead of the voltmeter to a good ground With the ignition key in the ON position and en gine not running check the sensor output voltage at the center terminal wire of the connector...

Page 1144: ...be between 500 and 900 rpm If the idle speed is outside of these specifications re place the throttle body Refer to Throttle Body in the Component Removal Installation section of this group 9 Disconne...

Page 1145: ...oper ventilation while operating the en gine Always return the engine idle speed to normal be fore disconnecting the exerciser tool J9414 47 Fig 38 IAC Motor 3 9U5 2U5 9L Engines Typical IDLE AIR CONT...

Page 1146: ...ion as described in step 5 b If the pintle operates properly check the IAC motor bore in the throttle body bore for blockage and clean as necessary Install the IAC motor and retest If blockage is not...

Page 1147: ...e relay to the ground side of a 12 Volt power source 6 Attach the other jumper wire to the positive side of a 12V power source Do not connect this jumper wire to relay at this time 85 30 86 87 87A ENE...

Page 1148: ...hough a mal function has occurred This may happen because one of the DTC criteria for the circuit has not been met Example assume that one of the criteria for the MAP sensor circuit is that the engine...

Page 1149: ...uel pressure regulator The PCM cannot detect a clogged fuel pump inlet filter clogged in line fuel fil ter or a pinched fuel supply or return line However these could result in a rich or lean conditio...

Page 1150: ...propriate Powertrain Diagnostic Procedures service manual DIAGNOSTIC TROUBLE CODE DTC On the following pages a list of diagnostic trouble codes is provided for all gas powered engines A DTC indicates...

Page 1151: ...t sensor Oxygen sensor input voltage maintained above the normal operating range If equipped with dual 02S sensors the DRB scan tool will specify left or right sensor Engine coolant temperature sensor...

Page 1152: ...t respond properly to the control signal Injector 7 output driver does not respond properly to the control signal Injector 8 output driver does not respond properly to the control signal An open or sh...

Page 1153: ...o shutdown relay circuit An open or shorted condition detected in the 1 coil circuit An open or shorted condition detected in the 2 coil circuit An open or shorted condition detected in the 3 coil cir...

Page 1154: ...eft or right sensor Oxygen sensor signal input indicates rich air fuel ratio condition at the left 02S sensor dur ing engine operation If equipped with dual 02S sensors the DRB scan tool will specify...

Page 1155: ...et tube Fig 1 at the side of the air cleaner housing 2 A band type screw clamp secures the air cleaner housing to the throttle body Loosen but do not remove this screw clamp Fig 1 Note the clamp posit...

Page 1156: ...10 ENGINE For air cleaner element required maintenance schedules listed in time or mileage intervals refer to Group 0 Lubrication and Maintenance A small amount of engine oil wetting the inside of th...

Page 1157: ...r to PDC cover BRAKE SWITCH Refer to Group 5 Brakes for removal installation procedures CAMSHAFT POSITION SENSOR For removal installation procedures refer to Group 8D Ignition System See Camshaft Posi...

Page 1158: ...is snapped onto the sensor It is not equipped with a lock type tab 4 Remove sensor from intake manifold or thermo stat housing INSTALLATION 1 Install sensor 2 Tighten to 11 N m 8 ft lbs torque 3 Conne...

Page 1159: ...group for removal installation procedures FUEL PUMP RELAY The relay is located in the power distribution cen ter PDC The PDC is located next to the battery in the engine compartment Fig 12 For the lo...

Page 1160: ...7 3 9L V 6 engine only Disconnect electrical connector at intake manifold air temperature sensor Do not remove sensor 8 Remove EVAP canister purge solenoid bracket assembly Fig 16 from intake manifold...

Page 1161: ...ry cable to battery 15 Start engine and check for leaks REMOVAL 8 0L V 10 ENGINE 1 Remove negative battery cable at battery 2 Remove air cleaner housing and tube 3 Perform the fuel pressure release pr...

Page 1162: ...o intake manifold Refer to Throttle Body removal in this group 12 Install throttle body linkage to throttle body 13 Install air cleaner tube and housing 14 Install negative battery cable at battery 15...

Page 1163: ...y removal in this section J9214 23 Fig 23 Typical Mounting Bolts Screws SAC Motor Fig 24 MAP Sensor L Shaped Rubber Fitting 3 9U 5 2U5 9L Engines Typical 3 Remove two MAP sensor mounting bolts screws...

Page 1164: ...n each left and right exhaust down pipe Fig 27 REMOVAL WARNING THE EXHAUST MANIFOLD BECOMES VERY HOT DURING ENGINE OPERATION ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR 1 Raise and support the...

Page 1165: ...osition PCM and install mounting bolts Tighten bolts to 1 N m 9 in lbs torque 3 Connect 60 way electrical connector to PCM Tighten bolt to 4 N m 35 in lbs torque 4 Connect negative battery cable to ba...

Page 1166: ...throttle body to intake manifold gasket 3 Install throttle body to intake manifold 4 3 9L 5 2L 5 9L Engines Install four mounting bolts Tighten bolts to 23 N m 200 in lbs torque 8 0L V 10 Engine Inst...

Page 1167: ...5 Install air cleaner Refer to Group 25 Emission Control Systems for procedures THROTTLE THROTTLE BODY POSITION THROTTLE SOCKET L O C A T I N G S H A F T T A N G S J9214 52 Fig 36 TPS Installation Ty...

Page 1168: ...RING J9314 188 Fig 39 Sensor Removal Installation Typical J9414 60 Fig 38 Vehicle Speed Sensor Location Typical 1 Raise and support vehicle 2 Clean the area around the sensor before re moval 3 Discon...

Page 1169: ...PCM Output 94 Vehicle Speed Sensor PCM Pin 47 PCM Input 96 Wait To Start Lamp Warning Lamp PCM Pin 36 PCM Output 95 Water ln Fuel Sensor PCM Pin 1 PCM Input 90 Water ln Fuel Warning Lamp PCM Pin 35 P...

Page 1170: ...ground SCI receive DRB scan tool connection Sensor return Throttle position sensor auto trans only Transmission temperature sensor auto trans only Vehicle speed sensor Water in fuel sensor Ignition s...

Page 1171: ...TRANSMISSION OVERDRIVE SWITCH AUTO ONLY THROTTLE POSITION SENSOR AUTO TRANS ONLY A C COMPRESSOR CLUTCH J9414 84 Fig 2 System Schematic 5 9L Diesel Engine...

Page 1172: ...p the PCM memory alive The memory stores diagnostic trouble code DTC messages mini mum and maximum TPS value from the previous key on and speed control adaptive memory BATTERY TEMPERATURE SENSOR This...

Page 1173: ...module PCM operates the 2 heating elements within the air heater assembly through the 2 intake manifold air heater relays The air heater elements are used to heat incoming air flowing into the intake...

Page 1174: ...r movement is a normal condition during the post heat cycle Refer to the following Air Heater Cycle Chart for a temperature time comparison of relay engagement The PCM is also programmed with battery...

Page 1175: ...e to the PCM will vary At idle speed the voltage should be 1 0 volt 2 volts At wide open throttle WOT the output voltage must be 2 2 to 2 9 volts higher than at idle speed ELECTRICAL CONNECTOR THROTTL...

Page 1176: ...ntrol strategy and electrical operation of both the overdrive and torque convertor solenoids Refer to Group 21 Transmissions for testing re placement and adjustment information TRANSMISSION TEMPERATUR...

Page 1177: ...o the battery in the engine compartment Fig 14 For the location of the relay within the PDC refer to PDC cover WATER IN FUEL WARNING LAMP PCM PIN 35 PCM INPUT The PCM turns the water in fuel indicator...

Page 1178: ...ide of the transmission Fig 16 TEMPERATURE SENSOR J9414 46 Fig 16 Transmission Temperature Sensor Location Typical TACHOMETER PCM PIN 43 PCM OUTPUT The powertrain control module PCM supplies en gine r...

Page 1179: ...ra tion of the speed control solenoids TORQUE CONVERTOR CLUTCH TCC SOLENOID PCM PIN 54 PCM OUTPUT AUTOMATIC TRANSMISSION This circuit Fig 18 controls operation of the transmission mounted torque conve...

Page 1180: ...the Diesel Engine Component Description System Operation section of this group For component removal and installation procedures refer to the Diesel Engine Component Removal Installation section of t...

Page 1181: ...TER TEMPERATURE SENSOR FOR LP GAUGE FUEL FILTER WATER SEPARATOR THROTTLE POSITION SENSOR AUTO TRANS ONLY FUEL SHUTDOWN SOLENOID FUEL WATER SEPARATOR AND DRAIN VALVE RUBBER PRIMER BUTTON FUEL TRANSFER...

Page 1182: ...top of the in take manifold Fig 4 6 Verify that the water in fuel WIF sensor elec trical connector is firmly attached to the sensor Fig 5 Inspect the connector for corrosion or damaged wires 7 Check...

Page 1183: ...n at the trans mission temperature sensor Fig 7 TEMPERATURE SENSOR J9414 46 Fig 7 Transmission Temperature Sensor Location Typical 19 Automatic Transmission Only Be sure the electrical connector is fi...

Page 1184: ...of the filter base with special fuel line adapter fittings To test fuel pressure drop 1 Remove the clamp bolt retaining the fuel drain manifold line to the cylinder head Fig 8 2 Remove the rear banjo...

Page 1185: ...from rev ving up It can also cause blue or white fog like ex haust If the heater is not operating in cold temperatures the engine may not operate due to fuel waxing The fuel heater is located on the...

Page 1186: ...ST A leaking fuel injector can cause fuel knock poor performance black smoke poor fuel economy and rough engine idle If the fuel injector needle valve does not operate properly the engine may misfire...

Page 1187: ...ion section of this group FUEL SUPPLY RESTRICTIONS LOW PRESSURE LINES Fuel supply line restrictions or a defective fuel transfer pump can cause starting problems and pre vent the engine from revving u...

Page 1188: ...remain in the run position fuel being supplied to injection pump Fig 17 If the solenoid shaft is not moving refer to the following 4 Disconnect the solenoid three wire pigtail wire harness from the m...

Page 1189: ...ot operate the fuel system with a fuel line or component suction restriction of more than 100 MM Hg 4 0 inch Hg Low transfer pump output can be caused by a worn eccentric on the engine camshaft The ma...

Page 1190: ...striction is higher than the specifications check for a kinked fuel line or a plugged fuel tank SIR Fig 23 Installing Hose Adapter Fig 24 installing Vacuum Gauge vent A partially clogged in tank fuel...

Page 1191: ...rt in figure 27 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 fl...

Page 1192: ...iesel Engine specifications chart for idle rpm 5 Tighten the locknut after adjustment LOW IDLE ADJUSTING SCREW FACTORY SEAL HIGH IDLE LOCKNUT STOP SCREW J9414 103 Fig 29 Low Idle Speed Screw IDLE SPEE...

Page 1193: ...preheat cycle If the engine starter is engaged before the preheat cycle of the heat ers is complete the PCM will stop the remain ing preheat cycle 3 Check for battery voltage at both air heater ter mi...

Page 1194: ...ss the large terminals If not replace relay and bracket as sembly 7 Repeat the same test on the opposite relay 8 After testing and repairing connect battery ca bles to both batteries For removal and i...

Page 1195: ...other jumper wire to the positive side of a 12V power source Do not connect this jumper wire to relay at this time CAUTION Do not allow the ohmmeter to contact terminals 85 or 86 during these tests D...

Page 1196: ...Sensor in the Diesel Engine Component Removal Installation section of this group for procedures Terminals TRANSMISSION TEMPERATURE SENSOR TEST AUTOMATIC TRANSMISSION ONLY To perform a complete test o...

Page 1197: ...cancels the DTC after 51 engine starts Certain criteria must be met for a diagnostic trou ble code DTC to be entered into PCM memory The criteria may be a specific range of engine rpm engine temperatu...

Page 1198: ...e shown in Fig 39 ERASING TROUBLE CODES After the problem has been repaired use the DRB scan tool to erase a Diagnostic Trouble Code DTC Refer to the appropriate Powertrain Diagnostic Pro cedures serv...

Page 1199: ...A C Clutch Relay Circuit 34 Speed Control Solenoid Circuits or Speed Control Switch Always Low or No crank reference signal detected during en gine cranking Direct battery input to PCM was disconnecte...

Page 1200: ...or shorted condition detected in the auto shutdown relay circuit An open or shorted condition exists in the en gine coolant temperature sensor circuit or a problem exists in the PCM s battery tempera...

Page 1201: ...he engine clockwise un til both intake and exhaust valves are closed will speed up locating engine TDC as described later in step 4 3 Insert the barring tool number 7471B through the access hole and i...

Page 1202: ...g the holder outboard with one hand while us ing the other hand to hold the spring fill piece and any shims from slipping out of the holder Place these parts Fig 45 as an assembly to a clean sur face...

Page 1203: ...9 Fig 49 Setting Dial Indicator 13 Be sure the timing pin is disengaged be fore rotating the engine to avoid damage to the timing pin a Rotate the engine clockwise slowly to TDC GENERAL DIAGNOSIS DIES...

Page 1204: ...mp at the correct plunger lift setting use special gear puller tool L 4407A to pull the injection pump gear off the taper of the in jection pump input shaft Leave the gear puller in stalled Fig 56 Aft...

Page 1205: ...l pump 29 Install the delivery valve assembly on top of the sealing washer as shown in figure 61 J9514 8 Fig 58 Rotating Injection Pump Gear 27 Remove the dial indicator and adaptor from the injection...

Page 1206: ...ft torque Fig 63 Next in one motion tighten the holder to 115 N m 85 ft lbs torque Fig 63 33 Install remaining engine components removed during the timing process Leave the injector end of the 1 high...

Page 1207: ...a plastic housing Fig 2 A yellow colored disc attached to the dia phragm moves along a graduated scale on the side of the Filter Minder After the engine has been shut off a ratcheting device located...

Page 1208: ...the hose alignment notches at both the in let hose and air cleaner cover Fig 1 7 Position the tube clamp to the inlet tube and tighten to 3 N m 25 in lbs torque AIR BLEED PROCEDURE A certain amount of...

Page 1209: ...AND ADEQUATE PRO TECTIVE CLOTHING AND 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...

Page 1210: ...s clip bolts 4 Place the feeler gauge between the sensor and the vibration dampener 5 Gently seat push down the sensor until it con tacts the feeler gauge Be sure the sensor is not near either of the...

Page 1211: ...artially drain the filter separator Refer to the following Draining Water from Filter DRAINING WATER FROM FILTER The filter should be drained whenever the water in fuel warn ing lamp remains illuminat...

Page 1212: ...separator with clean fuel 4 Apply a light film of clean unused engine oil to the filter separator seal 5 Install a new o ring seal to the filter separator housing Fig 13 6 Install filter separator to...

Page 1213: ...lay 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 PUMP REMOVAL 1 Disco...

Page 1214: ...air heater assembly at intake manifold five bolts figure 20 Discard both of the old air heater base gaskets 8 Remove the throttle control bracket cables and linkage assembly from the side of pump thr...

Page 1215: ...J9414 116 Fig 24 Fuel Delivery Valve Holders and Pressure Lines pump Fig 25 OIL SUPPLY LINE FITTING J9414 112 Fig 25 Engine Oil Supply Line Pump Mounting Nuts 14 Remove the oil fill tube bracket mount...

Page 1216: ...the barring tool counter clock wise will rotate the crankshaft clockwise Continue to rotate until the timing pin drops into the machined hole in the back of the camshaft gear When the pin aligns to t...

Page 1217: ...mshaft 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 sid...

Page 1218: ...TOOTH CENTERED IN ACCESS HOLE o J9414 77 Fig 35 Injection Pump Timing Tooth gine oil to the pump o ring seal at pump mounting area The injection pump shaft and its mounting area in the center of the...

Page 1219: ...remove barring tool 12 Remove the timing pin tool from the pump Reverse the position of this tool Fig 34 The slotted part of tool should be facing outward and will be stored in pump in this direction...

Page 1220: ...n 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...

Page 1221: ...ompound O RING Fig 42 Cleaning Cylinder Head Injector Bore o ring located above the holddown nut Fig 45 After tightening the injector push the o ring into the groove on the top of the injector 5 Tight...

Page 1222: ...TALLATION 1 Position solenoid to mounting bracket and in jection pump lever 2 Install clip at injection pump lever 3 Install and tighten two mounting bolts 4 Check and adjust the shaft length of the s...

Page 1223: ...nnector 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...

Page 1224: ...y from the engine as one unit PUMP INSTALLATION 1 Clean the mating surfaces of the fuel heater mounting bracket the fuel pump and the engine block of any gasket material 2 Position the new gaskets the...

Page 1225: ...igh pressure fuel lines are installed in the same order that they were re moved Prevent the injection pump delivery valve holders from turning when removing or installing high pressure lines from inje...

Page 1226: ...ine oil dipstick tube mounting bracket bolt at the side of the intake manifold Fig 58 3 Remove the two cable nuts and remove cables at the air heater electrical studs Fig 58 4 Remove the five bolts re...

Page 1227: ...ssion If the TPS is to be replaced on a diesel engine it must be tested after replacement REMOVAL 1 Disconnect the electrical connector on bottom of TPS Fig 60 IS OUTPUT WIRE B J L b W J9414 91 Fig 60...

Page 1228: ...en the left hand threaded nut Fig 62 9 Slowly rotate the flat Fig 62 on the linkage rod lengthen or shorten to achieve 1 0 volt 2 Fig 62 Throttle Lever Linkage Adjustment Diesel volts on the voltmeter...

Page 1229: ...esel section of this group for removal and installation procedures VEHICLE SPEED SENSOR Refer to the Multi Port Fuel Injection MFI Com ponent Removal Installation Except Diesel section of this group f...

Page 1230: ...he 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 jo...

Page 1231: ...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...

Page 1232: ...ts 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 whee...

Page 1233: ...nout 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...

Page 1234: ...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 extern...

Page 1235: ...ent 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 b...

Page 1236: ...n 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 s...

Page 1237: ...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...

Page 1238: ...oosen 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 g...

Page 1239: ...ing 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...

Page 1240: ...let 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 spri...

Page 1241: ...ly 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...

Page 1242: ...ss 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 joi...

Page 1243: ...s 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...

Page 1244: ...afts are supported 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 piston teeth mesh with the pitman sector sh...

Page 1245: ...Dodge Ram Truck power steering pumps are not interchangeable with pumps installed in other vehicles STEERING COLUMNS Two steering columns are used on Dodge Ram Truck vehicles A fixed or non tilt colum...

Page 1246: ...ow control valve operation Do not leave valve closed for more than five seconds as the pump could be damaged 8 Close valve fully three times and record highest pressure indicated each time All three r...

Page 1247: ...coupler and dash seal 2 Replace steering gear RATTLE OR CLUNK 1 Gear loose on front crossmember 2 Crossmember to frame bolts or studs loose 3 Tie rod looseness outer or inner 4 Loose lower control ar...

Page 1248: ...3 Extreme wear of pump internal parts 1 Fill to proper level and perform leakage diagnosis Recheck after system is free of aeration 2 Reposition hose Replace hose if tube ends are bent 3 Replace pump...

Page 1249: ...r replace belt 6 Replace pump 7 Correct condition See Steering Column Service Procedure 8 Realign as necessary 9 Correct binding condition 10 Replace steering gear SHAKE SHUDDER VIBRATION CONDITION PO...

Page 1250: ...NOT WANT TO RETURN TO CENTER POSITION 1 Tires not properly inflated 2 Improper front wheel alignment 3 Lack of lubrication in ball joint 4 Steering column U joints misaligned 5 Mispositioned dash cov...

Page 1251: ...ssary 7 Check and replace as required 8 Replace gear 9 Replace gear VEHICLE LEADS TO THE SIDE CONDITION POSSIBLE CAUSES CORRECTION WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Radial tire lead 2...

Page 1252: ...g and replace as required 3 Identify location of leak and repair or replace as indicated in Power Steering Pump and or Gear sections of this service manual FOAMY OR MILKY FLUID CONDITION POSSIBLE CAUS...

Page 1253: ...19 10 STEERING B R J9419 33 PUMP LEAKAGE DIAGNOSIS...

Page 1254: ...COVER BOLTS TO 60 N m 45 FT QUE THE HOSE FITTING NUT TO LBS REPLACE THE SIDE COVER 27 N m 20 FT LBS IF LEAKAGE SEAL IF THE LEAKAGE PERSISTS PERSISTS REPLACE THE SEAL 2 ADJUSTER PLUG SEAL REPLACE 4 PIT...

Page 1255: ...ITH ANY LOOSE OR DISCONNECTED HOSES DO NOT ALLOW THE HOSES TO TOUCH A HOT EXHAUST MANIFOLD OR THE CATALYTIC CONVERTER page Pump Replacement Gasoline Engine 15 Pump Reservoir 16 Service Information 12...

Page 1256: ...hole in block STEERING PUMP ENGINE BLOCK J9119 74 Fig 4 Oii Pressure Sending Unit 4 Disconnect and cap the oil feed line from the bottom of the vacuum pump Fig 5 BATTERY GROUND CABLE STEERING PUMP BRA...

Page 1257: ...nstallation INSTALLATION 1 Install the two pump body spacers Fig 9 PUMP SPACERS MOUNTING BRACKET J9119 69 Fig 9 Steering Pump Removai instaiiation 2 Rotate the drive gear until the steering pump and v...

Page 1258: ...OT ATTEMPT TO REMOVE THE PUMP WITHOUT REMOVING THE BELT FIRST THE AUTOMATIC TENSIONER IS UNDER A HIGH SPRING LOAD 1 Remove the serpentine drive belt Rotate ten sioner clock wise and hold in place and...

Page 1259: ...ler C 4333 Fig 14 Do not hammer on pulley because this will damage it and the pump 2 Replace pulley if bent cracked or loose INSTALLATION 1 Install the pulley with Installer C 4063 B Fig 15 Do not use...

Page 1260: ...procedure to remove air from the sys tem CAUTION The fluid level should be checked with engine off to prevent injury from moving compo nents Use only MOPAR Power Steering Fluid Do not use automatic tr...

Page 1261: ...studs from steering knuckle arms Fig 1 and 2 Use care to avoid damaging the seals 3 Remove inner tie rod ends from center link Fig 2 4 If equipped remove steering damper from cen ter link and frame br...

Page 1262: ...tman arm Fig 4 TIE ROD TIE ROD END J9419 24 Fig 4 Steering Linkage Link Coil Use care to avoid damaging the seals 3 Mark the pitman arm and shaft positions for reference Remove the nut and washer from...

Page 1263: ...not to score the housing bore when prying out seals and washers 4 Remove backup washer and double lip seal with screwdriver Start the engine and turn the steering wheel fully to the LEFT to force out...

Page 1264: ......

Page 1265: ...steering gear and slide shaft off gear Fig 3 INSTALLATION 1 Position the steering gear on the frame rail and install the bolts Tighten mounting bolts to 190 N m 140 ft lbs torque 2 Align steering coup...

Page 1266: ...t turn while tightening the locknut TEERING 19 23 FIRST MAiK J9219 30 Fig 8 Aligning To The Second Mark OVER CENTER ADJUSTMENT 1 Rotate the stub shaft from stop to stop and count the number of turns 2...

Page 1267: ...uster screw from turning while tightening adjuster lock nut Tighten the adjuster lock nut to 58 N m 43 ft lbs GEAR DISASSEMBLY INFORMATION CAUTION Cleanliness is extremely important when repairing a p...

Page 1268: ...5 GUIDE BALL RETURN 2 12 SEAL O RING VALVE BODY 3 36 CLAMP BALL RETURN GUIDE 13 RETAINER BEARING ADJUSTER 37 SCREW ASSY LOCKWASHER 2 14 SPACER THRUST BEARING 38 PLUG RACK PISTON 15 RACE UPPER THRUST B...

Page 1269: ...cover 2 Install preload adjuster nut Do not tighten nut until after pitman shaft adjustment has been made 3 Install gasket to side cover and bend tabs around edges of side cover 4 Install pitman shaft...

Page 1270: ...this section 2 Install pitman arm onto steering gear Refer to Steering Linkage in this group ADJUSTER PLUG ASSEMBLY REPLACEMENT R E M O V E 1 Remove steering gear from vehicle Refer to Power Steering...

Page 1271: ...aring spacer to adjuster plug 7 Install thrust washer bearing retainer to ad juster plug Fig 20 CAUTION When installing adjuster plug care should be taken NOT to cut the seals 8 Install adjuster plug...

Page 1272: ...y pulling and rotating from valve body Fig 24 Remove valve spool O ring seal Remove valve body teflon rings and O ring seals Fig 25 ASSEMBLE 1 Install valve spool O ring seal to valve spool STEERING 1...

Page 1273: ...ACEMENT REMOVE 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement in this section NOTCH IN CAP VALVE BODY PIN J9319 38 Fig 26 Stub Shaft Installation DISASSEMBLE 1 Remove pit...

Page 1274: ...piston Align worm shaft spiral groove with rack piston ball guide hole Fig 30 INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING WORM COUNTERCLOCKWISE J9319 39 Fig 30 Installing Balls in Rack Piston WAR...

Page 1275: ...ring Gear Replacement in this section PITMAN SHAFT SEALS AND BEARING REPLACEMENT REMOVE 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement in this section DISASSEMBLE 1 Remov...

Page 1276: ...Power Steering Gear Replacement in this section SPECIAL TOOL C 4171 WHEN TOOL BOTTOMS ON HOUSING BEARING IS FULLY INSTALLED SPECIAL TOOL C 4178 DO NOT BOTTOM BEARING N HOUSING i J9119 41 Fig 35 Pitman...

Page 1277: ...ings races and rack piston recirculating balls with petroleum jelly Lubricate all other parts with power steering fluid Steering Gear Adjustments Wormshaft Bearing Preload Torque 0 45 1 13 N m TO to 1...

Page 1278: ...DULE ATTACHED NEVER PLACE THE COLUMN ON THE FLOOR OR OTHER SURFACE WITH THE STEERING WHEEL OR MODULE FACE DOWM CAUTION Bumping jolting and hammering on steering column shaft and gear shift tube must b...

Page 1279: ...ll the steering wheel with the scored marks or master splines aligned 3 Install the retaining nut and tighten to 61 N m 45 ft lbs torque Force the steering wheel down on the shaft with the retaining n...

Page 1280: ...eel Installation CENTERING PROCEDURE If the rotating tape within the clockspring is not positioned properly the clockspring may fail during use The following procedures MUST BE USED to center the cloc...

Page 1281: ...ion switch with a 7mm socket Fig 12 11 Loosen the upper Support Bracket nuts to al low some slack This will aid in removal of the upper fixed shroud STEERING COLUMN ASSY J918J 1 MULTI FUNCTION SWITCH...

Page 1282: ...install the PRNDL driver cable Place shifter in Park position If indica tor needs adjusting turn recessed hex head screw un derneath cable retainer Fig 15 13 Install the lock housing shrouds Install...

Page 1283: ...nt Plug Locknut Adjustment Screw Locknut Gear to Frame Bolts Intermediate Shaft Pinch Bolts Upper and Lower Pitman Shaft Nut High Pressure Fluid Line Return Pressure Fluid Line Rack Piston Plug Side C...

Page 1284: ...is used with 3 9L and 5 2L engines and is available in two and four wheel drive configura tions The transmission gear case consists of two alumi num housings Fig 1 The clutch housing is not a re movab...

Page 1285: ...2 NV3500 MANUAL TRANSMISSION BR Fig 1 NV3500 Manual Transmission J9421 1...

Page 1286: ...of hoist is recommended for this purpose Lubricant capacity of the NV3500 is approximately 1 98 liters 4 2 pints This represents the approxi mate quantity needed to refill the transmission after a lub...

Page 1287: ...inute or so before checking These recommendations will ensure an accurate check and avoid an under or overfill condition HARD SHIFTING Hard shifting is usually caused by a low lubricant level improper...

Page 1288: ...15 Remove bolts and nuts attaching crossmember to frame rails Rotate crossmember diagonally and remove crossmember 16 Disconnect exhaust pipes at manifold and at converter or muffler connections as n...

Page 1289: ...nsfer case range lever 13 Remove bolts attaching shift linkage bracket to transfer case and move linkage and bracket aside 14 Remove nuts attaching transfer case to trans mission adapter housing 15 Re...

Page 1290: ...on 14 Install strut bolts nuts if removed 15 Connect vehicle speed sensor wires 16 Install and connect exhaust system Align ex haust components before tightening clamp and bracket bolts and nuts Be su...

Page 1291: ...rical wires have been connected 22 Check transfer case fluid level Add Mopar Dexron II or ATF Plus if necessary Correct level is to edge of fill plug hole Be sure transfer case is level before checkin...

Page 1292: ...N 21 1 Fig 4 Input Shaft Bearing Retainer Bolt Removal 8 Remove input shaft bearing retainer Use pry tool to carefully lift retainer and break sealer bead Fig 5 Fig 5 Loosening Bearing Retainer Sealer...

Page 1293: ...pring then plunger Fig 9 Detent Plunger And Spring Removal 13 Remove bolts that attach front housing to rear housing Fig 10 Three bolts at extreme rear of housing are actually for the output shaft bea...

Page 1294: ...2 Unseat roll pin that secures shift socket to shift shaft with Special Tool 6858 as follows Fig 14 Removing Shift Shaft Lever Detent Ball And Spring a Position Tool 6858 on shift socket Then cen ter...

Page 1295: ...shaft straight out of fork J9421 42 Fig 17 Pulling Shift Shaft Out Of Housing Shift Socket And Shift Forks Fig 20 Shift Shaft Removal c Remove input shaft bearing and 3 4 synchro ring d Remove 3 4 shi...

Page 1296: ...o support the re verse idler c Stand geartrain and rear housing upright on fixture Fig 23 Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position d Po...

Page 1297: ...g retainer to rear case Fig 26 Bolts are to rear of shift tower opening J9421 50 Fig 26 Removing Installing Output Shaft Bearing Retainer Bolts 2 Wheel Drive Transmission 2 Unseat output shaft bearing...

Page 1298: ...eel Drive Transmission 3 Locate dimples in face of rear seal Fig 31 Fabricated seal remover tool will be threaded into one of these dimples LOCATION OF mmE J942M97 Fig 31 Location Of Dimples In Seal F...

Page 1299: ...AFT GEARTRAIN DISASSEMBLY The synchronizer hubs and sleeves are differ ent and must not be intermixed It is recom mended that each synchronizer unit be removed as an assembly to avoid intermixing part...

Page 1300: ...RUST WASHER RETAINING RING J9421 23 Fig 39 Thrust Washer Retaining Ring Removal 5 Remove two piece thrust washer Fig 40 Note position of washer locating lugs in shaft notches for installation referenc...

Page 1301: ...BEARING J9421 28 Fig 44 First Gear And Needle Bearing Removal 10 Remove output shaft bearing snap ring Fig 45 SNAP RING PLIERS OUTPUT SHAFT BEARING BEARING SNAP RING J9421 29 Fig 45 Output Shaft Beari...

Page 1302: ...ring Fig 49 SNAP RING PLIERS FIFTH REVERSE SYNCHRO HUB AND SLEEVE SYNCHRO HUB SNAP RING J9421 33 15 Remove fifth reverse synchro hub and sleeve with shop press and standard type remover tool Fig 50 S...

Page 1303: ...internal components are worn or damaged er Components Shift Shaft And Forks Inspect the shift fork interlock arms and synchro sleeve contact surfaces Fig 53 Replace any fork ex hibiting wear or damag...

Page 1304: ...iner if the threads are damaged or if the retainer is bent or cracked Countershaft Bearings And Races The countershaft bearings and races are machine lapped during manufacture to form matched sets The...

Page 1305: ...roximately is ap proximately 33 mm 1 1 4 in long Output Shaft And Geartrain Inspect all of the gears Fig 55 for worn cracked chipped or broken teeth Also check condition of the bearing bore in each ge...

Page 1306: ...ED 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...

Page 1307: ...equivalent for the in put shaft bearing retainer Apply these products as indicated in the reassembly procedures It is very important that the transmission shift components be in Neutral position duri...

Page 1308: ...icate shaft gears and bearings Fig 56 with recommended lubricant during assembly Petro leum jelly can be used to hold parts in place 2 Check bearing surfaces of output shaft for nicks or scratches Smo...

Page 1309: ...le size pipe tool Fig 61 J9421 61 Fig 61 Fifth Reverse Synchro Assembly installation 10 Install new fifth reverse hub snap ring Fig 62 as follows a Snap rings are available in thicknesses from 2 00 mm...

Page 1310: ...on output shaft Fig 68 Be sure bearing is seated on shaft shoulder and is properly joined NV3500 MANUAL TRANSMISSION 21 27 Fig 67 Installing Output Shaft Bearing Snap Ring n Fig 68 First Gear Bearing...

Page 1311: ...tall new 1 2 synchro hub snap ring Fig 73 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 c Ve...

Page 1312: ...r Fig 78 29 Seat thrust washer retaining ring with plastic mallet Fig 79 30 Install third gear needle bearing on shaft Fig 80 31 Install third gear on shaft and bearing Fig 81 32 Install third speed s...

Page 1313: ...78 Starting Retaining Ring Over Two Piece Thrust Washer Fig 79 Seating Thrust Washer Retaining Ring 80 Fig 80 Third Gear Bearing Snstaiiation mm Fig 82 Third Speed Synchro Ring installation Fig 88 Sta...

Page 1314: ...GEAR SIDE FACING GEAR Fig 85 installing 3 4 Synchro Hub Snap Ring b Install thickest snap ring that will fit in shaft groove Use heavy duty snap ring pliers to install new ring c Verify that snap rin...

Page 1315: ...Fig 88 LOCK BALL THRUST WASHER SNAP RING GROOVE J9421 89 Fig 88 Idler Gear Rear Thrust Washer Installation 7 Install lock ball in dimple at front of shaft Hold ball in place with petroleum jelly if de...

Page 1316: ...Install assembled output shaft and geartrain in input shaft Fig 95 Carefully rotate output shaft until fourth speed synchro ring seats in synchro hub and sleeve 8 Install Adapter 6747 2 on front bear...

Page 1317: ...T AND GEARTRAIN REVERSE IDLER ASSEMBLY ON PEDESTAL TOOL PEDESTAL J9421 97 Fig 97 Reverse Idler Assembly Positioned On Assembly Fixture Pedestal 12 On 2 wheel drive transmission thread one Pi lot Stud...

Page 1318: ...iameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing Fig 103 4 Apply extra petroleum jelly to hold counter shaft rear bearing in place when...

Page 1319: ...tap housing into place 9 Install three bolts that secure rear bearing re tainer to rear housing as follows a Apply Mopar Gasket Maker or Loctite 518 to bolt threads bolt shanks and under bolt heads Fi...

Page 1320: ...adapter housing Fig 103 8 Install adapter housing on geartrain 9 Install rear bearing snap ring on output shaft Fig 108 10 Lubricate lip of new rear seal Fig 109 with Mopar Door Ease or transmission f...

Page 1321: ...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 112 Verify that groov...

Page 1322: ...CAUTION Correct positioning of the shift shaft de tent 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 di...

Page 1323: ...ft Then start roll pin into shift shaft by hand Fig 122 ROLL PIN p J9521 154 ft Socket 17 Seat roll pin in shift socket with pin punch Roll pin must be flush with socket after installation Fig 122 J95...

Page 1324: ...RAiSMISSIOi 21 41 AND SPRING J9421 117 Fig 126 Correct Seating Of Lever Detent Ball In Shift Fork Arms front housing race Fig 127 Large diameter side of bearing cage goes toward countershaft Fig 128 S...

Page 1325: ...r housing either the shift components are not in Neutral or one or more components are mis aligned Do not force the front housing into place This will only result in damaged components 9 Tap rear hous...

Page 1326: ...3 Installing Shift Shaft Bushing Lock Bolt CAUTION If the Jock 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 le ver...

Page 1327: ...t plug with brass punch i r r T P I Fig 138 installing Backup Light Switch 18 Install input shaft snap ring Fig 139 INPUT SHAFT SNAP RING J9421 133 J942 M39 Fig 139 installing input Shaft Snap Ring 19...

Page 1328: ...42 Although retainer is one way fit on hous ing be sure bolt holes are aligned before seat ing retainer Fig 142 Installing Input Shaft Bearing Retainer 22 Install and tighten bearing retainer bolts to...

Page 1329: ...assembly are securely fitted together Also be sure shift ball is seated in socket before installing tower bolts SHIFT TOWER AND LEVER ASSEMBLY ISOLATOR AND PLATE ASSEMBLY J952M82 Fig 145 Shift Tower...

Page 1330: ...ions are the same The NV4500 is a top loader style transmission The shift lever Is located in the shift cover and operates page Transmission Assembly and Adjustment 75 Transmission Cleaning and Inspec...

Page 1331: ...Fig 1 NV4500 Manual Transmission J9521 10...

Page 1332: ...0 74 1 Reverse gear 5 61 1 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 po sitio...

Page 1333: ...y the result of leaks or inaccurate fluid level check or refill method Leaks will be evident by the presence of gear oil around the leak point If leakage is not evident the condition is probably the r...

Page 1334: ...harness wires in clips on shift cover 12 Install transmission mount on transmission or rear crossmember 13 Install rear crossmember 14 Remove transmission jack and engine support fixture 15 Align and...

Page 1335: ...ot bearing release bearing bore release fork release fork ball stud propeller shaft slip yoke 2 Apply sealer to threads of PTO cover bottom drain bolt then install bolt in case 3 Mount transmission on...

Page 1336: ...al tool 27 Install shift lever boot and bezel 28 Connect battery negative cable TRANSMISSION DISASSEMBLY AND OVERHAUL SHIFT COVER REMOVAL 1 Remove shift cover bolts Fig 1 Fig 1 Shift Cover Bolt Remova...

Page 1337: ...n 2 wheel drive models remove extension housing seal Fig 7 Seal can be removed by collaps ing one side with punch then prying seal out with suitable tool 5 Note that 4 wheel drive adapter housing does...

Page 1338: ...Fig 9 2 Remove countershaft fifth speed clutch gear stop ring and bearing spacer Fig 11 3 Remove three struts and strut springs from countershaft fifth gear hub and sleeve Fig 11 4 Remove mainshaft fi...

Page 1339: ...Note position of washer for assem bly reference coned side of washer faces rear F I F T H G E A R N U T W A S H E R C O N E D F I F T H G E A R N U T 5 Remove roll pins that secure countershaft fifth...

Page 1340: ...uller set can be used on both standard and heavy duty trans missions Gear removal procedure is as follows a Position first puller jaw on gear Fig 19 Use Puller Jaws 6459 on standard duty mod els and P...

Page 1341: ...ange extends into and is fairly snug fit in case bore 3 Remove seal from front retainer Fig 25 Use small chisel to collapse one side of seal then pry it out with suitable tool Fig 25 Removing Bearing...

Page 1342: ...SPECIAL TOOL 6453 2 FRONT RETAINER J9221 180 Fig 28 Removing Bearing Cup From Front Retainer f Tighten puller bolt to draw bearing cup out of retainer Fig 28 Use holding wrench on puller and turn pull...

Page 1343: ...Reverse Idler Shaft 3 Remove bearing from drive gear as follows a Note that puller tool assembly and setup is similar to that used for removing fifth gear from mainshaft Figs 19 23 b Assemble Puller...

Page 1344: ...aft slightly b Grasp mainshaft rear splines Then turn spline end of mainshaft in counterclockwise direc tion to rotate shaft and geartrain out of case c Once mainshaft gears roll clear of counter shaf...

Page 1345: ...loosen bearing Fig 41 Removing Countershaft Rear Bearing _ E R Fig 42 Removing Countershaft From Gear Case 8 Remove countershaft front bearing as follows a Assemble Puller Flange 6444 1 and Puller Bol...

Page 1346: ...CIAL T O O L C 4171 J9221 145 Fig 45 Countershaft Front Bearing Cup Removal rail in case Fig 46 A small pin punch can be mod ified by putting a slight bend in it to drive pin com pletely out of shift...

Page 1347: ...if not previously removed 2 Remove fourth gear synchro struts and springs from 3 4 hub and sleeve Fig 50 Three struts and springs are used Keep springs and struts together for inspection and cleaning...

Page 1348: ...ins second gear thrust washer on mainshaft Fig 54 SECOND GEAR THRUST WASHER THRUST WASHER SNAP RING THIRD GEAR BEARING SPACER J922M22 Fig 54 Bearing Spacer And Snap Ring Location 9 Remove second gear...

Page 1349: ...ring Fig 60 15 Remove 1 2 synchro hub snap ring Fig 61 16 Mark position of 1 2 synchro sleeve and hub for assembly reference Side of hub with flat hub spring goes toward front Fig 62 Note that tapered...

Page 1350: ...ainshaft rear bearing as follows a Assemble Puller Flange 6444 1 and Puller Rods 6444 3 Fig 66 b Position first Puller Jaw 6445 on bearing cone Fig 66 c Seat Puller Flange 6444 1 In notch of first pul...

Page 1351: ...Fig 67 Removing Mainshaft Rear Bearing...

Page 1352: ...kwards causing shift prob lems 27 Remove reverse gear bearing assembly from mainshaft Fig 70 28 Remove reverse gear synchro stop ring and clutch gear Fig 70 FIRST GEAR REVERSE GEAR ASSEMBLY STOP RING...

Page 1353: ...lso worn or damaged Inspect the front bearing retainer and bearing cup Fig 77 Replace the bearing cup if scored cracked brinnelled or rough Check the release bearing slide surface of the retainer care...

Page 1354: ...he case top surface and in the housing adapter are tight and in good condition Run a tap through the gear case bolt holes if the threads need minor cleanup Helicoil inserts can be used to repair serio...

Page 1355: ...istorted synchro parts to avoid shift problems after assembly and In stallation The shift fork should be inspected for evidence of wear and distortion Check fit of the sleeve in the th Gear Components...

Page 1356: ...lso replace the springs if collapsed distorted or broken Inspect the mainshaft geartrain components Fig 83 Check the teeth on all gears hubs clutch gears stop rings and clutch rings The teeth must be...

Page 1357: ......

Page 1358: ...O SLEEVE 28 SYNCHRO STRUTS AND SPRINGS 4 EACH 29 1 2 SYNCHRO HUB INC RETAINER SPRINGS AND WEIGHTS 30 SYNCHRO HUB SNAP RING 31 SECOND GEAR SYNCHRO STOP RING 32 SECOND SPEED CLUTCH GEAR 33 SECOND GEAR S...

Page 1359: ...in place POSITION IDLER GEAR Fig 89 Positioning Idler Gear Front Thrust Washer In Case 7 Install reverse idler gear in case Fig 90 8 Install Idler gear rear thrust washer between Idler gear and case b...

Page 1360: ...at cap in case bore with wood block and mallet 15 Lubricate countershaft rear bearing cup and cone with petroleum jelly 16 Install countershaft rear bearing cup in gear case and over rear bearing Fig...

Page 1361: ...all countershaft rear bearing plate Fig 96 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 plat...

Page 1362: ...first gear snap ring Fig 101 Use heavy duty snap ring pliers to install this snap ring as ring tension is considerable Do not overspread snap ring and make sure it is fully seated in groove Reverse ge...

Page 1363: ...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 Sleev...

Page 1364: ...18 Install snap ring on mainshaft 1 2 synchro hub to secure clutch gear Fig 110 Be sure snap ring is fully seated in hub groove and against clutch gear Note that this is second of four snap rings used...

Page 1365: ...install sleeve on hub Be sure ta pered side of sleeve faces upward toward front Rotate sleeve until it slides onto hub Sleeve only fits one way and will easily slide onto hub when long slot in sleeve...

Page 1366: ...hro Hub 24 Install 1 2 synchro assembly and stop ring on mainshaft Rotate sleeve to align it with stop ring lugs If necessary Then seat assembly on shaft Fig 119 MAINSHAFT HUB 2 SYNCHRO ASSEMBLY TAPER...

Page 1367: ...t secures second speed clutch gear on mainshaft Fig 125 Use narrow blade screwdriver to work snap ring into hub groove as shown Be sure snap ring is fully engaged in mainshaft groove before proceeding...

Page 1368: ...cond gear thrust washer snap ring Fig 130 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 130 SECON...

Page 1369: ...ng Then align stop ring with synchro sleeve and hub and seat syn chro assembly with Tool C 4040 Fig 135 44 Verify that 3 4 synchro hub is fully seated on shaft Approximately 3 mm 1 8 in of shaft splin...

Page 1370: ...ig 140 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 rearward until mainshaft hub...

Page 1371: ...nstall 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 us...

Page 1372: ...engaged position 7 Position Spline Socket Wrench 6441 or 6442 on mainshaft splines Then install breaker bar in socket wrench and wedge bar against workbench 8 Tighten fifth gear nut with Nut Wrench 6...

Page 1373: ...h gear synchro sleeve and shift fork Fig 155 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 place with pl...

Page 1374: ...install bushing Note that installer tool SP5559 is part of tool set C 4469 5 Install extension housing seal with Tool C 4660 3 Fig 161 6 Clean mating surfaces of extension adapter housing and gear cas...

Page 1375: ...heel drive models install and index speedometer adapter in extension housing 10 Install and tighten drain bolt at bottom of PTO cover 11 Fill transmission to bottom edge of fill plug hole with Mopar M...

Page 1376: ...ver vent assembly consists of the vent tube connecting hose hose clamps and vent valve Fig 166 If the vent tube is removed for replacement or ser vice access apply Mopar silicone adhesive sealer to th...

Page 1377: ...n retainer Then press tool downward and turn retainer counterclock wise to release it from locking pins in shift tower SPECIAL RETAINER J9521 199 Fig 170 Shift Lever Retainer Unlocking Tool 5 Lift shi...

Page 1378: ...s a Reposition upper jaw of Remover Installer Tool 6783 above flange on lever extension Fig 173 Tool will now be used to press extension back onto shift lever b Tighten tool screw to press extension b...

Page 1379: ...y Mopar Gasket Maker or Loctite 518 to sealing surface of shift cover or gear case Do not over apply sealer material Excess can be squeezed into gear case and could block lubricant feed holes in time...

Page 1380: ...verdrive unit attached at the rear Figs 1 and 2 First through third gear ranges are provided by the clutches bands overrunning clutch and plan etary gear set in the transmission Fourth gear range is p...

Page 1381: ...TORQUE CONVERTER BODY Fig 1 42RH Transmission And Overdrive Unit...

Page 1382: ...m n TORQUE CONVERTER J9321 205 Fig 2 46RH 47RH Transmission And Overdrive Unit to m...

Page 1383: ...g ribs around the rear servo area of the case The converter housing bolt pattern is unique for diesel and gas engine versions of the 47RH Clutch Packs Clutch packs used in the V10 and diesel versions...

Page 1384: ...date The last number group is the transmis sion serial number Refer to this information when ordering replacement parts FOURTH GEAR OVERDRIVE COMPONENTS 42RH 46RH 47RH models have three transmission...

Page 1385: ...tput shafts cases bands valve bodies and governor assemblies are just a few of the changed items Tranmission changes affect the governor weight as sembly low reverse drum front annulus boost valve tub...

Page 1386: ...with the overdrive clutch The boost valve provides increased fluid apply pressure to the overdrive clutch during the 3 4 up shift and during fourth gear operation The overdrive piston engages the ove...

Page 1387: ...r It is used to smooth engagement during the 3 4 shift CONWERTER DRAINBACK WALWE The drainback valve is located in the transmission cooler outlet pressure line The valve prevents fluid from draining f...

Page 1388: ...h gear above 50 mph sensor inputs to the con trol module that determine clutch engagement and shift timing are coolant temperature verifies temperature mini mum of 60 F r engine speed vehicle speed th...

Page 1389: ...earshift Linkage 108 General Information 106 Hydraulic Pressure Test 109 Overdrive Fourth Gear Electrical Controls 108 Preliminary Diagnosis 106 Road Testing 108 Stall Test Analysis 112 Throttle Valve...

Page 1390: ...sted and reverse flushed as well Refer to the flow test and flushing procedures in the in vehicle service section EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air alon...

Page 1391: ...eed quality and part throttle downshift sensitivity If cable setting is too short early shifts and slip page between shifts may occur If the setting is too long shifts may be delayed and part throttle...

Page 1392: ...usu ally cannot be determined until hydraulic and air pressure tests are performed Practically any condi tion can be caused by leaking hydraulic circuits or sticking valves Unless a malfunction is obv...

Page 1393: ...ve transmission throttle lever from full for ward to full rearward position and read pressure at both gauges 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually i...

Page 1394: ...Fig 4 for pressure diagnosis CONVERTER STALL TEST Stall testing involves determining maximum engine rpm obtainable at full throttle with the rear wheels locked and the transmission in D range This te...

Page 1395: ...RATION Air pressure testing can be used to check transmis sion front rear clutch and band operation with the transmission either in the vehicle or on the work bench as a final check after overhaul Air...

Page 1396: ...nt note color of fluid Transmission fluid is red Engine oil ranges in color from brown to green or to black when oil is dirty 7 If probe upper surface is wet converter and seal are not at fault A path...

Page 1397: ...ig 10 Converter Hub Seal Cup 46RH 47RH B R E A K E D G E 1 1 6 M I N W E L D O R B R A Z E l 8 S E A L T H I S E N D A I R T I G H T 3 4 M A T E R I A L 1 1 2 I N C H O D T H I N W A L L E D S T E E L...

Page 1398: ...cted leak areas CAUTION The recommended test pressure is S psi The maximum allowable test pressure is 10 psi Do not exceed specified pressure 5 Pressurize transmission to 8 psi with air pump 6 Observe...

Page 1399: ...ssion fluid or petroleum jelly and install con verter 9 Install transmission and converter housing dust shield 10 Lower vehicle DIAGNOSIS CHARTS The diagnosis charts provide additional reference when...

Page 1400: ...if threads are damaged 8 Check pressures remove overhaul or adjust valve body as needed repair oil pump if necessary 9 Remove valve body and replace piston seal or spring as needed 10 Replace converte...

Page 1401: ...overfilled If fluid is highly aerated full of bubbles and foamy oil pump gasket or seal may have failed or pump body is porous or cracked 7 Remove valve body and air test clutch band and servo operati...

Page 1402: ...e disassemble and inspect valve body replace valve body as assembly if any valve or bore is damaged clean and reassemble correctly if all parts are in good condition MOVES IN 2ND OR 3RD GEAR ABRUPTLY...

Page 1403: ...3 Front band out of adjustment 3 Adjust band 4 Hydraulic pressures too high or too low due to sticking governor valve body malfunction or incorrect hydraulic control pressure adjustments 4 Perform hyd...

Page 1404: ...nkage warped band servo piston stuck 3 Dragging clutch does not release fully 4 Broken or seized planetary gears 5 Overrunning clutch worn broken or seized 1 Adjust bands 2 Air pressure check servo op...

Page 1405: ...POINTS AND SHOULD ALL BE CHECKED 1 Speedometer adapter 2 Pan gasket 3 Filler tube where tube enters case 4 Fluid lines and fittings 5 Valve body manual lever shaft seal 6 Pressure port plug loose 7 R...

Page 1406: ...flow blockage OVERHEAT DURING NORMAL OPERATION FLUID DISCOLORED SMELLS BURNED 1 Low fluid level 2 Fluid cooler lines blocked or cooler cracked oii in engine coolant 3 Switch valve sticking 4 Clutch p...

Page 1407: ...are both overloaded 1 If contamination is severe cooler flushing converter replacement and another overhaul may be necessary particularly so if shift problems were also present 2 If transmission is op...

Page 1408: ...ith tester and replace if necessary 10 Overdrive piston seal failure 10 Replace both seals 11 Wrong overdrive piston spacer 11 Remove unit check end play and install correct spacer 12 Low hydraulic pr...

Page 1409: ...make sure all valves and plugs slide freely in bores polish valves with crocus cloth if needed 5 Test PCM with DRB II tester and replace controller if faulty NO 4 3 DOWNSHIFT 1 Circuit wiring and or c...

Page 1410: ...Overdrive unit overrunning clutch rollers rough scored or output bushings are worn 1 Remove unit and rebuild clutch pack 2 Remove and disassemble unit replace either thrust bearing if damaged 3 Remov...

Page 1411: ...r or replace as needed CONVERTER CLUTCH WILL NOT DISENGAGE 1 Converter clutch or switch valve sticking 2 Valve body fault loose screws causing cross leakage misassembled clutch module parts etc 1 Remo...

Page 1412: ...ded 2 Realign grounded pipes Replace restricted parts 3 Drain and refill with MOPAR ATF Plus type 7176 4 Adjust cable 5 Top off fluid and check for leak 6 Replace torque converter 7 Reverse flush syst...

Page 1413: ...ged Overhaul transmission and replace converter if plugging is caused by large quantities of clutch material and or metal particles 2 Remove and overhaul pump Look for worn seals or reaction shaft sea...

Page 1414: ......

Page 1415: ...HYDRAULIC FLOW IN NEUTRAL 42RH 46RH 47RH J9421 156...

Page 1416: ...HYDRAULIC FLOW IN REVERSE 42RH 46RH 47RH...

Page 1417: ...46RH 47RH SELECTOR LEVER IN DRIVE FIRST GEAR PART THROTTLE LINE PRESSURE 70 78 psi IMO GOVERNOR PRESSURE 0 75 psi THROTTLE PRESSURE To 40 psi CONVERTER L U B E PRESSURE 5 75 psi PUMP SUCTION OVERDRIV...

Page 1418: ...HYDRAULIC FLOW IN D SECOND OEAR 42RH 46RH 47RHJ...

Page 1419: ...OVERNOR VALVE SELECTOR LEVER IN DRIVE TK SD GEAR CONVERTER CLUTCH NOT APPLIED UNE PRESSURE 57 94 psi GOVERNOR PRESSURE 0 60 psi THROTTLE PRESSURE 0 94 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION...

Page 1420: ...OR V A L V E SELECTOR LEVER IN DRIVE OVERDRIVE 4TH GEAR CONVERTER CLUTCH NOT APPLIED UNE PRESSURE 57 94 psi THROTTLE PRESSURE 0 94 psi 1 2 SHIFT CONTROL 25 70 psi GOVERNOR PRESSURE 0 57 psi CONVERTER...

Page 1421: ......

Page 1422: ...MANUAL FIRST GEAR 1 42RHJ46RH 47RH LINE PRESSURE 55 62 psi 1 2 SHIFT CONTROL 25 35 psi GOVERNOR PRESSURE 10 30 psi CONVERTER LUBE PRESSURE 15 57 psi PUMP S U C T I O N OVERDRIVE PRE FILL PRESSURE 0 5...

Page 1423: ......

Page 1424: ...cantly 7 If fluid level is too high excess fluid can be drained with suction gun and flexible tubing Tubing will have to be adapted to suction gun nozzle and be long enough to extend through fill tube...

Page 1425: ...se park brake remove funnel and reseat dipstick in fill tube GEARSHIFT LINKAGE ADJUSTMENT Check linkage adjustment by starting the engine in Park and Neutral Adjustment is OK if the engine starts only...

Page 1426: ...igned off center cable will have to be adjusted as described in following adjustment procedure 7 Reconnect cable end to attachment stud Then with aid of a helper observe movement of transmis sion thro...

Page 1427: ...at this time 9 Raise vehicle and secure cable in body clips 10 Attach cable to transmission throttle valve le ver 11 Be sure lever return spring is attached Fig 13 Transmission will not shift properly...

Page 1428: ...ension C 3705 must be used to reach adjuster screw tighten screw to only 5 N m 47 50 in lbs torque 5 Tighten band adjusting screw to 8 N m 72 in lbs torque Then back off adjusting screw as follows 2 1...

Page 1429: ...re installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 17 These numbers will correspond to number of teeth on pinion 8 Install s...

Page 1430: ...le 2 Mark propeller and axle yokes for alignment reference Then disconnect shaft at yoke and remove shaft 3 Remove old seal with Seal Remover C 3985 B Fig 19 4 Install new seal Start seal in housing T...

Page 1431: ...oosen clamp bolts and remove throttle valve and shift levers from valve body manual lever shaft 4 Remove park neutral position switch 5 Remove filter from valve body 6 Remove valve body attaching scre...

Page 1432: ...ction models will have a new style fit ting that does not require any type of release tool This fitting has a plastic insert with built in release tabs Fig 24 Cooler Line And Fitting Service The coole...

Page 1433: ...sure of approximately 2 psi The valve is serviced as an assembly it is not re pairable Do not clean the valve if restricted or con taminated by sludge or debris If the valve fails or if a transmission...

Page 1434: ...in 20 seconds is intermittent or does not flow at all 3 If vehicle is equipped with auxiliary cooler test cooler flow as described in step 2 TRANSMISSION COOLER REVERSE FLUSHING The flushing procedur...

Page 1435: ...install cooler brackets and attaching fasteners Tighten cooler line fittings and hose clamps securely 8 If condenser was removed install condenser and evacuate and recharge air conditioning system 9 I...

Page 1436: ...t battery negative cable 2 Disconnect and lower or remove necessary ex haust components 3 Remove engine to transmission struts if equipped Fig 1 4 Disconnect fluid cooler lines at transmission 5 Remov...

Page 1437: ...r to frame and remove crossmember 22 On 4 x 4 models disconnect speed sensor wires and vent hose from transfer case Then remove transfer case with transmission jack or aid of helper 23 Remove all conv...

Page 1438: ...tool First start the tool into the seal by hand Next thread the tool into the seal as far as it will go Use a wrench on the tool hex to turn the tool Continue tightening until all the tool threads fir...

Page 1439: ...etainer grommet on any shift linkage rod or lever that was disconnected Grommets should not be reused Use pry tool to re move rod from grommet and cut away old grommet Use pliers to snap new grommet i...

Page 1440: ...verhaul will be necessary 16 If overdrive unit does not require any service leave alignment tool in position Tool will prevent ac cidental misalignment of planetary gear and overrun ning clutch spline...

Page 1441: ...ry to remove and disas semble overdrive unit to realign splines 12 Align slip fit governor tubes and work over drive unit forward on intermediate shaft until seated against transmission case 13 Instal...

Page 1442: ...ve shift and throttle levers from valve body manual lever shaft 4 Remove bolts attaching overdrive unit to trans mission Fig 1 Fig 1 Overdrive Unit Attaching Bolt Removal 5 Loosen overdrive unit Use p...

Page 1443: ...C 3861 36RH 46RH 47RH J9521 47 Fig 6 Oil Pump Seal Removal 10 Remove park neutral position switch Fig 7 BR Fig 7 Park Neutral Position Switch Removal installation 11 Remove oil pan bolts and remove oi...

Page 1444: ...remove plug as shown mm TRANSMISSION OVERHAUL 21 161 ACCUMULATOR OUTER Fig 12 Accumulator Piston And Springs Fig 13 Front Band Reaction Pin Access Plug Removal 17 Loosen front band adjusting screw loc...

Page 1445: ...Remove front band lever Fig 17 Fig 17 Front Band Lever Removal _ mm 25 Slide front band rearward and onto driving shell Band will not be removed until after front rear clutch removal 28 Remove front a...

Page 1446: ...ds during re moval Do not allow machined surfaces on intermedi ate shaft or overdrive piston retainer to become nicked or scratched 32 Loosen rear band adjusting screw 4 5 turns Fig 22 Front Band Remo...

Page 1447: ...t 1 8 inch with Valve Spring Compressor C 3422 B Fig 30 A C clamp and Special Tool C 4470 can also be used to compress rod guide Fig 26 Rear Band Pivot And Reaction Pin Location Fig 27 Low Reverse Dru...

Page 1448: ...e sized service bushings are available for replace ment purposes Only the sun gear bushings are not serviced Replace the gear and bushings as an assem bly Heli Coil inserts can be used to repair damag...

Page 1449: ...hem to air dry after clean ing Inspect condition of each clutch part after cleaning Replace the rollers and the retainer and spring as sembly if the rollers springs or spring retainer are worn or dama...

Page 1450: ...ot removed during transmis sion disassembly remove seal with punch and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 40 Oil PUMP AMD REACTION SHAFT SUPPORT GLEAMING AND INSPECTION...

Page 1451: ...ance with a feeler gauge and straightedge Fig 41 Clearance should be 0 010 0 06 mm 0 0004 0 0025 in STRAIGHT EDGE fij j J9321 215 Fig 41 Measuring Pump Gear End Clearance J942M51 Shaft Support Compone...

Page 1452: ...to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of bushing 5 Assemble Bushing Installer Tools C...

Page 1453: ...ion shaft support on pump housing Fig 50 9 Align reaction support on pump housing Use alignment marks made at disassembly Or rotate Fig 49 Hub Seal Ring Position support until bolt holes in support an...

Page 1454: ...er 6 Remove seals from clutch piston and clutch re tainer hub Discard both seals as they are not reus able FRONT CLUTCH S P R I N G COMPRESSOR TOOL C 3575 A SPRING RETAINER RETAINER SNAP RING J 9 1 2...

Page 1455: ...r Check Ball Location FRONT CLUTCH RETAINER BUSHINGS NON SERVICEABLE J9321 223 FRONT CLUTCH ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install spring in p...

Page 1456: ...LUTCH OVERHAUL REAR CLUTCH DISASSEMBLY 1 Remove fiber thrust washer from forward side of clutch retainer F E E L E R G A U G E RH288 Fig 59 Measuring Clutch Pack Clearance 2 Remove selective clutch pa...

Page 1457: ...if either part is distorted warped or broken Check the lug grooves in the clutch retainer The clutch and pressure plates should slide freely in the slots Replace the retainer if the grooves are worn...

Page 1458: ...r and on top of piston Fig 56 Concave side of spring faces up as shown 9 Install wave spring in retainer Fig 66 Be sure spring is completely seated in retainer groove 10 Install bottom pressure plate...

Page 1459: ...ate shaft 2 Remove front annulus gear and support assem bly 3 Remove front planetary front thrust washer SELECT FRONT FIT ANNULUS PLANETARY SNAP SNAP RING FRONT ANNULUS THRUST WASHER DRIVING SHELL REA...

Page 1460: ...tic ular attention to the machined bushing bearing sur faces on the shaft Replace the intermediate shaft if any machined surfaces are scored pitted or damaged in any way Also replace the shaft if the...

Page 1461: ...st plate Plate goes over sun gear at rear of driv ing shell Fig 75 11 Position wood block on bench and support sun gear on block Fig 76 This makes it easier to align and install sun gear lock ring Kee...

Page 1462: ...annulus gear support Fig 80 Use liberal quantity of petroleum jelly to hold plate in place 17 Install front planetary gear on intermediate shaft and in driving shell Fig 81 18 Install front thrust was...

Page 1463: ...es for ad justment purposes BR Fig 85 Checking Planetary Geartrain End Play FRONT SERVO AND BAND OVERHAUL FRONT SERVO DISASSEMBLY FIG 86 1 Remove small snap ring from servo piston 2 Remove piston rod...

Page 1464: ...ace the band if dis torted the lining is burned or flaking off or the lin ing is excessively worn Check the band pivot and reaction pins Minor pin scoring can be cleaned up with crocus cloth However r...

Page 1465: ...rk the valve body springs for refer ence as they are removed Do not allow them to be come intermixed 1 Remove boost valve cover Fig 90 2 Remove boost valve retainer valve boost valve and plug Fig 91 s...

Page 1466: ...rew bracket to valve body and transfer plate Hold bracket firmly against spring tension while removing last screw 11 Remove adjusting screw bracket line pressure adjusting screw pressure regulator spr...

Page 1467: ...ing 3 4 shift valve and spring pressure regula tor valve spring clutch valve clutch valve spring and clutch valve plug Fig 103 LOWER HOUSING CLUTCH VALVE AND SPRING 3 4 SHIFT VALVE AND SPRING PRESSURE...

Page 1468: ...r plate from upper housing Fig 107 Fig 107 Removing Transfer Plate From Upper Housing 23 Turn transfer plate over so upper housing sep arator plate is facing upward Fig 108 24 Remove brace plate from...

Page 1469: ...Fig 113 SECONDARY I SPRING AND GUIDES SHUTTLE VALVE J912M79 Fig 112 Shuttle Valve E Ciip And Secondary Spring Location 4 Remove throttle plug primary spring shuttle valve secondary spring and spring g...

Page 1470: ...B R 42RH TRANSMISSION OVERHAUL 21 187 Fig 114 Upper Housing Control Valve Locations...

Page 1471: ...valve and shift valve covers Fig 115 10 Remove limit valve housing Then remove re tainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 115 11 Remove 1 2 shift control valve and...

Page 1472: ...3 Remove 3 4 quick fill valve spring and plug 4 Remove 3 4 shift valve and spring 5 Remove converter clutch valve spring and plug 6 Remove converter clutch timing valve retainer and valve spring 3 4 A...

Page 1473: ...rface with a sheet of crocus cloth Position the crocus cloth on a surface plate sheet of plate glass or equally flat sur face If distortion is severe or any surfaces are heavily scored the valve body...

Page 1474: ...LE PRESSURE PLUG SHUTTLE VALVE C O V E R VALVE A N D S P R I N G RETAINER B O O S T VALVE S P R I N G 2 3 SHIFT VALVE G O V E R N O R PLUG SHUTTLE VALVE P L U G LINE PRESSURE A D J U S T I N G S C R E...

Page 1475: ...arator plate on transfer plate Fig 109 4 Install brace plate Fig 108 Tighten brace at taching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching screws Tighten screws to 4...

Page 1476: ...E clip in groove at end of shuttle valve d Verify that spring and E clip are properly seated before proceeding 7 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in lbs torque...

Page 1477: ...Spring Compressor C 3422 B and install each servo snap ring Fig 132 4 Examine bolt holes in overrunning clutch cam Note that one hole is not threaded Fig 133 This hole must align with blank area in cl...

Page 1478: ...ugs on band are seated against reaction pin 12 Install low reverse drum and check overrun ning clutch operation as follows a Lubricate overrunning clutch race on drum hub with transmission fluid b Gui...

Page 1479: ...eartrain assembly Fig 143 Fig 142 Rear Band Lever And Pivot Pin Installation 18 Install thrust plate on intermediate shaft hub Fig 144 Use petroleum jelly to hold thrust plate in place 19 Check seal r...

Page 1480: ...23 Align drive teeth on rear clutch discs with small screwdriver Fig 149 This makes installation on front planetary easier 24 Raise front end of transmission upward as far as possible and support case...

Page 1481: ...clutch retainer Verify that front rear clutches are still seated before continuing e n J9121 124 Fig 150 Front Rear Clutch Assembly Installation Fig 151 Front Band And Reaction Pin Installation 31 Co...

Page 1482: ...verdrive piston thrust plate Fig 157 Use liberal quantity of petroleum jelly to hold thrust plate in position on piston 42 Install overdrive piston thrust bearing in di rect clutch hub Fig 158 Use lib...

Page 1483: ...king Alignment Of Overdrive Planetary Gear And Overrunning Clutch Splines a Attach dial indicator to converter housing b Position indicator plunger against input shaft and zero indicator c Move input...

Page 1484: ...al Position 56 Install magnet in oil pan Magnet goes on small protrusion at corner of pan 57 Position new oil pan gasket on case and in stall oil pan Tighten pan bolts to 17 N m 13 ft lbs 58 Install n...

Page 1485: ...s sion 3 Remove shift and throttle levers from shaft of valve body manual lever 4 Remove bolts attaching overdrive unit to trans mission case Fig 1 OVERDRIVE ATTACHING BOLTS J932M31 Fig 1 Removing Ove...

Page 1486: ...ssion with wood blocks 11 Remove pump oil seal with Special Tool C 3861 Fig 8 Be sure to tighten tool threads com pletely into seal before using puller bolt to withdraw seal J932M82 Seas Removs 12 Rem...

Page 1487: ...TRANSMISSION OVERHAUL Fig 9 Oil Pan Removal Installation Fig 10 Oil Pan Gasket Removal installation Pig 11 Oil Pan Magnet Location Fig 12 Park Neutral Position Switch Removal J9321 135 Fig 14 Waive Bo...

Page 1488: ...UMULATOR PISTON OUTER SPRING J9121 208 Fig 16 Accumulator Component Removal 18 Remove front band lever pin access plug Fig 17 Use square end of 1 4 in drive extension to re move plug as shown 19 Remov...

Page 1489: ...Removal 20 Remove oil pump gasket Fig 21 Note gasket position in case for assembly reference OIL P U M P Fig 22 Front Band Linkage Fig 23 Front Band Removal J9121 18 FRONT CLUTCH RETAINER J9121 19 Fig...

Page 1490: ...Fig 25 Front Band Lever And Pin Removal 26 Remove intermediate shaft thrust washer Tri angular shaped washer will either be on shaft pilot hub or in rear clutch retainer Fig 26 27 Remove thrust plate...

Page 1491: ...rust washer from spotface in hub of low reverse drum Then slide low reverse drum off piston retainer hub and out of rear band Fig 30 d Remove rear band adjusting lever reaction lever and reaction pin...

Page 1492: ...to push pivot pin out rear of case Fig 34 REAR BAND FEVER ALLEN WRENCH REAR BAND REACTION PIN J9421 443 Fig 36 Rear Band Reaction Pin Removal 47RH LEVER PIVOT PIN Fig 34 Rear Band Pivot Pin Removal 4...

Page 1493: ...ess fit on the hub splines Do not attempt to re move the race OVERRUNNING LOW REVERSE J9221 8 Fig 40 Overrunning Clutch Race Position 32 Remove overrunning clutch assembly Fig 41 Assembly can be remov...

Page 1494: ...e gasket from rear of case after remov ing piston retainer Fig 44 Overdrive Piston Retainer Removal OVERHAUL SERVICE INFORMATION Inspect all the transmission bushings during over haul Bushing conditio...

Page 1495: ...band lever adjusting screw locknut pivot pin link and strut Replace any component ex hibiting wear or damage Remove and replace the O rings on the band pivot pin Lubricate the new O rings with transmi...

Page 1496: ...46RH 47RH TRANSMISSION OVERHAUL 11 211 J9521 28 Fig 45 Low Reverse Drum Thrust Washer And Overdrive Piston Retainer BALL J9521 74 Fig 46 Overdrive Piston...

Page 1497: ...d bolt Fig 51 Insert bolt through cam case and adapter tool Be sure plate is seated squarely on cam 9 Hold puller plate and bolt in place and install puller nut SP 3701 on puller bolt Fig 52 10 Tighte...

Page 1498: ...reverse drum but do not install thrust washer or snap ring at this time Tilt drum slightly and carefully engage clutch race on drum hub in overrunning clutch rollers Then raise drum to level position...

Page 1499: ...g and spring from servo piston 2 Remove and discard servo piston seal ring 3 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with Mopar ATF Plus transmission fluid 4...

Page 1500: ...ust washer on the reaction shaft support The seal rings do not need to be replaced unless cracked severely worn or no longer hooked together Inspect the pump and support components Replace the pump or...

Page 1501: ...ng should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in PUMP Fig 61 Pump Vent And Bushing Location 311 PUMP BUSHING REPLACEMENT 1 Position pump housing on clean smooth sur face with gear cavity facing...

Page 1502: ...lation 3 If reaction shaft seal rings are being replaced install new seal rings on support hub Lubricate seal rings with transmission fluid or petroleum jelly after installation Squeeze each ring unti...

Page 1503: ...and spring retainer if ei ther are distorted warped or broken Check the lug grooves in the clutch piston retainer The steel plates should slide freely in the slots Re place the piston retainer if the...

Page 1504: ...retainer 6 Remove installer tools and clean retainer thor oughly J9221 247 Fig 71 Front Clutch Retainer Bushing Replacement 2 Install new inner and outer seals on clutch pis ton Be sure seal lips fac...

Page 1505: ...LUTCH DISASSEMBLY FIG 74 1 Remove clutch pack snap ring 2 Remove reaction plate and remove clutch plates and discs 3 Remove pressure plate wave spring spacer ring and piston spring from clutch retaine...

Page 1506: ...iscs in transmission fluid before assembly ponents 46RH 47RH 2 Install new seals on clutch piston Lubricate seals with Mopar Door Ease or Ru Glyde to ease in stallation Be sure seal lips face input sh...

Page 1507: ...ll thrust washer on piston retainer hub Fig 74 Use petroleum jelly to hold thrust washer in place J932M67 Fig 76 Measuring Rear Clutch Pack Clearance PLANETARY GEARTRAIN OVERHAUL PLANETARY GEARTRAIN D...

Page 1508: ...t washer from rear plane tary gear Fig 83 Note washer position on gear for assembly reference 7 Remove rear planetary gear and rear annulus gear from intermediate shaft Fig 84 8 Remove thrust plate fr...

Page 1509: ...nt is worn or damaged remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then re place the necessary component Replace the sun gear as an assembl...

Page 1510: ...planetary gear Fig 91 Seat washer tabs in matching slots in face of gear carrier Use extra pe troleum jelly to hold washer in place if desired 7 Lubricate sun gear bushings with petroleum jelly or tra...

Page 1511: ...ce of gear carrier Use extra petroleum jelly to hold washer in place if desired Fig 94 Installing Thrust Washer On Front Planetary Gear 46RH Shown 11 Install front annulus gear over and onto front pla...

Page 1512: ...nd 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 VALVE BODY SERVICE AND ADJUSTMENT VALVE BODY MAIN COMPONENT DISASS...

Page 1513: ...nual lever far enough to clear detent housing 6 Remove retaining tool and remove detent ball and spring Fig 103 AND SPRING J9321 139 Fig 103 Detent Ball And Spring Removal B R 7 Remove washer at top o...

Page 1514: ...ition 13 Note routing of solenoid wires for assembly reference Fig 109 14 Remove screws attaching solenoid assembly to valve body lower housing and remove solenoid and connector assembly Fig 110 15 Re...

Page 1515: ...and not fall out when lower housing and transfer plate are re moved 20 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig BOOST VALVE TUBE LOWER HOUSING UPPER HOU...

Page 1516: ...all locations for as sembly reference before removing it Fig 120 Check ball will be plastic or steel depending on valve body production date VALVE BODY UPPER HOUSING DISASSEMBLY 1 Note location of che...

Page 1517: ...231 46RH 47RH TRANSMISSION OVERHAUL B R LARGE DIAMETER CHECK BALL 1 J9321 154 Fig 121 Valve Body Check Bail Locations Fig 123 Shuttle And Boost Valve Components...

Page 1518: ...valve housing Then remove re tainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 125 11 Remove 1 2 shift control valve and spring Fig 125 12 Remove 1 2 shift valve and spring...

Page 1519: ...8 46RH 47RH TRANSMISSION OVERHAUL BR UPPER HOUSING PLUG RETAINER AND VALVE COVER SPRING COVER J9321 157 Fig 125 Upper Housing Shift Waives And Pressure Plugs Fig 126 Lower Housing Shift Waives And Spr...

Page 1520: ...lly flat sur face If distortion is severe or any surfaces are heavily scored the valve body will have to be re placed CAUTION Many of the valves and plugs such as the throttle valve shuttle valve plug...

Page 1521: ...URE PLUG 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 THROTTLE PRESSURE ADJUSTI...

Page 1522: ...all brace plate Fig 118 Tighten brace at taching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in lbs torque Upper And Lower Housing...

Page 1523: ...valve body screw holes Fig 131 6 Install and finger tighten three screws that se cure tube brace to valve body housings Fig 131 7 Bend tube brace tabs up and against tube to hold it in position Fig 1...

Page 1524: ...f spring Then hold detent ball and spring in detent housing with Re tainer Tool 6583 Fig 102 8 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manua...

Page 1525: ...ts during as sembly Keep the transmission case and components clean Also make sure the tools and workbench area used for reassembly operations are equally clean Shop towels used for wiping off tools a...

Page 1526: ...as follows a On 46RH compress rear servo piston with C clamp or Valve Spring Compressor C 3422 B Fig 141 b On 47RH use C clamp to compress retainer and spring as compressor tool will not fit on the re...

Page 1527: ...asket with feed passages in case Fig 144 Install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer Fig 144 Case Gasket Instal...

Page 1528: ...Install snap ring that secures low reverse drum to rear support hub Fig 148 Fig 148 Low Reverse Drum Snap Ring Installation 46RH 47RH e Install new O rings on band reaction pin Then insert pin into c...

Page 1529: ...BR R E A C T I O N P I N L U G S J9421 445 Fig 153 Installing Assembled Rear Band And Low Reverse Drum 47RH washer has two locating tabs Be sure tabs are seated in notches of overdrive piston re tain...

Page 1530: ...BR 46RH 47RH TRANSMISSION OVERHAUL 21 249 J9521 28 Fig 154 Low Reverse Drum And Thrust Washer 47RH Fig 156 Rear Band Lever And Pin installation 47RH...

Page 1531: ...onal cut ends of front seal rings are firmly seated against each other as shown Lubricate seal rings with petroleum jelly after checking them SHAFT THRUST PLATE INTERMEDIATE SHAFT PILOT HUB i Fig 159...

Page 1532: ...over servo rod guide Then install front band lever pin in case and slide it through lever 46RH 47RH TRANSMISSION OVERHAUL 21 211 Fig 163 Front And Rear Clutch Installation 10 Coat threads of front ban...

Page 1533: ...ther correctly Also be sure fiber thrust washer is in position Fig 167 Use ex tra petroleum jelly to hold washer in place if neces sary 5 Lubricate oil pump seals with petroleum Mopar ATF Plus 6 Mount...

Page 1534: ...nit cannot be fully installed on intermediate shaft Overdrive unit will have to be disassembled in order to re align splines 8 Carefully withdraw alignment tool from over drive unit 9 Lubricate interm...

Page 1535: ...46RH Shown Rotate overdrive output shaft with socket to free pawl and allow rod to engage b Align and seat valve body on case Be sure manual lever shaft and overdrive connector are fully seated in cas...

Page 1536: ...Use C clamp or metal strap to hold converter in place for installation Be sure converter is fully seated before installing clamp 14 Mount transmission on jack for installation in vehicle 15 Apply die...

Page 1537: ...emoval Installation 2 Remove intermediate shaft spacer Fig 2 Re tain spacer It is a select fit part and can be reused I N T E R M E D I A T E S H A F T Fig 2 intermediate Shaft Spacer Location 3 Remov...

Page 1538: ...VERHAUL 21 217 Fig 6 Overdrive dutch Pack Removal Fig 9 Locating Ring Access Cower Removal 9 Cover provides access to output shaft front bear ing locating ring Fig 10 Releasing Shaft Front Bearing Fro...

Page 1539: ...Fig 14 16 Remove output shaft rear bearing snap ring Fig 15 Remove snap ring with long jaw internal type snap ring pliers Or rotate snap ring until one end is adjacent to notch in case Then unseat ri...

Page 1540: ...VERDRIVE UNIT OVERHAUL 21 253 Fig 16 Governor Valve And Shaft Removal Installation Fig 1 9 Governor Drive Key Removal Fig 17 Removing Installing Governor Snap Ring Fig 2 0 F r o n t B e a r i n g S n...

Page 1541: ...press plates as shown and center assembly under press ram 9 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pa...

Page 1542: ...RH 46RH 47RH OVERDRIVE U11T OVERHAUL 2 1 261 Fig 24 Direct Clutch Pack Removal Fig 27 Overrunning Clutch Removal DIRECT DIRECT OVERRUNNING J9121 312 Fig 26 Sun Gear Thrust Bearing And Planetary Gear R...

Page 1543: ...d output shaft for as sembly alignment reference Fig 32 23 Remove annulus gear from output shaft Fig 33 Use rawhide or plastic mallet to tap gear off shaft 24 Remove output shaft front bearing if not...

Page 1544: ...binding occurs Check condition of the annulus gear direct clutch hub clutch dram and clutch spring Fig 34 Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or...

Page 1545: ...s and set CG46 for large bushings New bushings can be installed with tools from an all pur pose installer kit such as the Snap On A257 bushing driver set GOVERNOR OVERHAUL 42RH 46RH models have an alu...

Page 1546: ...uld slide freely in the governor body r Components Check the governor drive seal rings Replace the seal rings only if they exhibit wear or damage Be sure the seal ring grooves in the drive are in good...

Page 1547: ...to right of key slot as shown in Figure 40 GOVERNOR BODY GOVERNOR DRIVE J9521 22 Fig 40 Governor Body And Filter Position On Drive SPECIAL TOOL 6823 INNER WEIGHT SNAP RING INTERMEDIATE WEIGHT SUITABLE...

Page 1548: ...Install front bearing and bearing snap ring on output shaft Fig 45 INTERLOCKED RING ENDS GOVERNOR DRIVE J9521 26 Fig 43 Governor Drive Seal Ring Installation 4 Align and install annulus gear on outpu...

Page 1549: ...if it does not seat squarely 11 Install overrunning clutch Fig 50 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion 12 Instal...

Page 1550: ...y thrust bearing on sun gear Fig 53 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...

Page 1551: ...ll clutch hub and clutch pack on direct clutch spring Fig 59 23 Mount geartrain assembly in shop press Fig 60 WARNING THE NEXT STEP IN GEARTRAIN ASSEM BLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AN...

Page 1552: ...42RH 46RH 47RH OVERDRIVE UNIT OVERHAUL 21 271 J9421 262 Fig 56 Direct Clutch Pack Components...

Page 1553: ...SPECIAL TOOL Fig 57 Correct Position Of Direct dutch Reaction MB990891 Plate SPECIAL TOOL 6227 1 DIRECT CLUTCH PACK CLUTCH DRUM J9221 2 _ F g S i Mounting Geartrain Assembly in Shop Press Fig 58 Corr...

Page 1554: ...in place if neces sary OUTPUT SHAFT DRIVE KEY FRONT BEARING SNAP RING II J9521 76 Fig 64 Front Bearing And Drive Key Installation 3 Install governor body and drive assembly on output shaft as follows...

Page 1555: ...install bearing snap ring Be sure snap ring is fully seated 11 Position park pawl and spring in case and in stall park pawl shaft Fig 14 Verify that spring end is hooked to pawl and straight end of sp...

Page 1556: ...t shaft front bearing locating ring in case Fig 74 J9121 339 Fig 74 Front Bearing Locating Ring Installation 19 Support geartrain on Tool 6227 1 Fig 75 Be sure tool is securely seated in clutch hub 20...

Page 1557: ...21 276 42RH 46RH 47RH OVERDRIVE OilT OVERHAUL BR Fig 76 Overdrive Clutch Pack Components Fig 77 Overdrive Clutch Fling identification Fig 78 Shaft End Play Measurement...

Page 1558: ...ition Dial Caliper C 4962 over gauge tool c Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312 Lock scale in place Remove dial...

Page 1559: ...or use on hard surface roads The only exception being when the road surface is covered by ice and snow page Transfer Case Application 278 Transfer Case Assembly 295 Transfer Case Changes 279 Transfer...

Page 1560: ...6 pints for the NP231 HD TRANSFER CASE SHIFT MECHANISM The transfer case is operated by an adjustable floor mounted shift linkage The transfer case shift lever e NP241 HD Version Shown is directly att...

Page 1561: ...nsfer case in the vehicle The rear extension rear retainer and companion flange can all be removed for access while the trans fer case is mounted in the vehicle Removal installa tion procedures are de...

Page 1562: ...e 7176 or DEXRON II Automatic Transmission Fluid e Disassemble unit and replace worn or damaged components as necessary a Drain and refill to edge of fill hole with MOPAR ATF PLUS Type 7176 or DEXRON...

Page 1563: ...case shift lever or from floor shift arm whichever provides easy access Fig 7 Use channel lock style pliers to press rod out of lever grommet 8 Support transmission with jack stand 9 Remove rear cross...

Page 1564: ...30 ft lbs If case has 3 8 studs tighten nuts to 41 47 N m 30 35 ft lbs 4 Install rear crossmember 5 Remove jack stand from under transmission 6 Align and connect propeller shafts 7 Connect speed sens...

Page 1565: ...Fig 7 Note that screw has O ring seal Remove and dis card seal this seal 10 Remove poppet plunger with magnet Fig 8 11 Remove rear extension bolts Fig 9 A 13 or 15 mm socket is required for removal 1...

Page 1566: ...TER GEAR Ik PRY TOOL J9421 276 Fig 13 Loosening Rear Retainer 16 Remove rear retainer and output bearing as assembly Fig 14 17 Remove speedometer gear rear retaining ring Fig 15 Then remove speedomete...

Page 1567: ...ignment dowels Fig 20 REAR CASE J9421 283 Fig 20 Removing Rear Case From Alignment Dowels REAR CASE FRONT CASE J9421 284 Fig 21 Rear Case Removal 23 Remove oil pump pickup tube and filter as as sembly...

Page 1568: ...n as assembly Fig 25 5 Remove front output shaft from bearing in case Fig 26 6 Pull mainshaft assembly out of input gear slid ing clutch and case Fig 27 7 Remove mode fork sliding clutch and shift rai...

Page 1569: ...Range Fork Retaining Ring Removal J9421 293 Fig 30 Range Fork And Support Sleeve Removal INPUT GEAR AND P L A N E T A R Y REMOVAL 1 Remove input bearing retainer bolts Fig 33 A 10 mm socket is require...

Page 1570: ...ear Retaining Ring 4 Tap input gear out of bearing with plastic mal let Fig 36 5 Remove input gear and planetary PTO gear as assembly Fig 37 PLANETARY AND INPUT GEAR DISASSEMBLY The only removable par...

Page 1571: ...Note that lock ring and thrust washer are both tabbed THRUST WASHER LOCK RING PLANETARY J9421 302 Fig 39 Planetary Lock Ring And Front Thrust Washer Removal 4 Remove input gear from planetary carrier...

Page 1572: ...ows a Turn puller tool bolt until jaws retract enough to fit into bearing Fig 44 GEAR J9421 307 Fig 44 Puller Jaws In Retracted Position b Insert puller bolt and jaws into bearing Fig 45 Then turn pul...

Page 1573: ...om hub Note position of springs for installation refer ence Fig 50 4 Remove brass stop ring Fig 51 Discard stop ring if worn cracked or any teeth are missing 5 Remove drive sprocket Fig 52 Note that s...

Page 1574: ...ficult Blind hole SPECIAL TOOL 7828 SPECIAL TOOL C 4171 J9421 318 Fig 55 Input Bearing Removal puller tools like those found in Snap On Tool Sets CG40B CG46 and CG2545AB will be required for bearing r...

Page 1575: ...reads or distortion Replace either case half if nec essary However stripped threads can be repaired ents And Bearings with Heli Coil stainless steel thread inserts The case vent tube can be re secured...

Page 1576: ...he NP241 The standard model is not equipped for PTO capability TRANSFER CASE ASSEMBLY Gaskets are not used in the transfer case Instead use Mopar Gasket Maker Loctite 518 or Mopar sili cone adhesive s...

Page 1577: ...nstaller and verify that seal is re cessed the proper amount Seal should be 2 03 to 2 5 mm 0 080 to 0 100 in b e l o w top edge of seal bore in front case Fig 64 This is correct final seal position CA...

Page 1578: ...7828 Fig 67 7 Lubricate sector shaft with transmission fluid and install shift sector in case Fig 68 Position slot in sector so it will be aligned with shift fork pin when shift forks are installed 8...

Page 1579: ...sleeve in planetary carrier Fig 72 Be sure sleeve is seated 6 Install new needle bearing in input gear if nec essary Fig 73 Use Handle C 4171 and Installer 5065 to install bearing flush with upper ed...

Page 1580: ...r or PTO gear on HD models with hammer handle to seat planetary pinions in an nulus gear Fig 77 14 Install retaining ring on input gear Fig 78 MAINSHAFT SHiFT FORK ASSEMBLY AND INSTALLATION 1 Support...

Page 1581: ...hub slots Be sure spring is positioned under struts to properly secure them Fig 83 d Turn hub over and install remaining spring in hub Position hooked end of second spring 180 away from first spring e...

Page 1582: ...the hub so a clutch spline is centered over each strut as shown Fig 87 If the clutch is installed s a gap between splines is aligned with one or more struts gear clash will result SLIDING CLUTCH SYNC...

Page 1583: ...tion 11 Install mode fork and shift rail in sliding clutch Fig 91 12 Install mainshaft mode fork assembly Fig 92 Guide mainshaft through hub and into input gear and shift rail through range fork and i...

Page 1584: ...liding clutch on synchro hub if neces sary Press synchro struts inward to ease realign ment Be sure mainshaft is fully seated before proceeding RETAINING RING J9421 353 Fig 95 Front Sprocket Retaining...

Page 1585: ...p and position pump in rear case Fig 101 6 Apply bead of Mopar Gasket Maker Loctite 518 or Mopar silicone adhesive sealant to mating surface of front case Keep sealer bead width to max imum of 3 16 in...

Page 1586: ...Fig 105 Speedometer Gear installation REAR RETAINER AND EXTENSION INSTALLATION 1 Apply bead of Mopar Gasket Maker Loctite 518 or Mopar silicone adhesive sealant to mating surface of rear retainer Kee...

Page 1587: ...hen 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 and underside of bolt heads Then install...

Page 1588: ...REW 8 Check stud at end of case halves Fig 116 If stud was loosened or came out during disassembly apply Loctite 242 to stud threads and reseat stud in case 9 Apply Loctite 242 to remainder of rear ca...

Page 1589: ...switch Tighten switch to 20 34 N m 15 25 ft lbs torque Install new O ring on switch beforehand if necessary 13 Install drain plug Tighten plug to 41 54 N m 30 40 ft lbs torque 14 Transfer case can be...

Page 1590: ...achment to the overdrive unit gear case page PTO Accessory Equipment 311 PTO Adapter Operating Ranges and Shifting 310 PTO Adapter Service 311 Recommended Lubricant and Fill Level 311 Shift Lever and...

Page 1591: ...it Operating ranges consist of drive D and neutral N D range is used for normal driving and for PTO ac cessory operation while the vehicle is in motion N range is used for PTO accessory operation when...

Page 1592: ...e Sealer or Loctite 518 ADAPTER SERVICE DIAGNOSIS The PTO adapter should not be removed until di agnosis indicates a fault has actually occurred Verify that the other driveline components transmission...

Page 1593: ...cant level leak or underfilled shift rod loose or misadjusted shift lever nut loose or missing engine transmission mounts loose damaged adapter shift fork or sleeve damaged Fluid Leaks Fluid leaks fro...

Page 1594: ...ct vehicle speed sensor wires at sensor Fig 10 GROMMET SPEED SPEEDOMETER J9421 224 Fig 10 Shift Rod And Speed Sensor Wire Attachment 4 Disconnect shift rod from grommet in adapter shift lever Fig 10 U...

Page 1595: ...retaining ring A torx head bit is required to remove cover screws 3 Remove input bearing retainer bolts Fig 3 4 Remove input bearing retainer as follows In sert pry tool in retainer slot Fig 4 Then pr...

Page 1596: ...BR i f 121 PTO ADAPTER 21 315 Fig 3 Removing input Bearing Retainer Bolts Fi 9 6 Input Gear Retaining Ring Removal Fig 8 Poppet And Spring Removal Fig 5 Input Bearing Retainer Removal...

Page 1597: ...L O C A T I O N O F B O L T S R E Q U I R I N G A W A S H E R W O O D B L O C K S J 9 4 2 1 3 9 0 Fig 12 Location Of Rear Extension Bolts Requiring Washers P R Y T O O L I N E X T E N S I O N S L O T...

Page 1598: ...e rear output bearing retaining ring from mainshaft Fig 17 15 Remove output bearing from mainshaft Note position of snap ring groove in bearing for in stallation reference Fig 18 16 Remove speedometer...

Page 1599: ...se Fig 22 20 Remove shift fork and shift sleeve as assembly Fig 23 21 Separate shift fork and sleeve Fig 24 Note position of sleeve for installation reference 22 Roll case on side and off wood blocks...

Page 1600: ...input gear Fig 27 Then slide PTO gear off input gear Fig 28 26 Remove sector shaft O ring retainer Fig 29 and O ring Fig 30 27 Remove input bearing from front case with Driver Handle C 4171 and Tool C...

Page 1601: ...d nicks can be smoothed off J9421 412 Fig 33 Tightening Puller Nut To Pull Bearing From Gear Fig 34 Bearing Removed From Gear with emery cloth Damaged threads can be repaired with Heli Coil stainless...

Page 1602: ...shaft bore Do not reuse the original O rings Check condition of the plastic inserts on the shift fork Be sure the inserts are not worn through or otherwise damaged Replace the fork if worn or dam aged...

Page 1603: ...sector shaft O ring Fig 41 and O ring retainer Fig 42 in sector shaft bore O RING _ RETAINER J9421 417 Fig 42 Sector Shaft Ring Retainer installation 5 Install shift sector in front case Fig 43 J9421...

Page 1604: ...48 Then install fork and sleeve Fig 49 Be sure sleeve is seated in input gear Fig 48 Assembling Shift Fork And Sleeve Fig 49 Shift Fork And Sleeve Installation 15 Align and install shift fork pin in s...

Page 1605: ...snap ring on shaft Fig 55 followed by speedometer gear Fig 56 Then install second snap ring to secure gear on shaft Fig 57 J9421 383 Fig 53 Installing Tightening Shift Lever Nut And Washer MAINSHAFT S...

Page 1606: ...taiiation 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 adhesiv...

Page 1607: ...ut Bearing Retaining Ring Fig 62 Correct Seating Of Retaining Ring 30 Install access cover and gasket in rear exten sion Fig 63 Then install and tighten torx screws to 8 11 N m 75 95 in lbs Fig 64 31...

Page 1608: ...Retainer Oii Channel And Case Oil Feed Hole Locations 33 Install poppet plunger and spring in front case detent bore Fig 68 34 Install new O ring on poppet plunger screw Then install screw in front ca...

Page 1609: ...iner Bolts 30 35 N m 22 26 ft lbs Shift Tower Bolts 7 10 N m 5 7 ft lbs Slave Cylinder Attaching Nuts 23 N m 200 in lbs Transfer Case Attaching Nuts 47 N m 35 ft lbs U Joint Clamp Bolts 19 N t h 170 i...

Page 1610: ...7176 Automatic Transmission Fluid J9521 201 S P A C E R T H R U S T PLATE SNAP RING SPECIFICATIONS 42 RH 46 RH 47 RH Front Clutch Thrust Washer on reaction shaft support hub 0 061 in 0 061 in 0 084 i...

Page 1611: ...13 ft lbs Converter Bolts 46RH Converter 31 N m 270 in lbs 47RH C o n v e r t e r 47N m 35 ft lbs Crossmember Bolts Nuts 68 N m 50 ft lbs Driveplate Bolts 46RH 75 N m 55 ft lbs 47RH 102 N m 75 ft lbs...

Page 1612: ...5 ft lbs 41 47 N m 30 35 ft lbs 20 34 N m 15 25 ft lbs 16 24 N m 12 18 ft lbs Access Cover Screws 8 11 N m 75 95 in lbs Adapter Mounting Nuts With 5 16 stud With 3 8 stud Adapter Shift Lever Nut Fill...

Page 1613: ...e encoded in the letters and numbers imprinted on the side wall of the tire Refer to the chart to decipher the tire identification code Fig 1 page Rotation 3 Tire Inflation Pressures 2 Tire Noise or V...

Page 1614: ...tterns Reduced tread life Reduced fuel economy Unsatisfactory ride Cause the vehicle to drift Fig 2 Under Inflation Wear Fig 3 Over Inflation Wear Refer to the Tire Inflation Pressure brochure for in...

Page 1615: ...rns These effects can be reduced by rotat ing the tires according to the maintenance schedule in the Owners Manual This will improve tread life traction and maintain a smooth quiet ride The recommende...

Page 1616: ...ise will change in intensity as speed varies Tire noise will usually remain constant TIRE WEAR PATTERNS Under inflation will increase wear on the shoulders of the tire Over inflation will increase wea...

Page 1617: ...G N M E N T N O T O K A D J U S T A L I G N M E N T T O P R E F E R R E D S E T T I N G S OK 1 CAR LEADS OPPOSITE DIRECTION PROBABLE CAUSE TIRES SWITCH TIRES FRONT TO REAR LEFT FRONT TO LEFT REAR LEF...

Page 1618: ...g surface Fig 2 The slots in the wheel must be aligned to provide access to the valve stem Fig 3 Fig 2 Flat Face Wheel Fig 3 Dual Rear Wheels C WHEEL INSTALLATION The wheel studs and nuts are designed...

Page 1619: ...nut wrench It is recommended to remove and install dual rear wheels only when the proper wrench is available The wrench is also use to remove wheel center caps for more information refer to Owner s M...

Page 1620: ...ion of heavy spot causing imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counterbalance the area of imbalance Place half of this weight on the inner rim...

Page 1621: ...eak down the tire and remount it 180 de grees on the rim Fig 8 VALVE STEM REFERENCE MARK 1ST MEASUREMENT HIGH SPOT MARK TIRE AND RIM VALVE STEM WHEEL REFERENCE MARK J9322 4 J9322 3 Fig 7 First Measure...

Page 1622: ...e tire can be rotated on the wheel See Method 2 METHOD 1 RELOCATE WHEEL ON HUB Check accuracy of the wheel mounting surface ad just wheel bearings Drive vehicle a short distance to eliminate tire flat...

Page 1623: ...peed engine speed and engine torque When the vibration has been identified refer to the Vibration Diagnosis chart for causes Consider cor recting only those causes coded in the chart that are related...

Page 1624: ...torque vehicle speed sen sitive mechanical audible vibration The axle will not cause mechanical vibration unless the axle shaft is bent Worn or damaged axle pinion shaft or differen tial gears and bea...

Page 1625: ...S 22 13 LUG N U T T O R Q U E DESCRIPTION TORQUE BR1500 5 Stud Wheel 130 N m 95 ft lbs BR2500 8 Stud Wheel 180 N m 135 ft lbs BR3500 8 Stud Dual Wheels 195 N m 145 ft lbs J9422 4 T O R Q U E S P E C I...

Page 1626: ...Wheels 14 Rear Splash Shields 13 Rear Wheelhouse Liner 14 Right Front Fender 6 Roof Joint Molding 9 Roof Rail Weatherstrip and Retainer 9 Side View Mirror 7 Stick On Body Side Moldings 11 Tailgate 15...

Page 1627: ...NCER MEMOWAL 1 Release hood latch and open hood 2 Remove push in fasteners holding silencer to hood Fig 4 3 Separate hood silencer from vehicle mm GRILLE CLIP J9423 14 Fig 4 Hood Silencer HOOD SAFETY...

Page 1628: ...m hood to hinge attaching bolts Separate the hood from the vehicle INSTALLATION Align all marks and secure bolts The hood should be aligned to 5 mm 0 2 in gap to the front fenders and flush across the...

Page 1629: ...s holding hood latch to radiator clo sure panel crossmember Fig 8 3 Separate hood latch from crossmember 4 Disconnect release cable from hood latch INSTALLATION Reverse the preceding operation HOOD SL...

Page 1630: ...use Fig 1 5 Remove plastic rivets holding liner to front bumper fascia 6 Separate front wheelhouse liner from vehicle INSTALLATION Reverse the preceding operation LEFT FRONT FENDER REMOVAL 1 Release h...

Page 1631: ...t holding front fender to hinge pil lar mounting bracket Fig 5 15 Remove bolts holding top of fender to radiator closure panel Fig 5 16 Separate left front fender from vehicle INSTALLATION Reverse the...

Page 1632: ...hicle SIDE VIEW MIRROR REMOVAL 1 Remove door trim panel 2 Remove mirror flag door seal Fig 8 DOOR MIRROR FLAG DOOR SEAL J9523 148 Fig 8 Mirror Flag Door Seal 3 Disengage power mirror wire connector fr...

Page 1633: ...door panel Fig 11 3 Separate mirror from vehicle INSTALLATION Place insulation washers between support frame and painted door panel and reverse the preceding op eration DOOR LATCH STRIKER REMOVAL 1 R...

Page 1634: ...ent Wipe surface dry with lint free cloth 6 Remove protective cover from tape on back of seal and apply seal to body 7 Heat body and seal see step one Firmly press seal to body surface to assure adhes...

Page 1635: ...apply a length of masking tape par allel to the edge of the original tape stripe to aid in stallation 2 Warm the panel to approximately 38 C 100 F using a suitable heat lamp or heat gun 3 Peel tape st...

Page 1636: ...nel out using a body putty applicator squeegee Fig 8 CAUTION Do not cut into painted surface of body panel when trimming overlay to size 11 Trim overlay to size using a razor knife Leave at least 13 m...

Page 1637: ...e of the molding to use as a guide if necessary 7 Remove protective cover from tape on back of molding Apply molding to body below the masking tape guide 8 Remove masking tape guide and heat body and...

Page 1638: ...uitable adhesive removing solvent REMOVAL PIG 13 1 Warm the tailgate applique and tailgate metal to approximately 38 C 100 F using a suitable heat lamp or heat gun 2 Pull applique from tailgate 3 Remo...

Page 1639: ...l plastic rivets holding rear wheelhouse liner to rear wheel opening lip EAR FENDER WITH D U A L REAR WHEELS REMOVAL 1 Open fuel fill door left side only 2 Remove screws holding fuel fill neck to rear...

Page 1640: ...ate from vehicle INSTALLATION Reverse the preceding operation TAILGATE HANDLE ESCUTCHEON REMOVAL FIG 6 1 Lift and hold tailgate latch release handle 2 Using a trim stick C4755 pry bottom of es cutcheo...

Page 1641: ...INSTALLATION Reverse 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 dr...

Page 1642: ...lam bumper on vehicle 2 Install screw holding slam bumper to cargo box 3 Close tailgate and verify operation CAHGO BOI REMOVAL 1 Open fuel fill door 2 Remove screws holding fuel fill neck adaptor to c...

Page 1643: ...installation 6 Support door on a suitable lifting device 7 Remove bolts holding lower door hinge to hinge pillar Fig 2 page Door Lock Cylinder 22 Door Trim Panel 19 Door Water Dam 20 Inner Door Belt...

Page 1644: ...Release door latch and open door 2 Roll window down 3 Remove window crank Fig 4 if equipped DOOR HANDLE REMOVAL TOOL Fig 4 Window Crank Typical 4 Remove screws holding door trim panel to door from ins...

Page 1645: ...ig 8 Inner Door Beit Weatherstrip INSTALLATION Reverse the preceding operation OUTER DOOR BELT WEATHERSTRIP REMOVAL FIG 9 1 Roll door glass down 2 Remove mirror 3 Using a hook tool inserted into the e...

Page 1646: ...INDOW DOOR GLASS REGULATOR ASSEMBLY J9423 38 Fig 12 Door Glass Window Regulator 1 Remove door trim panel 2 Remove water dam 3 Remove nuts holding door glass to window reg ulator 4 Remove glass from do...

Page 1647: ...Fig 14 8 Separate retaining bracket from door 9 Separate outside door handle from vehicle INSTALLATION Reverse the preceding operation DOOR LOCI CYLINDER DOOR LOCK CYLINDER TO LATCH NUT DOOR LATCH Fi...

Page 1648: ...tch to door end panel 5 Separate door latch lock from vehicle INSTALLATION Reverse the preceding operation D O O R LATCH LOCK ADJUSTMENT 1 Insert a hex wrench through the elongated hole in the door en...

Page 1649: ...e painted surfaces when removing the moulding or cutting urethane around the glass It is difficult to salvage a windshield or rear glass during the removal operation The windshield or rear glass is pa...

Page 1650: ...by 4 in by 20 in blocks placed par allel 75 cm 2 5 ft apart Fig 5 3 Clean inside of windshield with Mopar Glass Cleaner and lint free cloth 4 Apply clear glass primer 25 mm 1 in wide around perimeter...

Page 1651: ...ass at the opening insert the hinge studs in the B pillar holes and install the retaining nuts Tighten the nuts with 11 N m 95 in lbs torque 3 Attach the latch to the rear side panel with the screws T...

Page 1652: ...emove rear closure panel trim 5 Bend rear window retaining tabs inward against glass 6 Using a suitable pneumatic knife from inside the vehicle cut urethane holding rear glass frame to opening fence 7...

Page 1653: ...he closed position Fig 16 3 Slide the upper left and upper right run chan THIS END OF THE UPPER RUN CHANNEL SHOULD BE INSTALLED OVER THE SLIDING GLASS PIECE WHEN IT IS IN THE CLOSED POSITION RUN CHANN...

Page 1654: ...p seal Insert the cord into the window opening flange channel in the weatherstrip seal Fig 17 Position the window glass and the weatherstrip seal in the window opening with the free ends of the cord i...

Page 1655: ...lit Bench 32 Split Bench Seat 32 Sun Visor 39 BENCH 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 1 4 Move seat t...

Page 1656: ...ecure left and right side J Straps INTERIOR COMPONENTS 23 31 Fig 5 J Strap Installation 5 Verify stitching lines are straight correct as necessary A S S E M B L Y 1 Align seat cushion with seat back F...

Page 1657: ...e 3 Install bolt holding inboard seat track to bot tom of center occupant seat Tighten the bolt with 28 N m 250 in lbs torque 4 Install nuts holding outboard and inboard tracks to floor Tighten the nu...

Page 1658: ...rame side up 2 Remove rear J Strap 3 Remove Left and right J Straps 4 Remove front J Strap 5 Roll cushion cover off of foam cushion SEAT CUSHION COVER INSTALLATION 1 Position cushion cover on cushion...

Page 1659: ...Tap out con sole lid hinge pin 6 Separate lid from console CONSOLE LIO INSTALLATION 1 Align console lid with console Verify lid tension spring is in position 2 Install hinge pin 3 Position trim bezel...

Page 1660: ...l cover to floor at door sill Fig 1 Fig 1 Door Sill and Cowl Cover 3 Separate door sill and cowl trim from vehicle INSTALLATION Reverse the preceding operation A PILLAR GRAB HANDLE REMOVAL 1 Using a s...

Page 1661: ...up holder Fig 5 4 Remove lower seat belt anchor bolts Fig 6 5 Remove screws holding club cab quarter trim panel to quarter panel Fig 6 6 Separate club cab quarter trim panel from quarter panel 7 Pull...

Page 1662: ...to quar ter panel 7 Separate seat belt retractor from vehicle INSTALLATION Reverse the preceding operation SEAT BELT RETRACTORS CLUB CAB REMOVAL 1 Remove seat belt lower anchor bolts 2 Remove club cab...

Page 1663: ...Turn release handle to disengage seat from stowed position and push seat cushion downward to lock into place HEADLINER REMOVAL FIG 4 1 Remove sun visors and visor hooks 2 Remove overhead assist handle...

Page 1664: ...8 Sun Visor REAR FLOOR STOWAGE TRAY REMOVAL 1 Move seat tracks to forward position 2 Remove screws holding rear floor stowage tray to floor Fig 9 Fig 9 Rear Floor Stowage Tray 3 Disengage hooks on sto...

Page 1665: ...ews holding floor shift boot to floor 8 Remove gear shift knob 4 Separate gear shift boot from floor 5 Lift floor shift boot off shifter INSTALLATION Reverse the preceding operation FLOOR SHIFT Fig 12...

Page 1666: ...rim 8 Fold carpet or mat toward center of cab 9 Remove carpet or mat through door opening INSTALLATION Reverse the preceding operation INSULATION OR CARPET REAR INNER SEAT MOUNT J9423 26 Fig 15 Floor...

Page 1667: ...ak occurs when the vehicle is parked on an in cline hoist the end or side of the vehicle to simulate page Water Leaks 42 Wet Sanding Buffing and Polishing 43 Wind Noise 43 this condition This method c...

Page 1668: ...ece of tape is applied re move tape locate and repair defect POSSIBLE CAUSE Of WIND iOISE Moldings standing away from body surface can catch wind and whistle Gaps in sealed areas behind overhanging bo...

Page 1669: ...ck C C DX8 9700 15214 99 34858 90 5950 CHA85 DX8 Dk Silver Met C C KS7 4274 21077 B9137 44046 CHA91 KS7 Silver Star Met C C KAC 4276 21083 B9141 44048 CHA91 KAC Bright White C C G W 7 4037 18238 B8833...

Page 1670: ...heater core Air intake openings must be kept free of snow ice and other obstructions for the heater system to pick up a sufficient volume of outside air A temperature control door in the heater housi...

Page 1671: ...ter A C System Airflow Front View On air conditioned vehicles outside air can be shut off by opening the recirculating air door This will re circulate the air that is already inside the vehicle This i...

Page 1672: ...a refrigerant and must be replaced with O rings made of the same material SERVICE PORTS The low and high pressure ser vice ports are attached to the refrigerant lines These ports are used to attach A...

Page 1673: ...manifold hose YELLOW or WHITE with BLACK STRIP is used to recover evacuate and charge the refrigerant system When the low or high pressure valves on the manifold gauge set are opened the refrigerant...

Page 1674: ...rosive to metal surfaces Follow the operating instructions supplied with equipment being used CAUTION DO NOT use R 12 equipment or parts on the R 134a system Damage to the system will re sult CAUTION...

Page 1675: ...OOLANT AND IS HARMFUL IF SWAL LOWED OR INHALED IF SWALLOWED DRINK TWO GLASSES OF WATER AND INDUCE VOMIT ING IF INHALED MOVE TO FRESH AIR AREA S E E K MEDICAL ATTENTION IMMEDIATELY WARNING KEEP OUT OF...

Page 1676: ...before the system can be charged Moisture and air mixed with refrigerant will raise the compressor head pressure above acceptable page Recovering Refrigerant System 7 Refrigerant Oil Level Check 7 op...

Page 1677: ...k point will be evident by the pres ence of a wet shiny surface around the leak Refrigerant oil must be added when a accumulator evaporator or condenser are replaced refer to the Refrigerant Oil Capac...

Page 1678: ...umper wire across the terminals of the clutch cycling pres sure switch connector 7 With the A C clutch engaged record the dis charge air temperature and the compressor discharge pressure and evaporato...

Page 1679: ...e system LOW SIDE PRESSURE HIGH AND HIGH SIDE PRESSURE LOW 1 Internal compressor leak 2 Compressor head gasket leaking 3 Drive belt slipping 1 Replace the compressor 2 Replace the compressor 3 Replace...

Page 1680: ...pply hose locate and repair engine coolant flow obstruction in heater system Possible locations or cause of obstructed cool ant flow Pinched or kinked heater hoses Improper heater hose routing Plugged...

Page 1681: ...OOR Bl LEVEL PANEL or RECIRC with A C Pause after each selection The test gauge should return to the calibrated setting of 27 kPa 8 in Hg after each selection is made If the gauge cannot achieve the c...

Page 1682: ...ing Blower wheel loose on motor shaft Blower wheel out of balance or bent Blower motor defective 2 Possible location or cause of blower motor noise are as follows To verify blower noise disconnect blo...

Page 1683: ...ation If voltage is detected at the cut off switch recon nect switch Then check for battery voltage between the compressor clutch connector terminals If voltage is detected perform A C Clutch Coil Tes...

Page 1684: ...E PERFORMING THE FOLLOWING PROCEDURE REMOVAL 1 Disconnect negative cable from battery 2 Remove the serpentine belt refer to Group 7 Cooling System 3 Disconnect compressor clutch wire lead 4 If the com...

Page 1685: ...all refrigerant lines to manifold 4 Evacuate and charge the A C system refer to Refrigerant Service Procedures 5 Connect the negative cable to the battery COMPRESSOR CLUTCH COIL ASSEMBLY REVIEW WARNIN...

Page 1686: ...wire under clip on top of com pressor front housing and tighten the retaining screw J8924 23 Fig 6 Loosen Coil Lead Wire Fig 7 Snap Ring and Field Coil 3 Support the compressor on the 4 mounting ears...

Page 1687: ...nsistent around the circumference lightly pry up at the minimum variations Lightly tap down at points of maximum variation J8924 27 Fig 10 Clutch Plate installation J8924 28 Fig 11 Check Air Gap The a...

Page 1688: ...spring is expanded pull fittings apart within the tool 5 Remove the tool from the disconnected cou pling 6 Separate the two ends of the coupling INSTALL 1 Check to ensure that the garter spring is in...

Page 1689: ...e glove box and can be removed from the passenger compartment REMOVAL 1 Disconnect the negative cable from the battery 2 Disconnect the blower motor cooling tube Fig 4 3 Remove the blower motor electr...

Page 1690: ...y HEATING AND AIR CONDITIONING 24 21 Fig 7 Blower Motor Resistor HEATER A C HOUSING REMOVAL 1 Disconnect the negative cable from the battery 2 Recover refrigerant system into a recovery recy cle devic...

Page 1691: ...ine com partment side of the dash panel Tighten the nuts to 7 N m 60 in lbs torque 4 Connect the heater hoses to the heater core lines 5 Connect the A C hoses to the evaporator lines 6 Install the coo...

Page 1692: ...the top half of the heater A C housing in place Carefully turn the housing over Install and tighten the retaining screws 3 Snap on the center adaptor heat duct 4 Install the heater A C housing into th...

Page 1693: ...2 Disconnect the cable from the top of the hous ing Fig 14 3 Disconnect the cable from the heater A C con trol Fig 15 INSTALLATION 1 Connect the cable to the heater A C control 2 Connect the cable to...

Page 1694: ...upside down 3 Separate the door pivot connection from the door pivot pin 4 Disconnect the vacuum line 5 Remove the retaining screws holding the two halves together Remove the center adaptor heat duct...

Page 1695: ...A C hoses from the condenser Plug the openings 4 Remove the screws and condenser Fig 20 or 21 5 Carefully remove the condenser from the vehi cle INSTALLATION 1 Carefully position the condenser into t...

Page 1696: ...Connect the quick connect fittings at the con denser 3 Evacuate and charge the A C system refer to Refrigerant Service Procedures 4 Connect the negative cable to the battery J9424 36 Fig 21 A C Conden...

Page 1697: ...er Systems 3 Disconnect the vacuum hose Fig 26 4 Remove the reservoir attaching screws Fig 26 Remove the vacuum reservoir INSTALLATION 1 Install the vacuum reservoir Install and tighten the vacuum res...

Page 1698: ...4 29 T O R Q U E S P E C I F I C A T I O N S HEATING AND AIR CONDITIONING DESCRIPTION Compressor Mounting Bolts Manifold Bolts Bracket Bolts Shaft Nut TORQUE 27 N m 20 ft lbs 25 N m 19 ft lbs 41 N m 3...

Page 1699: ...ir in jection AIR pump The 3 9L 5 2L 5 9L LDC gas engines or the diesel engine will not use an AIR pump Maintenance requirements for LDC and HDC emis sion systems differ because of different load and...

Page 1700: ...n front of the radiator Fig 3 and contains the following Engine family and displacement Evaporative family Emission control system schematic Certification application Engine timing specifications if a...

Page 1701: ...PONENTS The powertrain control module PCM performs an On Board Diagnostic OBD check for certain emis sion system components on all vehicles This is done by setting a diagnostic trouble code DTC A DTC...

Page 1702: ...VALVE EVAPPURGE SOLENOID THROTTLE BODY FILTER MAP SENSOR CHECK VALVE W ORIFICE CRANKCASE BREATHER INTAKE MANIFOLD ORIFICE FRONT OF VEHICLE TO AIR CLEANER ENGINE VALVE COVER TO BRAKE BOOSTER ENGINE VAC...

Page 1703: ...ICE CHECK VALVE W ORIFICE IDLE PURGE OFF IDLE PURGE THROTTLE BODY CRANKCASE BREATHER FITTING R H VALVE COVER INT MANIFOLD FRONT OF VEHICLE LH VALVE COVER J9425 9 can also be found in the General Diagn...

Page 1704: ...ufactured If replacement becomes neces sary it is important to use only fuel resistant hose EVAP CANISTER A sealed maintenance free EVAP canister is used on all gas powered vehicles only The canister...

Page 1705: ...information Refer to the Component Removal Installation sec tion of this group for replacement procedures PRESSURE RELIEF ROLLOVER VALVE These vehicles are equipped with a combination pressure relief...

Page 1706: ...manifold vacuum the plunger is only pulled part way back from inlet This results in maximum vapor flow through the valve Fig 10 TESTING 1 With engine idling remove the PCV valve from the cylinder hea...

Page 1707: ...to reduce 4 Turn engine off and remove PCV valve from cylinder head valve cover The valve should rattle when shaken Fig 13 EMISSION CONTROL SYSTEMS 25 S CRANKCASE BREATHER REMOVED J9325 17 Fig 12 Chec...

Page 1708: ...be necessary for vehicles operated extensively on short run stop and go or extended en gine idle service The filter must be replaced at correct intervals Re fer to Lubrication and Maintenance Group 0...

Page 1709: ...ber hose connects the back pressure fitting on the EGR valve to the back pressure fitting on the valve control Fig 18 When the ground signal is removed from the elec tric portion of the valve control...

Page 1710: ...ngines are equipped with two fittings lo cated on the EGR valve Fig 21 The upper fitting located on the vacuum motor supplies engine vac uum to a diaphragm within the EGR valve for valve operation The...

Page 1711: ...idle is rough or slow the poppet valve Fig 18 at the base of the EGR valve may be leaking in the closed position The diaphragm Fig 18 within the EGR valve may also be ruptured 1 The engine should be o...

Page 1712: ...ect the electrical connector Fig 16 at the valve control This will simulate an open circuit no ground from the PCM at the valve control 16 Start the engine and bring to operating tem perature Hold the...

Page 1713: ...ons and carbon monoxide in the exhaust stream The system does not interfere with the ability of the EGR system to control nitrous oxide NOx emis sions pL HDC ENGINE Air is drawn into the pump through...

Page 1714: ...allowed to flow through these valves in one direction only to wards the catalytic convertors Downstream air flow assists the oxidation process in the catalyst but does not interfere with EGR op eratio...

Page 1715: ...TION POSSIBLE CAUSES CORRECTION EXCESSIVE 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...

Page 1716: ...ump from mounting bracket INSTALLATION 1 Position air injection pump to mounting bracket 2 Install two pump mounting bolts to mounting bracket Tighten bolts to 40 N m 30 ft lbs torque 3 Install pump p...

Page 1717: ...l hose and hose clamp to valve ENGINE COOLANT TEMPERATURE SENSOR For description operation diagnosis and removal installation procedures refer to Group 14 Fuel Sys tems EGR VALVE 3 IL UL 1 9L ENGINES...

Page 1718: ...tallation for procedures EGR TUBE 3 9L 5 2L 5 9L ENGINES REMOVAL 1 Remove air cleaner housing 2 Remove the spark plug cable loom and plug ca bles from valve cover mounting stud at rear of right valve...

Page 1719: ...EGR tube mounting bolts at right exhaust manifold Fig 7 and remove EGR tube Fig 7 EGR Tube 8 0L V 10 Engine INSTALLATION 1 Clean the EGR tube and exhaust manifold at EGR tube mounting point of any old...

Page 1720: ...SOLENOID 8J L V ll ENGINE REMOVAL 1 Remove air cleaner housing assembly 2 Disconnect wiring connector at solenoid 3 Disconnect vacuum harness at solenoid 4 Remove two solenoid mounting bracket bolts a...

Page 1721: ...to Group 14 Fuel Systems POWERTRAIN CONTROL MOOULE PCM For PCM operation and removal installation proce dures refer to Group 14 Fuel Systems For diagno sis refer to the appropriate Powertrain Diagnost...

Page 1722: ...OCEDURE 14 126 AIR CLEANER ENGINE 0 23 0 28 AIR CLEANER HOUSING AIR CLEANER ELEMENT EMISSION CONTROL SYSTEMS 25 18 AIR CLEANER HOUSING AIR CLEANER ELEMENT FUEL SYSTEM 14 125 AIR CLEANER HOUSING AIR CL...

Page 1723: ...EMBLY REPLACEMENT DRIVE 2 22 AXLE FRONT DRIVE 2 2 AXLE MODEL 44 2 45 AXLE MODEL 44 FRONT 2 44 AXLE MODEL 60 FRONT SUSPENSION AND AXLE 2 45 AXLE MODEL 60 REAR SUSPENSION AND AXLE 3 51 AXLE MODEL 60 70...

Page 1724: ...20 BRAKE PEDAL LOW 5 4 BRAKE PEDAL PULSATION 5 5 BRAKE PEDAL REMOVAL 5 19 BRAKE PULL 5 5 BRAKE ROTOR INSPECTION AND SERVICE DISC 5 57 BRAKE ROTOR INSTALLATION WITH TAPERED BEARINGS DISC 5 59 BRAKE RO...

Page 1725: ...CARPET OR MAT CLUB CAB FLOOR 23 41 CASE 4WD VEHICLES TRANSFER 0 32 CASE APPLICATION TRANSFER 21 278 CASE ASSEMBLY OVERDRIVE GEARTRAIN 21 273 CASE ASSEMBLY TRANSFER 21 295 CASE CHANGES TRANSFER 21 279...

Page 1726: ...VERRUNNING 21 214 CLUTCH OVERHAUL REAR 21 173 21 224 CLUTCH PEDAL INSTALLATION 6 17 CLUTCH PEDAL POSITION SWITCH 6 3 CLUTCH PEDAL REMOVAL 6 17 CLUTCH PROBLEM CAUSES 6 4 CLUTCH RELAY AIR CONDITIONING A...

Page 1727: ...ON METRIC lntro 31 CONVERSION METRIC AND ENGLISH SAE lntro 26 CONVERTER AND DRIVE PLATE SERVICE 21 154 CONVERTER CATALYTIC 11 1 CONVERTER CLUTCH CONTROL 21 104 CONVERTER DIAGNOSIS TORQUE 21 128 21 129...

Page 1728: ...SIS AUDIO SYSTEMS 8F 2 DIAGNOSIS BATTERY STARTING CHARGING SYSTEMS D I A G N O S T I C S 8A 10 8A 11 8A 18 8A 3 DIAGNOSIS CHIME BUZZER WARNING SYSTEMS 8U 2 DIAGNOSIS COOLING SYSTEM 7 4 DIAGNOSIS HORNS...

Page 1729: ...AXLE 2 35 DIFFERENTIAL ASSEMBLY REAR SUSPENSION AND AXLE 3 33 DIFFERENTIAL DISASSEMBLY FRONT SUSPENSION AND AXLE 2 33 DIFFERENTIAL DISASSEMBLY REAR SUSPENSION AND AXLE 3 30 DIFFERENTIAL INSTALLATION...

Page 1730: ...ERSIZE 9 110 9 50 9 79 ENGINE COOLANT TEMPERATURE GAUGE 8W 40 1 ENGINE COOLANT TEMPERATURE SENSOR EMISSION CONTROL SYSTEMS 25 19 ENGINE COOLANT TEMPERATURE SENSOR FUEL SYSTEM 14 76 ENGINE COOLANT TEMP...

Page 1731: ...SYSTEMS 25 6 EVAP CANISTER PURGE SOLENOID FUEL SYSTEM 14 76 EVAP CANISTER PURGE SOLENOID 3 9L75 2L 5 9L ENGINE 25 22 EVAP CANISTER PURGE SOLENOID 8 0L V 10 ENGINE 25 22 EVAP CANISTER PURGE SOLENOID PC...

Page 1732: ...3 FUEL INJECTION MFIV COMPONENT DESCRIPTION SYSTEM OPERATION EXCEPT DIESEL MULTI PORT 14 28 FUEL INJECTION MFI COMPONENT REMOVAL INSTALLATION EXCEPT DIESEL MULTI PORT 14 73 FUEL INJECTION MFI GENERAL...

Page 1733: ...GENERAL INFORMATION PROPELLER SHAFTS 16 1 GENERAL INFORMATION REAR SUSPENSION AND AXLE 3 24 3 1 3 6 GENERAL INFORMATION RESTRAINT SYSTEMS 8M 1 GENERAL INFORMATION SPLICE INFORMATION 8W 70 1 GENERAL IN...

Page 1734: ...RH 21 138 HYDRAULIC FLOW IN D FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 42RH 46RH 47RH 21 137 HYDRAULIC FLOW IN D SECOND GEAR 42RH 46RH 47RH 21 135 HYDRAULIC FLOW IN D THIRD GEAR 42RH 46RH 47RH 21 136...

Page 1735: ...TION CLUTCH COVER AND DISC 6 12 INSTALLATION CLUTCH PEDAL 6 17 INSTALLATION DIFFERENTIAL 2 41 INSTALLATION DISC BRAKE CALIPER 5 56 INSTALLATION DISC BRAKESHOE 5 51 INSTALLATION FRONT SPEED SENSOR 5 43...

Page 1736: ...IDENTIFICATION ID 8L 12 LAMP CARGO 8L 10 LAMP CHMSL BULB CENTER HIGH MOUNTED STOP 8L 10 LAMP CHMSL CENTER HIGH MOUNTED STOP 8L 10 LAMP DIAGNOSIS 8L 1 LAMP DIAGNOSIS FOG 8L 3 LAMP DOME INTERIOR LIGHTIN...

Page 1737: ...ARM 2 11 2 14 LOW REVERSE DRUM AND REAR BAND SERVICE 21 214 LUBRICANT 3 24 LUBRICANT AND CAPACITY RECOMMENDED 21 278 LUBRICANT AND FILL LEVEL RECOMMENDED 21 311 LUBRICANT CHANGE 2 21 LUBRICANT LEVEL A...

Page 1738: ...REMOVE INSTALL AIRBAG CONTROL 8M 7 MODULE REMOVE INSTALL BUZZER 8U 4 MODULE REMOVE INSTALL COMPASS THERMOMETER 8C 6 MODULE REMOVE INSTALL FUSEBLOCK 8E 19 MODULE SCHEMATIC BUZZER 8U 3 MODULE SNOW PLOW...

Page 1739: ...3 20 OUTLET POWER 8W 41 1 OUTLET REMOVE INSTALL CIGAR LIGHTER POWER 8E 20 OUTPUT AIR CONDITIONING RELAY PCM PIN 34 PCM 14 42 14 95 OUTPUT AUTOMATIC SHUTDOWN ASD RELAY PCM PIN 51 PCM 14 46 14 97 OUTPUT...

Page 1740: ...EDAL BRAKELIGHT SWITCH POWER BRAKE BOOSTER BRAKE 5 16 PERFORMANCE TEMPERATURE AND PRESSURE A C 24 10 PERFORMANCE TEST A C 24 9 PERFORMANCE TEST AIR CONDITIONING AND HEATER 24 9 PERFORMANCE GASOLINE EN...

Page 1741: ...TION SENSOR PCM PIN 22 PCM INPUT THROTTLE 14 39 14 93 POSITION SENSOR PCM PIN 24 PCM INPUT CRANKSHAFT 14 41 POSITION SENSOR PCM PIN 44 PCM INPUT CAMSHAFT 14 45 POSITION SWITCH CLUTCH PEDAL 6 3 POSITIO...

Page 1742: ...PUMP RELAY FUEL FUEL SYSTEM 14 77 PUMP RELAY FUEL FUEL IGNITION 8W 30 2 8W 30 7 PUMP RELAY TEST FUEL 14 59 PUMP RELAY PCM PIN 51 PCM OUTPUT FUEL 14 46 PUMP REPLACEMENT VACUUM 5 24 PUMP REPLACEMENT DI...

Page 1743: ...ING 14 113 14 64 RELAYS PCM PINS 15 AND 16 PCM OUTPUT INTAKE MANIFOLD AIR HEATER 14 91 RELEASE BEARING REPLACEMENT 6 15 RELEASE PROCEDURE FUEL SYSTEM PRESSURE 14 80 14 5 RELEASE REMOVE INSTALL INSIDE...

Page 1744: ...OLDING 23 9 ROOF RAIL WEATHERSTRIP AND RETAINER 23 9 ROTATION 22 3 ROTOR IGNITION CABLES DISTRIBUTOR CAP 0 24 ROTOR INSPECTION AND SERVICE DISC BRAKE 5 57 ROTOR INSTALLATION WITH TAPERED BEARINGS DISC...

Page 1745: ...11 SENSOR THROTTLE POSITION FUEL SYSTEM 14 145 SENSOR THROTTLE POSITION FUEL IGNITION 8W 30 4 8W 30 8 SENSOR TPS THROTTLE POSITION 14 84 SENSOR TRANSMISSION TEMPERATURE 14 147 14 85 SENSOR VEHICLE SP...

Page 1746: ...TEM AND INTAKE MANIFOLD 11 22 SPECIFICATIONS FUEL SYSTEM 14 148 SPECIFICATIONS IGNITION SYSTEMS 8D 36 SPECIFICATIONS INSTRUMENT PANEL AND GAUGES 8E 29 SPECIFICATIONS 4X2 AND 4X4 ALIGNMENT SPECIFICATIO...

Page 1747: ...8W 32 4 STOP LAMPS AND CHMSL LAMPS 8W 51 1 STOP TURN SIGNAL AND BACK UP LAMP BULB CHASSIS CAB TAIL 8L 11 STOP TURN SIGNAL AND BACK UP LAMP BULB PICKUP TAIL 8L 11 STOP TURN SIGNAL AND BACK UP LAMPS CHA...

Page 1748: ...SYSTEM TURN SIGNAL 8J 1 SYSTEM USING ON BOARD DIAGNOSTIC BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS 8A 22 SYSTEM USING ON BOARD DIAGNOSTIC VEHICLE SPEED CONTROL SYSTEM 8H 3 SYSTEM WINDSHIELD WASHE...

Page 1749: ...HERMOSTAT 7 30 THIRD GEAR 42RH 46RH 47RH HYDRAULIC FLOW IN D 21 136 THIS GROUP HOW TO USE 8W 1 THREAD NOTATION SAE AND METRIC lntro 28 THREAD REPAIR ALUMINUM 21 152 THREADS REPAIR DAMAGED OR WORN 9 4...

Page 1750: ...REMOVAL AND INSTALLATION 42RH 46RH 47RH 21 153 TRANSMISSIONS MANUAL 0 31 TRANSMISSION TRANSFER CASE IDENTIFICATION ENGINE lntro 2 TRANSMISSION TRANSFER CASE SPECIFICATIONS 21 328 TRAY REAR FLOOR STOW...

Page 1751: ...HEAD NOT REMOVED 9 118 9 24 9 56 9 85 VALVE CONTROL EGR SOLENOID EGR 25 20 VALVE CONTROL SOLENOID PIN 35 PCM OUTPUT EGR 14 43 VALVE CONVERTER DRAINBACK 21 104 VALVE FLOW CONTROL SHIFT 21 104 VALVE FR...

Page 1752: ...D CHASSIS CAB 8 0L OR DIESEL GROSS VEHICLE lntro 17 WEIGHT RATING 2WD CLUB CAB GROSS V E H I C L E lntro 11 WEIGHT RATING 2WD STD CAB GROSS VEHICLE lntro 9 WEIGHT RATING 4WD CHASSIS CAB 5 9L GROSS VEH...

Page 1753: ...t m a y b e h e l p f u l to s e n d a c o p y o f t h e s e r v i c e m a n u a l p a g e m a r k e d w i t h y o u r c o m m e n t s What features do y o u find most useful What errors have y o u fo...

Page 1754: ...Fold Here Place Stamp Here Chrysler Corporation Service Publications CiyS 424 81 55 25999 Lawrence Ave Center Line Ml 48015 Fold Here...

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Dodge RAM 1995, Service Manual

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