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Chrysler DODGE AD100 1993, Service Manual

The Chrysler Dodge AD100 1993 Service Manual is an essential resource for all vehicle owners. This comprehensive manual covers everything from maintenance and repairs to troubleshooting and diagnostic procedures. Download this invaluable manual for free from manualshive.com to ensure your vehicle is always in top shape.

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Summary of Contents for DODGE AD100 1993

Page 1: ...1 9 9 3 SERVICE MANUAL D W150 350 RAMCHARGER REAR WHEEL DRIVE TRUCK ...

Page 2: ...L SYSTEM OR 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 right to make changes in design or to make additions to or improvements in its products without imposing any obliga tions upon itself to install them on its products previously manufactured Lith...

Page 3: ...Tab Locator on the following page The solid bar after the group title is aligned to a solid tab on the first page of each group The first page of the group has a contents section that lists major topics within the group Tightening torques are provided as a specific value throughout this manual This value represents the midpoint of the acceptable engineering torque range for a given fastener applic...

Page 4: ...ystem and Intake Manifold 1 3 F r a m e and Bumpers 14 F u e l System 1 6 Propeller Shafts 19 Steering 2 1 Transmission and Transfer Case 2 2 Wheels and Tires 2 3 B o d y Components 24 Heating and Air Conditioning 2 5 Emission Control Systems Component and System Index Service Manual Comment Forms Rear of Manual Navigation Tools Click on the Group below or use the Bookmarks to the left ...

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Page 6: ...The label also lists the Month and year of vehicle manufacture Gross Vehicle Weight Rating GVWR The gross front and rear axle weight ratings GAWR s are based on a minimum rim size and maximum cold tire inflation pressure Vehicle Identification Number VIN Type of vehicle Type of rear wheels single or dual Bar code Month Day and Hour MDH of final assembly VEHICLE IDENTIFICATION NUMBER VIN PLATE The ...

Page 7: ... nine positions of row 7 will contain a 2 digit code and a 6 digit serial number The last code on a vehicle code plate will be fol lowed by the imprinted word END When two plates are required the last available spaces on the first plate will be imprinted with the letters CTD for con tinued When a second vehicle code plate is necessary the first four spaces on each row will not be used because of t...

Page 8: ...e Digit 19 Open Space Digit 20 22 Engine Sales Code Digit 23 Open Space Line 3 Digit 1 12 Vehicle Order Number Digit 13 Open Space Digit 14 16 Vinyl Roof Code Door Combo Digit Code Pillette Digit 17 Open Space Digit 18 23 Model J901N 20 MAJOR COMPONENT IDENTIFICATION Refer to the applicable group for identification data EQUIPMENT IDENTIFICATION PLATE The Equipment Identification Plate is located a...

Page 9: ...3 AD 8 2692 mm 106 in Sport Utility 4 x 4 1778 mm 1588 mm 62 5 in 1062 mm 41 8 in 2 99 m3 105 8 ft3 AD 1 3378 mm 133 in Sweptline 1981 mm 6 5 ft 1984 mm 78 1 in 1778 mm 70 in 485 mm 19 1 in 1 71 m3 60 4 ft3 AD 1 AD 2 AD 5 AD 6 3785 mm 149 in Sweptline Club Cab 2438 mm 8 ft 2489 mm 98 in 1778 mm 70 in 485 mm 19 1 in 2 15 M 3 75 8 ft3 Driver seat to tailgate 2 Based on S A E procedure Jl 100 J901N 3...

Page 10: ... k g 7400 lbs o s o D250 4 x 2 3327 mm 131 in 3785 mm 149 in 3860 k g 8510 lbs s s o D250 4 x 2 3327 mm 131 in 3785 mm 149 in 3860 k g 8510 lbs O s o D350 4 x 2 3327 mm 131 in 3946 k g 8700 lbs s s o D350 4 x 2 3327 mm 131 in 3946 k g 8700 lbs O s o D350 4 x 2 3327 mm 131 in 4581 kg 10 100 lbs S s o D350 4 x 2 3327 mm 131 in 4581 kg 10 100 lbs o s o W150 4 x 4 2921 mm 115 in 3327 mm 131 in 2858 k ...

Page 11: ... s o 3429 mm 135 in 4039 mm 159 in 4763 kg 10 500 lbs o s o W250 4 x 4 3327 mm 131 in 3860 kg 8510 lbs s s o W250 4 x 4 3327 mm 131 in 3860 kg 8510 lbs s s o o s o W350 4 x 4 3327 mm 131 in 3946 kg 8700 lbs s s o W350 4 x 4 3327 mm 131 in 3946 kg 8700 lbs s s o o s o 3429 mm 135 in 4581 kg 10 100 lbs s s o 4989 kg 11 000 lbs o s o R A M C H A R G E R S P O R T UTILITY D100 4 x 2 2692 mm 106 in 254...

Page 12: ...45 kg 2097 kg 4289 lbs 4622 lbs W150 AD5 4 x 4 61 2858 kg 6300 lbs 978 kg 2156 lbs 1880 kg 4144 lbs W150 AD5 4 x 4 62 2903 kg 6400 lbs 966 kg 2131 lbs 1936 kg 4269 lbs W150 AD5 4 x 4 32 2903 kg 6400 lbs 789 kg 1740 lbs 2114 kg 4660 lbs W250 AD6 4 x 4 62 3402 kg 3860 kg 7500 lbs 8510 lbs 1364 kg 1769 kg 3007 lbs 3899 lbs 2038 kg 2092 kg 4493 lbs 4611 lbs W250 AD6 4 x 4 32 3402 kg 3860 kg 7500 lbs 8...

Page 13: ...RGER SPORT UTILITY M O D E L FAMILY BODY 3 STYLE G V W R PAYLOAD A L L O W A N C E S CURB WEIGHT 2 D100 AD4 4 x 2 71 2540 kg 5600 lbs 603 kg 1330 lbs 1937 kg 4270 lbs D150 AD4 4 x 2 71 2540 kg 5600 lbs 606 kg 1336 lbs 1934 kg 4264 lbs W100 AD8 4 x 4 71 2722 kg 6000 lbs 618 kg 1363 lbs 2103 kg 4637 lbs W150 AD8 4 x 4 71 2722 kg 2903 kg 6000 lbs 6400 lbs 621 kg 796 kg 1369 lbs 1755 lbs 2102 kg 2107 ...

Page 14: ...D 11 500 12 500 5 9L Auto 4 spd H D 12 000 13 000 13 500 14 000 D 250 3 9L Auto 3 spd 8 800 9 200 5 2L Auto 4 spd O D 10 500 10 500 Auto 4 spd H D 11 500 12 500 5 9L Auto 4 spd H D 12 000 13 000 13 500 14 000 D 350 5 9L Auto 4 spd H D 12 000 13 000 13 500 14 000 W 1 5 0 3 9L Auto 4 spd H D 8 800 9 200 5 2L Auto 4 spd H D 11 500 12 500 5 9L Auto 4 spd H D 12 000 13 000 13 500 14 000 W 2 5 0 5 9L Au...

Page 15: ...NDOW DEFOGGER sp REARWINLX W WIPER CD l m REAR WINDOW WASHER FUEL ENGINE COOLANT TEMPERATURE BATTERY CHARGING CONDITION ENGINE OIL SEAT BELT k y 11 J LIGHTER BRAKE FAILURE PARKING BRAKE FRONT HOOD REAR HOOD TRUNK HORN 11 J LIGHTER 93IN 9 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS The graphic symbols illustrated in the chart below are used to identify various instrument controls The symbols ...

Page 16: ... The difference is described in the Thread Notation chart GRADE CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8 The higher the grade number the greater the bolt strength Identification is determined by the line marks on the top of each bolt head Fig 1 The actual bolt strength grade corresponds to the number of line marks plus 2 A grade 2 bolt has no line marks on to...

Page 17: ...he most commonly used metric bolt strength classes are 9 8 and 12 9 The metric strength class identification number is imprinted on the head of the bolt Fig 2 The higher the class number the SAE CLASSIFICATION GRADE 5 GRADE 8 MARKINGS FOUND ON TOP OF BOLT HEAD INDICATE GRADE 120 60 GRADE 2 GRADE 5 GRADE 8 SAE BOLTS IDENTIFICATION MARKS CORRESPOND TO BOLT STRENGTH INCREASING NUMBERS REPRESENT INCRE...

Page 18: ...8465 28 37 9629 48 65 0793 68 92 1956 88 119 3120 8 5 9005 28 20 6517 48 35 4030 68 50 1542 88 64 9545 9 12 2024 29 39 3187 49 66 4351 69 93 5514 89 120 6678 9 6 6381 29 21 3893 49 36 1405 69 50 8918 89 65 6430 10 13 5582 30 40 6745 50 67 7909 70 94 9073 90 122 0236 10 7 3756 30 22 1269 50 36 8781 70 51 6293 90 66 3806 11 14 9140 31 42 0304 51 69 1467 71 96 2631 91 123 3794 11 8 1132 31 22 8644 51...

Page 19: ......

Page 20: ...g to the maintenance schedule and to pay for the necessary parts and labor Vehicles with a Gross Vehicle Weight Rating GVWR of 3 855 kg 8 500 lbs or less must conform to light duty emission standards Vehicles with a Gross Vehicle Weight Rating GVWR of 3 856 kg 8 501 lbs or more must conform to heavy duty emission standards The GVWR for each vehicle is listed on the Safety Certification Label This ...

Page 21: ...SE EMISSION APPLICABLE TO MEDIUM AND HEAVY DUTY TRUCKS THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT OF 1972 A THE REMOVAL OR RENDERING INOPERATIVE OTHER THAN FOR PURPOSES OF MAINTENANCE REPAIR OR REPLACEMENT OF ANY NOISE CONTROL DEVICE OR ELEMENT OF DESIGN LISTED IN THE OWNERS MANUAL INCORPORATED INTOTHIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTR...

Page 22: ...PI Service Grade specifications also apply to energy con serving engine oils Fig 3 For maximum gasoline engine protection use API Service Grade SG SG CD or SG CE engine oil For maximum Diesel engine protection use API Service CE or SG CE engine oil GEAR LUBRICANTS A dual grade is also used to specify the viscosity of multi purpose gear lubricants The API grade designation identifies gear lubri can...

Page 23: ...pumps Generator bearings Brake booster cylinder Clutch release bearings Distributors Drive belts Drive belt idler pulleys Drive shaft center bearings Idler arms Rubber bushings Starter motor bearings Suspension strut bearings Rear spring shackle bolts Rear wheel bearings not equipped with a Dana or 70 axle Throttle control cables Throttle linkage ball joints Water pump bearings ...

Page 24: ... 112 A 120 Where both time and mileage Miles Thousand are shown follow the interval which occurs first Kilometers Thousand 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 Coolant Condition Coolant Hoses Clomps X X X X X X O O O O O O O O o O Exhaust System Check X X X X X X O O O o O O O o o o Oil Change 6 months X X X X X X O O O o o O O o o o Oil Filter Change 2nd Oil Change X X X o o O ...

Page 25: ...lace X2 1 For California vehicles this maintenance is recommended by Chrysler Motors to the owner but is not required to maintain the warranty on the air pump drive belt 2 Requires Emission Maintenance Reminder Light If so equipped these parts are to be replaced at the indicated mileage or when the emissions maintenance reminded light remains on continuously with the key in the on position whichev...

Page 26: ...ase NGLI grade 2 EP Multi Purpose Lubricant Propeller Shaft Slip Spline A D 1 A D 2 2 piece P shaft 1 36 0 0 0 km 22 500 miles or 2 years For severe service every 4 8 0 0 km 3 000 miles or 3 months Daily if vehicle is operated in water Multi purpose grease NGLI grade 2 EP Multi Purpose Lubricant Suspension Ball Joints A D 1 A D 2 4 36 0 0 0 km 22 500 miles or 2 years every engine oil change for of...

Page 27: ...km 1 000 miles Daily if vehicle is operated in water Multi purpose grease NGLI grade 2 EP Multi Purpose Lubricant P shaft Slip Spline AW3 135 WB 1 39 000 km 24 000 miles or 2 years For severe service every 4 800 km 3 000 miles or 3 months Daily if vehicle is operated in water Multi purpose grease NGLI grade 2 EP Multi Purpose Lubricant Suspension Ball Joints AD2 3 4 39 000 km 24 000 miles Multi pu...

Page 28: ...CONVERTER T O OVER HEAT AND RUPTURE BOOSTER BATTERY WARNING TO PREVENT P E R S O N A L INJURY OR DO NOT ALLOW BATTERY ACID TO CONTACT EYES SKIN O R CLOTHING D O NOT LEAN OVER A BATTERY WHEN CONNECTING JUMPER C A B L E S DO NOT ALLOW THE POSITIVE A N D NEGATIVE C A B L E C L A M P S TO CONTACT EACH OTHER KEEP OPEN FLAMES A N D S P A R K S AWAY FROM THE BATTERY ELECTROLYTE VENT HOLES A L W A Y S W E...

Page 29: ...od electrical continuity 6 Start the engine WARNING THE USE OF ANY JUMPER CABLE DIS CONNECTION PROCEDURE OTHER THAN THAT DESCRIBED BELOW COULD RESULT IN PERSONAL INJURY CAUSED BY BATTERY ACID SQUIRTING FROM THE BATTERY VENTS PERSONAL INJURY AND OR PROPERTY DAM AGE CAUSED BY BATTERY EXPLOSION DAMAGE TO THE BOOSTER VEHICLE OR THE DISABLED VEHICLE CHARGING SYSTEM 7 After the engine is started the jum...

Page 30: ...F BALANCE CHANGES 4WD VEHICLES A standard hoist can be used to lift a 4WD vehicle The hoist should be inspected for adequate clearance The lift arms pads or ramps should be adjusted to ensure that there is adequate clearance Fig 9 ADJUSTMENT PAD ii 7 M A I N T A I N CLEARANCE HOIST ARM RK44 Fig 9 Lifting 4WD Vehicle With Single Post Hoist Typical When a twin post hoist is used a 4 x 4 x 12 inch wo...

Page 31: ...irst be supported by safety stands Do not allow passengers in a vehicle being towed Observe all state and local laws involving warning signals night illumination speed etc Do not exceed a towing speed of 48 km h 30 mph Avoid towing distances of more than 24 km 15 miles whenever possible Do not attach tow chains or a tow sling to a bumper the steering linkage the universal joints or a drive shaft R...

Page 32: ...ng for a vehicle equipped with an AUTOMATIC TRANSMISSION is not rec ommended CAUTION lt is not recommended to flat tow a vehi cle LOCKED VEHICLE TOWING When a locked vehicle must be towed use a tow dolly or flat bed hauler POSITION CENTER BAR AND WOOD BEAM BEHIND BUMPER AND AHEAD OF STRUTS TO SUPPORT CHAINS CLEAR OF SWAY BAR RN966 Fig 12 Front End Raised Towing Typical ...

Page 33: ...ired The original engine oil installed is a high quality lubri cant New engines tend to consume more fuel and oil un til after the break in period has ended ENGINE OIL SPECIFICATIONS API SERWICE GRADE Use an engine oil that conforms to API Service Grade S5 SG CD or SG CE MOPAR provides engine oils that conform to all of these service grades SULFATED ASH DIESEL ENGINES Oils that contain an excessiv...

Page 34: ...r is recommended when the filter is changed OIL CHANGE AND FILTER REPLACEMENT Bring engine up to normal operating temperature A more complete drainage of oil will result 1 Remove the drain hole plug and drain the en gine oil from the crankcase 2 Install the drain hole plug with a replacement gasket For gasoline engines the oil filter should be replaced during every second engine oil change For Die...

Page 35: ...r pressure Inspect and test radiator cap when cooling system service is performed MAIN FLUSH AND FILL WARNING ANTI FREEZE ETHYLENE GLYCOL IS POISONOUS KEEP OUT OF THE REACH OF CHIL DREN Drain flush and fill the cooling system at the in terval specified in maintenance schedule For proper service instructions see Group 7 Cooling System HOSES AND FITTINGS It is recommended that rubber hoses be period...

Page 36: ...G USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT PUT YOUR HANDS NEAR THE DRIVE BELT S PULLEYS OR FAN BLADE DO NOT STAND IN A DIRECT LINE WITH THE FAN BLADE 1 With the engine idling accelerate momen tarily The valve shaft counterweight should move CLOCKWISE 2 If no movement is observed either the shaft is binding or the thermostat spring is weak or broken 3 If the thermostat spring is weak...

Page 37: ...r housing nipple in the cylin der head cover grommet Connect the fresh air hose to the upper port Fig 8 J9000 52 Fig 8 Crankcase Air Inlet Filter THROTTLE CONTROL LINKAGE Transmission linkage pivot pin areas Fig 9 should be serviced The areas lubricated every second oil change with a multi purpose lubricant NLGI GC LB PIVOT AREAS Fig 9 Transmission Linkage Pivot Areas FUEL SYSTEM INSPECTION The fu...

Page 38: ...llowing emission controls should be replaced at the interval specified in the maintenance sched ule Bi level purge check valves Delay valves Heated air temperature sensor HATS Air cleaner vacuum motors EXHAUST GAS RECIRCULATION EGR SYSTEM MAINTENANCE SCHEDULE Replace the EGR valve and tube and clean the passages at the interval specified in maintenance schedule If necessary refer to Group 25 Emiss...

Page 39: ... not over tighten the nuts 5 Connect the battery positive cable and then the negative cable to the battery 6 Apply a small amount of chassis lubricant or an equivalent protective coating to the cable termi nals RUBBER PLASTIC COMPONENTS INSPECTION Components should be inspected at the same time as scheduled underhood maintenance is conducted Rubber plastic components should be replaced imme diatel...

Page 40: ...spect for the following conditions and correct as necessary Exhaust system leaks misalignment Contact with body panels or the frame Catalytic converter bulging or excessive heat dam age CAUTION A catalytic converter will become con taminated if leaded gasoline is burned in the en gine If this occurs the complete converter must be replaced AIR CONDITIONER COMPRESSOR LUBRICANT AND REFRIGERANT The lu...

Page 41: ...ith clean moisture free brake fluid FLUID SPECIFICATION The only fluid recommended for use is MOPAR Brake Fluid or an equivalent product The SLAVE CYLINDER CLUTCH HOUSING 23 N m 200 IN LBS product is identified as SAE J 1703 or DOT 3 flu id Do not use any other type of fluid CAUTION Never use reclaimed brake fluid or fluid from an unsealed container Do not use fluid that has been opened and allowe...

Page 42: ... Capacities chart AUTOMATIC TRANSMISSIONS FLUID LEWEL It is recommended that the fluid ATF level in au tomatic transmissions be checked while involved with other underhood maintenance Vehicle operation with an incorrect ATF level will greatly reduce the life of the transmission Fig 3 Getrag 360 Manual Transmission MANUAL TRANSMISSION DRAIN REFILL INTERVALS Normal Service Light Duty Cycle 60 000 km...

Page 43: ...VEL The vehicle must be level when the fluid level is checked The transfer case drain fill hole plugs are located at the rear of the housing Figs 4 and 5 Determine the transfer case fluid level according to the following procedure 1 Raise and support the vehicle 2 Remove the fill hole plug Figs 4 and 5 from the transfer case The fluid level should be at the bottom edge of the fill hole The level c...

Page 44: ... The transfer case shift mechanism should be cleaned and lubricated as necessary Lubricate the pivot the sliding contact areas and the shift linkage pivot ends with light weight engine oil Figs 6 and 7 AXLES INSPECTION LUBRICANT LEVEL For normal vehicle operation periodic axle lubri cant level checks are not necessary The exterior of the axle housing should be inspected for leakage Check the lubri...

Page 45: ...A friction additive must also be used in 8 25 and 9 25 limited slip differentials The use of a friction modifier is helpful in preventing axle chatter Dana axles do not require any friction additive FRONT AXLE U JOINT AND PIVOT BEARINGS MODEL W350 WITH DANA 60 AXLE For vehicles subject to the LIGHT DUTY CYCLE Maintenance Schedule lubricate the pivot bearings at each 12 000 km 7 500 miles interval ...

Page 46: ...icate the U joint and CV joints every 12 000 km 7 500 miles for LIGHT DUTY CYCLE vehicles For HEAVY DUTY CYCLE vehicles the couplers should be lubricated every 9 600 km 6 000 miles Refer to Figures 11 and 12 If the vehicle is operated in water the U joint CV joint couplers should be lu bricated daily If a vehicle is used in a severe driving condi tion lubricate the U joint CV joints every 4 800 km...

Page 47: ...ds Lubricate the ball studs with MOPAR Multi Mile age Lubricant Wipe the excess lubricant from the exterior sur faces of the ball joints page Power Brake System 30 Power Steering System 29 Rear Wheel Bearings 30 Speedometer Cable 33 Steering Linkage 28 Tires 32 FRONT SUSPENSION BALL JOINTS INSPECTION When a vehicle is raised for lubrication general maintenance the ball joints should be inspected L...

Page 48: ...UTY CYCLE Mainte nance Schedule At each 19 000 km 12 000 miles interval for ve hicles subject to the HEAVY DUTY CYCLE Mainte nance Schedule For vehicles used for extensive off road 4WD operation the front wheel bearings should be in spected every 1 600 km 1 000 miles The bearings should be cleaned and re packed with a high temperature multi purpose EP lu bricant whenever the disc brake rotors are ...

Page 49: ...ings should be inspected each time the underside of the vehicle is serviced INSPECTION The lower suspension arm bushings can be visually inspected by raising the vehicle on a hoist and in specting from underneath The upper suspension arm bushings can be inspected after removing the front wheels If failure exists replace the bushing refer to Group 2 Front Suspension for the proper proce dures The s...

Page 50: ...dition 7 Inspect the rear wheel cylinder dust boots for fluid leaks Inspect the pistons and cylinder bores for proper appearance 8 Inspect the brake differential warning valve and housing for indications of leakage kinked hoses and loose fittings BRAKE FLUID HOSES TUBING The rubber brake fluid hoses should be inspected for Correct length Severe surface cracking Swelling Pulling Scuffing Excessivel...

Page 51: ... be lubricated periodi cally 5 The door lock cylinders should be lubricated 2 times each year preferably autumn and spring Spray a small amount of lock cylinder lubricant di rectly into the lock cylinder Apply a small amount to the key and insert it into the lock cylinder Rotate it to the locked position and then back to the unlocked position several times Remove the key Wipe the lubricant from it...

Page 52: ... Oil Tailgate Latches As Required White Spray Lubricant 3 Tailgate Release Handle Pivot Slide Contact Surfaces As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Window System Components Regulators Tracks Rods Channel Areas Except Glass Run Weatherstrips and Felt Lubricator if Equipped As Required White Spray Lubricant 3 Lock Cylinders Twice Year Lock Cylinder Lubricant 4 Parking Brake Mechanism A...

Page 53: ... ...

Page 54: ...now Plow Package with the Diesel engine Refer to the Own ers Manual for additional information FRONT DRIVE AXLE The front axle on 4WD Ram Truck and Ram charger vehicles has a hypoid gear differential Model 44 and 60 axles consists of an iron center cast ing with axle shaft tubes extending from either side Ram Truck and Ramcharger vehicles equipped for standard duty 4WD operation use the Model 44 f...

Page 55: ...2 2 FRONT SUSPENSION AND AXLE ...

Page 56: ...angle that the steering knuckles are tilted Fig 1 The inclination angle has a fixed relationship with the camber angle This will not change except when a spindle or ball stud is damaged or bent The angle is not adjustable and the damaged component s must be replaced to correct mis alignment CAUTION Do not attempt to modify any suspension or steering component by heating and bending PRE ALIGNMENT I...

Page 57: ... POWER STEERING FLUID LEVEL BROKEN OR WEAK REAR SPRING WORN UPPER SUSPENSION ARM BUSHINGS WORN TIE ROD END BALL STUDS WORN TIE ROD END BALL STUDS SHOCK ABSORBER NOT FUNCTIONING CORRECTLY LACK OF ASSIST FROM POWER STEERING PUMP LOOSE OR WORN SUSPENSION BUSHINGS WORN LOWER SUSPENSION ARM PIVOT BUSHINGS INCORRECT STEERING GEAR ADJUSTMENT LOOSE OR WORN SUSPENSION ARM BUSHINGS INCORRECT STEERING GEAR A...

Page 58: ...quipment The acceptable range is 1 to 1 Refer to the Specifications chart Road test the vehicle and observe the steering wheel return to center position Before road testing check and correct the tire inflation pressures Inflate both of the front tires with exactly the same pressure During the road test make vehicle turns to both the left and right If the steering wheel returns to ward the center p...

Page 59: ...AMP RN1036 Fig 3 Toe Position Adjustment Typical ALIGNMENT SPECIFICATIONS ALIGNMENT 4 W D ASGSPTABLE RANGE PREFERRED Camber r t o r 0 Caster 1 2 to 37 2 King Pin Inclination 8 5 8 5 Toe In at Hub Height 0 05 to 0 45 0 20 ALIGNMENT 2 W D ACCEPTABLE RANGE PREFERRED Camber 0 to 1 1 2 Caster 1 to 2 1 2 Toe in at Hub Height 0 to 0 50 0 25 Turning Angle Base Tire Left and Right 33 3 3 J9102 64 lf vehicl...

Page 60: ... to prevent the inner wheel bear ing and bearing seal from contacting the steering knuckle spindle threads during removal Fig 1 Otherwise the threads bearing and seal could all be damaged 7 Carefully slide the wheel hub rotor from steer ing knuckle spindle Fig 1 8 For bearing cleaning or replacement remove the seal and inner wheel bearing from the wheel hub rotor bore Fig 1 CLEANING AND INSPECTION...

Page 61: ...ad torque Next tighten the nut finger tight install the nut lock Install a re placement cotter pin 8 The wheel bearing adjustment above should have 0 001 to 0 003 inch 0 254 to 0 0762 mm end play 9 Clean the dust cap Apply a coating of multi purpose NLGI grade 2 EP type lubricant to internal surface Install the cap Do not fill the dust cap with lubricant 10 Install the brake caliper refer to Group...

Page 62: ...he bolts nuts to 23 Nnn 200 in lbs torque 2 Install the outer retainers and rubber bushings on the link rods Fig 3 3 Install the link rod nuts Fig 3 Tighten the nuts to 11 Nnn 100 in lbs SHOCK ABSORBER REMOVAL 1 Raise vehicle on hoist Position support stands on frame and lower front hoist 2 Remove upper nut and retainer 3 Remove two lower mounting bolts lower shock from suspension arm Fig 4 4 Remo...

Page 63: ...hicle INSTALLATION 1 Position lower suspension arm on vehicle 2 Install mounting bolt tighten finger tight 3 Follow procedure under Coil Spring Installa tion 4 Lower the vehicle to the surface with the wheels tires supporting the vehicle weight Tighten the lower suspension arm mounting bolt to 305 Nnn 225 ft lbs torque LOWER BALL STUD INSPECTION 1 Raise the front of the vehicle Install safety floo...

Page 64: ...with a hammer to loosen the upper ball stud Do not at tempt to force the ball stud out of the steering knuckle bore with the loosening tool 6 Remove the loosening tool Remove the nuts eccentric cam bolts and suspension arm from the vehicle Fig 9 INSTALLATION 1 Position the suspension arm and install the ec centric cam bolts Fig 9 and nuts finger tight 2 Install upper ball stud into steering knuckl...

Page 65: ...stall the wheel tire Remove the support and lower the vehicle to the surface BUSHING SP 3953 RH393 UPPER SUSPENSION ARM BUSHING REPLACEMENT REMOVAL 1 Follow procedure under Upper Suspension Arm Removal 2 Place the upper suspension arm in a vise As semble Remover Installer C 3962 and Adaptor SP 3953 Fig 10 over the bushing Tighten the nuts and force the bushing out of the arm bore INSTALLATION Be s...

Page 66: ...nd tighten to 291 Nnn 215 ft lbs torque 6 Remove the shock absorber from the vehicle refer to the removal procedures 7 Install Spring Compressor Tool DD 1278 in the spring Fig 5 Tighten the nut finger tight and then loosen the nut 1 2 of a turn 8 Remove the cotter pins and the lower and up per ball stud nuts at the steering knuckle 9 Install Ball Stud Loosening Tool C 3564 A on the lower ball stud...

Page 67: ...ta bilizer bar Fig 1 STABILIZER BAR FRONT STABILIZER BAR BUSHING RETAINER LINK ROD J9017 37 Fig 1 Stabilizer Bar 2 Remove the outer retainers and rubber bush ings from the link rods Fig 1 3 Remove the bolts or nuts from the U shaped stabilizer bar support brackets Remove the stabilizer bar from the vehicle Fig 1 INSTALLATION 1 Position the stabilizer bar ends over the link rods Install the U shape...

Page 68: ...ing from the vehicle Fig 3 INSTALLATION 1 Align the spring front eye with the bolt hole in the frame bracket and install the pivot bolt and nut Fig 3 2 Position the shackle plates at the spring rear eye and frame rail bracket Install the nuts Fig 3 3 Tighten the shackle plate nuts and front pivot bolt nut until all slack is taken up 4 Position the spring on the axle tube with the spring center bol...

Page 69: ...d 9 Install the alignment clips 10 Install the spring in the vehicle If necessary refer to the installation procedure LEAF SPRING EYE BUSHING REPLACEMENT 1 Assemble tools shown Fig 5 Tighten the nut located at the socket wrench end of the threaded rod until the bushing is forced out 2 Assemble and align the bushing installation tools 3 Align the bushing with the spring eye and tighten the nut loca...

Page 70: ...re supported by the spin dles attached to the steering knuckles The removable stamped steel cover provides a means for inspection and service without removing the complete axle from the vehicle page Pinion Gear Depth Measurement and Adjustment with Tool Set C 3715 B 40 Pinion Gear Depth Measurement and Adjustment with Tool Set D 115 44 38 Pinion Shaft Seal 19 Specifications 48 Steering Knuckle Arm...

Page 71: ...J9202 105 Fig 1 Model 44 Front Axle ...

Page 72: ... cover within 5 minutes af ter applying the sealant If not installed the seal ant must be removed and another bead applied 7 Install the cover on the differential with the bolts Install the identification tag Tighten the cover bolts to 47 Nnn 35 ft lbs torque CAUTION Overfilling the differential can result in the lubricant foaming and overheating 8 Refill the differential housing with the speci fi...

Page 73: ...e and support the front of vehicle 2 Remove the wheel tire 3 Remove the brake caliper and adapter refer to Group 5 Brakes Support the caliper to the frame structure with wire 4 Remove the dust cap and drive hub snap ring Fig 7 Fig 7 Drive Hub Snap Ring 5 Remove the drive hub and spacer Fig 8 6 Remove the wheel bearing outer lock nut with Wrench C 4170 A Fig 9 7 Remove the lock washer and inner loc...

Page 74: ...ER LOCK NUT Fig 10 Lock Washer Removal Installation Fig 11 Spindle Removal 4 Right side only carefully install the axle shaft through the knuckle into the axle housing Ensure the axle shaft splines are engaged with the differen tial side gears Avoid damaging the differential seals 5 Left side only remove the shift motor housing from axle Position the shift collar on the intermedi ate axle shaft In...

Page 75: ...k nut 135 150 degrees to set the free play 12 Install the tabbed lock washer in the nearest hole in the washer Fig 8 Install and tighten the outer nut lock with Wrench C 4170 Fig 19 to 68 N m 50 ft lbs torque The end play after the final Fig 14 Spindle Needle Bearing Installation Fig 15 Seal Installation bearing adjustment should be within 0 001 inch to 0 010 inch 0 03 to 0 25 mm 13 Install the sp...

Page 76: ...drive the vertical yoke down ward to remove the upper needle bearing and cap out Fig 20 4 Reverse the position of the yoke and remove op posite needle bearing and cap Fig 20 5 Remove the yoke from the spider 6 Position the open ends of the spider in a soft jawed vise Repeat steps 3 and 4 above to remove remaining bearings and caps 7 Remove the spider from the yoke 8 Clean and inspect all the compo...

Page 77: ...on 5 Use a short plug or a socket wrench to force the bearing cap into the correct position and install the snap ring 6 Repeat the instructions in steps 1 through 5 for installing remaining bearings caps and yoke STEERING KNUCKLE UPPER AID LOWER BALL STUDS REMOVAL DISASSEMBLY 1 Remove axle shaft refer to Hub Spindle and Axle Shaft Removal 2 Disconnect the tie rod end from the steering knuckle arm ...

Page 78: ...ls and remove the upper ball stud Fig 28 9 Clean all components with solvent and dry with compressed air Inspect all the components for Fig 28 Upper Ball Stud Removal burrs chips excessive wear and cracks Replace com ponents as necessary ASSEMBL Y INSTALLA TION 1 Install lower ball stud with Remover Installer C 4212 L and Adaptor Set C 4288 Fig 29 Install the snap ring retaining the lower ball stu...

Page 79: ...Wrench C 4169 6 Install the upper ball stud nut and tighten to 136 Nnn 100 ft lbs torque Tighten the nut until C 4212 L C 4288 1 J9202 90 Fig 30 Upper Ball Stud Installation the cotter pin can be installed Do not loosen the nut to align the hole and the slot Install a new cotter pin VACUUM SHIFT MOTOR VACUUM CONTROL SYSTEM FIG 31 The disconnect axle control system consists of Vacuum control switch...

Page 80: ...P O U N D S NEWTON METRES FULLY SEATED HAND TIGHTENED 55 IN 6 15 FT 20 CLIP ALIGN WHITE TAPE TO END OF CLIP VIEW IN DIRECTION OF ARROW Z WITH V 6 CLIP SHIFT MOTOR ROUTE HOSE TO REAR OF DISTRIBUTOR VIEW IN DIRECTION OF ARROW Z VIEW IN DIRECTION OF ARROW X J9102 61 Fig 31 Disconnect Axle Vacuum Hose Routing ...

Page 81: ... PLACE T R A N S M I S S I O N IN NEUTRAL TEST FOR VACUUM IN VACUUM HOSE THAT C O N N E C T S TO I N B O A R D SHIFT MOTOR PORT VACUUM SHOULD BE BETWEEN 10 20 IN HG CHECK TRANSFER CASE REPAIR AS NECESSARY N O VACUUM O R LOW VACUUM VACUUM OK INSPECT INTAKE M A N I F O L D VACUUM SUPPLY H O S E C O N N E C T I O N TRANSFER CASE VACUUM SWITCH C O N N E C T I O N VACUUM RESERVOIR A N D SHIFT SYSTEM VA...

Page 82: ...CUUM STOP ENGINE H VACUUM OK INSPECT INTAKE MANIFOLD VACUUM SUPPLY HOSE C O N N E C T I O N TRANSFER CASE VACUUM SWITCH C O N N E C T I O N VACUUM RESERVOIR A N D SHIFT SYSTEM VACUUM HOSES FOR PROPER C O N N E C T I O N RESTRICTION LEAKS A N D DAMAGE REPAIR OR REPLACE A S NECESSARY C O N N E C T A VACUUM PUMP TO THE OUTBOARD SHIFT MOTOR PORT APPLY 15 INCHES HG VACUUM A N D ROTATE LEFT WHEEL N O VA...

Page 83: ...e 5 Install the shift motor housing shield and bolts Tighten the bolts to 14 N m 10 ft lbs torque INTERMEDIATE AXLE SHAFT REMOVAL DISASSEMBLY 1 Remove the vacuum motor housing from the axle refer to Vacuum Shift Motor Removal 2 Remove the hub spindle and axle shaft refer to the removal procedures above 3 Remove the shift collar from the shift motor housing 4 Remove the differential housing cover a...

Page 84: ... motor housing refer to Vac uum Shift Motor Installation STEERING KNUCKLE ARM REMOVAL 1 Install Puller C 4150 on each drag link ball stud Apply sufficient force with the tool to loosen the drag link ball stud from the steering arm 2 Remove the lock nuts that attach the steering arm to the knuckle Fig 37 Tap the steering arm to loosen it from the knuckle Pry upward to remove Fig 37 Steering Knuckle...

Page 85: ... the vehicle and re move the block from the brake pedal 10 Raise the vehicle Bleed and adjust the brakes Lubricate all the ball stud fittings Inspect the differential housing lubricant level Re fer to Group 0 Lubrication and Maintenance 11 Lower the vehicle and test the axle and sus pension operation DIFFERENTIAL DISASSEMBLY REMOVAL DISASSEMBLY 1 Note the installation reference letters stamped on ...

Page 86: ...d shims Fig 42 Record the thickness of the shims This will Fig 41 Pinion Yoke Removal save time if they should become misplaced 13 Remove the front pinion bearing cup with Re mover D 158 and Handle C 4171 Fig 43 14 Remove the rear bearing cup from housing Fig 44 Use Remover D 162 and Handle C 4171 15 Remove the depth shims from the housing bore Record the thickness of the depth shims 16 Remove the...

Page 87: ...ase from the vise SPECIAL TOOL C 293 PA Fig 46 Mate Shaft Lock Pin Removal 22 Remove the bearings from the differential case with Press C 293 PA Plug C 293 3 Plate C 293 18 and a vise Fig 49 Use care that adapter rings are placed so they do not damage the bearing cage 23 Remove bearing shims from case hubs and mark them with hub identity for assembly refer ence Record the thickness of the shims CL...

Page 88: ...42 Fig 49 Differential Bearing Removal 4 Examine the differential pinion mate shaft pinion gears side gears and thrust washers for wear and damage Replace all defective components If either of the differential pinion gears is not reusable both gears must be replaced as a matched set only Do not replace only one gear 5 Examine the ring gear and the pinion gear for worn and chipped teeth Examine the...

Page 89: ...ach Dial Indicator C 3339 to the pilot stud Load indicator plunger against the back of the ring gear Fig 53 8 Insert a small pry bar between the bearing cap and left side of differential case Pry the case as far as possible to right side Fig 53 Zero the dial indi cator pointer 9 Pry the case to left side and record the travel distance The measurement above is the shim thickness necessary for case ...

Page 90: ...ans the shim pack must decrease by the same number of thousandths If a negative marking this means the shim pack must increase by the same number of thousandths FRONT SUSPENSION AND AXLE 2 37 Fig 55 Pinion Gear Standard Depth Distance DRIVE Fig 56 Shim Locations If marked zero will use the nominal setting as de termined in this procedure Shims are available in 0 003 inch 0 005 inch 0 010 inch and ...

Page 91: ...L HOUSING ARBOR DISC TOOL ARBOR TOOL J9003 103 DIFFERENTIAL HOUSING J9003 101 Fig 57 Pinion Block In Shaft Bore 2 Place Disc D 115 4 on Arbor D 115 3 and posi tion in the bearing cradles Fig 58 This is the cen terline of the ring gear axle shaft 3 Place Pinion Height Block D 115 1 on top of master pinion block tool and against arbor tool Fig 59 4 Place Gauge Block D 115 2 and Dial Indicator D 106 ...

Page 92: ...aring preload torque with an inch pound torque wrench Fig 65 The torque necessary to rotate the pinion gear should be Original Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 to 5 N m 20 to 40 in lbs SPECIAL TOOL C 4171 J9202 95 Fig 61 Pinion Rear Bearing Cup Installation SPECIAL TOOL D 144 SPECIAL Fig 62 Pinion Front Bearing Cup Installation If the preload torque is not within the specified to...

Page 93: ...rrectly seated Assemble C 3715 B Tool Set as described Fig 66 Shim Locations Position Spacer SP 5586 over Shaft SP 5385 Position pinion rear bearing on shaft Position tools with bearing in the housing Install Sleeve SP 5585 Install pinion front bearing m Install Sleeve SP 3194 B Washer SP 534 and Nut SP 3193 3 Prevent compression sleeve tool from turning with Wrench C 3281 Tighten the nut to seat ...

Page 94: ...nd of SP 526 Install Cap Screw SP 536 and tighten with Wrench SP 531 6 Position Crossbore Arbor SP 5183 in the dif ferential housing J9202 35 Fig 70 Pinion Front Bearing Cup Installation Center the arbor in cradles so equal space exists at both ends Position the bearing caps on the arbor tool Install the bolts Tighten the cap bolts to 14 N m 10 ft lbs torque 7 Trial fit depth shim s or feeler gaug...

Page 95: ...tact should exist 14 Install the rear bearing and slinger if used on the pinion gear with Installer W 262 until com pletely seated Fig 74 15 Install pinion in housing bore 16 Assemble preload shims onto pinion and in stall the pinion gear in housing 17 Install pinion front bearing oil slinger yoke washer and nut Install the yoke with Installer C 3718 and Wrench C 3281 Fig 75 J9203 58 Fig 73 Rear B...

Page 96: ... 80 23 Install a new yoke nut and tighten to 271 298 N m 200 220 ft lbs torque REMOVE SHIMS SHIM PACKS RY660 Fig 77 Shim Locations C 452 J9102 31 Fig 78 Pinion Yoke Removal RING GEAR BACKLASH ADJUSTMENT 1 Place Master Differential Bearing D 135 D 345 on the case hubs 2 Install a pilot stud at the right side of housing Attach Dial Indicator C 3339 to the pilot stud Load indicator plunger against th...

Page 97: ...ator and pilot stud 6 Remove the differential case from housing 7 Remove the master bearing tools from the dif ferential case hubs Fig 81 Ring Gear Backlash Measurement 8 Position the backlash shims with determined thickness on case hub ring gear side Install bear ing on the hub with Installer D 156 and Handle C 4171 Fig 82 Fig 82 Differential Bearing Installation 9 Position the remaining zero end...

Page 98: ...re fully seated Remove the spreader 18 Observe the assembly reference marks and po sition the bearing caps at their original locations Fig 84 Tighten the bearing cap bolts to 95 122 N m 70 90 ft lbs torque 19 Rotate assembly several revolutions to seat bearings Measure backlash at three equally spaced locations with a dial indicator Fig 85 FRONT SUSPENSION AND AXLE 2 45 Fig 84 Differential Bearing...

Page 99: ...ential housing and the case flange This action will produce distinct contact pat terns on both the drive side and coast side of the ring gear teeth 3 Note patterns in compound Refer to Fig 86 for interpretation of contact patterns and adjust ac cordingly 4 Install the axle shafts Refer to Axle Shaft In stallation within this group 5 Install the housing cover Refill the differential with lubricant ...

Page 100: ...ST SIDE OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH Fig 86 Gear T...

Page 101: ...F Axle Ratio 3 54 To 1 3 92 4 09 Track 66 9 in GAWR 3500 lbs Differential Bearing Preload Shim 0 015 in 0 38 mm Differential Side Gear to Case Clearance 0 000 0 007 in 0 00 0 18 mm Ring Gear Backlash 0 005 0 008 in 0 12 0 20 mm Drive Pinion Gearshaft Bearing Break Away Preload Torque Original Bearings 10 20 in lbs 1 2 N m Replacement Bearings 20 40 in lbs 2 5 N m Drive Pinion Gear Depth Select shi...

Page 102: ...he integral type housing hypoid gear design has the centerline of the pinion set below the centerline of the ring gear The axles are equipped with full floating axle shafts meaning that loads are supported by the spin dles attached to the steering knuckles Two tapered opposed roller bearings allow the hub and rotor as sembly to rotate on the spindle The removable stamped steel cover provides a mea...

Page 103: ...ING SLINGER U JOINT AXLE SHAFT NUT WASHER SPINDLE STEERING ARM AND CAP STUDS LEFT STEERING KNUCKLE BEARING CAP f BOLT Fig 1 Model 60 Front Axle MATE SHAFT SCREW GASKET OR SEALER COVER PLUG J9202 67 oi 3 0 O e m 22 o x w ...

Page 104: ...t If not installed the seal ant must be removed and another bead applied 7 Install the cover on the differential with the bolts Install the identification tag Tighten the cover bolts to 47 Nnn 35 ft lbs torque CAUTION Overfilling the differential can result in the lubricant foaming and overheating 8 Refill the differential housing with the speci fied quantity of MOPAR Hypoid Gear Lubricant 9 Insta...

Page 105: ... tire 3 Remove the brake caliper refer to Group 5 Brakes Support the caliper to the frame structure with wire DIFFERENTIAL Fig 6 Tightening Pinion Shaft Nut 4 Remove the allen head screws that retain the cap to the hub Fig 7 Fig 7 Allen Head Screw Removal 5 Remove the snap ring retaining the axle shaft in the hub Fig 8 6 Remove the lock ring from the groove in the hub Fig 9 7 Install two allen hea...

Page 106: ...steering knuckle Remove the spindle from the knuckle use a soft faced mallet if necessary to tap loose Fig 12 SNAP HUB LOCKING PRESSURE CLUTCH SNAP RING SEAL CAP J9202 71 Fig 10 Locking Hub Components Fig 11 Lock Nut Ring Removal 12 Pull the axle shaft with spacer seal and slinger from the steering knuckle Fig 13 13 Clamp the spindle in a soft jawed vise Do not clamp at the bearing contact surface...

Page 107: ...lubricant NLGI Grade 2 EP or an equivalent lubricant Fig 15 Spindle Needle Bearing Installation Fig 16 Spindle Seal Installation 4 Carefully install the axle shaft through the knuckle into the axle housing Ensure the axle shaft splines are engaged with the differential side gears 5 Install the spacer on the axle shaft end 6 Install the brake splash shield and brake cali per support bracket 7 Insta...

Page 108: ...he free play 12 Install the tabbed lock washer in the nearest hole in the washer Install and tighten the outer lock nut with Wrench 7158 Fig 11 to 217 278 N m 160 205 ft lbs torque The end play after the final bear ing adjustment should be within 0 001 inch to 0 010 inch 0 03 to 0 25 mm 13 Install the locking body assembly in the hub 14 Install the lock ring in the groove in the hub Ensure the rin...

Page 109: ...pper Cap Removal 4 Remove the steering knuckle lower cap Fig 25 5 Dislodge the cap from the steering knuckle and yoke 6 Remove the tapered bushing from the top of the kingpin in the knuckle Fig 26 Remove the knuckle 7 Use Remover Installer D 192 to remove the up per kingpin Fig 27 Discard the seal 8 Use Tool C 4212 1 C 4366 1 and C 4366 2 to remove lower ball socket from lower arm bore Fig 28 Disc...

Page 110: ...new king pin bearing oil seal Reposition Tools C 4212 L TAPERED BUSHING J9202 53 Fig 26 Tapered Bushing Removal J9202 66 Fig 27 Upper Kingpin Removal C 4366 3 and C 4366 5 Fig 30 and press the lower bearing cup and seal into yoke lower arm bore 5 Use Remover Installer D 192 to install the up per kingpin Fig 31 Tighten the kingpin to 668 813 N m 500 600 ft lbs torque Install the seal over the kingp...

Page 111: ...r the steering knuckle upper studs Install the upper cap and steering arm C 4212 L C 4366 3 RH434A Fig 30 Lower Bearing Seal Installation TORQUE WRENCH SEAL J9202 66 Fig 31 Upper Kingpin Installation on the left side Install the bolts nuts and tighten to 96 122 N m 70 90 ft lbs torque 11 Lubricate the upper and lower king pin through the fittings with MOPAR Multi Mileage Lu bricant or equivalent ...

Page 112: ... spring U bolts Remove the complete front axle from the ve hicle INSTALLATION 1 Position the front axle under the front of the vehicle with the axle spring pads under the springs Place the spring brackets over the springs Make sure the stabilizer bar link bolt holes face toward the rear of the vehicle 2 Install the spring U bolts washers and nuts Refer to Front Suspension 4WD Vehicles within this ...

Page 113: ...dicator 7 Pry the differential case loose from the hous ing To prevent damage pivot on housing with the end of the pry bar against case 8 Remove the case from housing If they are re usable retain the differential bearing cups and bear ings together as matched sets 9 Clamp the differential case in a vise equipped with soft jaws Remove and discard the ring gear bolts Tap the ring gear with a rawhide...

Page 114: ...Fig 38 Pinion Front Bearing and Preload Shims HAMMER DRIVER HANDLE FRONT BEARING CUP J9203 57 J9203 58 Fig 39 Front Bearing Cup Removal 16 Remove the pinion rear bearing Fig 41 Use Puller DD 914 P Adapter Ring DD 914 9 and Plate C 293 37 17 Remove the differential side gears and thrust washers Fig 40 Rear Bearing Cup Removal 18 Remove the case from the vise 19 Remove the bearings Fig 42 with Remov...

Page 115: ...drift and ham mer Fig 44 23 Rotate the differential side gears and remove Fig 43 Mate Shaft Lock Pin Removal Fig 44 Mate Shaft Removal the pinion mate gears and thrust washers Fig 45 24 Remove axle shaft oil seals from differential housing with a pry bar CLEANING INSPECTION 1 Wash and clean all the differential components with cleaning solvent Dry with compressed air Do not steam clean the differe...

Page 116: ...FERENTIAL ASSEMBLY ASSEMBLY 1 Install the following components in the differ ential case Fig 47 Differential side gears and thrust washers Pinion gears and thrust washers Pinion gear mate shaft align holes in shaft and case 2 Install and seat the lock pin in the differential case and mate shaft with a punch and hammer Fig 46 Peen metal part of case over pin in two places If replacement gears and t...

Page 117: ... of the pinion gear This number is the amount in thousandths of an inch the depth varies from the standard depth setting The standard depth provides the best teeth contact pattern DRIVE PINION Fig 50 Pinion Gear ID Numbers The standard depth is the distance Fig 51 from the centerline of the axle shaft ring gear to the shoulder of the rear pinion bearing Model 60 axle the standard depth distance is...

Page 118: ...m Locations If equipped the oil slinger must be measured and the thickness included with the total shim pack thickness The shim thickness for the new pinion gear must be determined before installing the differential case PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance Original Pinion Gear Depth Variance 4 3 2 1 0 1 ft 3 4 0 008 0 007 0 006 0 00...

Page 119: ...arbor while ob serving indicator Record the longest travel distance whether inward or outward indicated by the pointer Fig 55 Pinion Height Block Against Arbor Fig 56 Pinion Gear Depth Measurement Plunger travel distance indicated plus or mi nus the amount etched in gear is required thick ness 6 Measure the thickness of each depth shim with a micrometer and combine the shims necessary for total re...

Page 120: ...70 ft lbs torque 14 Check bearing preload torque with an inch pound torque wrench Fig 61 The torque necessary to rotate the pinion gear should be Original Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 to 5 N m 20 to 40 in lbs If the preload torque is not within the specified tol erance correct the shim thickness accordingly Fig 62 Increase the preload torque decrease the shim thickness J9103 ...

Page 121: ...nate measurement and adjustment proce dure involves using Pinion Depth Measurement Gauge Set C 758 D6 Fig 65 1 Install the pinion rear bearing cup Fig 66 with Installer D l l l and Handle C 4171 Ensure the cup is correctly seated 2 Install the pinion front bearing cup with In staller C 4203 and Handle C 4171 Fig 67 Assemble C 758 D6 Tool Set as described Fig 68 SPECIAL TOOL C 452 J9102 31 Fig 63 P...

Page 122: ...SUSPENSION AND AXLE 2 69 Fig 68 Seating Pinion Bearings of the depth shim s is determined according to the following information 4 Loosen the compression nut tool Lubricate the pinion gear front and rear bearings with gear lubri cant Re tighten the compression nut tool to 1 to 3 Nnn 15 to 25 in lbs torque Rotate the pinion gear several complete revolutions to align the bearing rollers 5 Install Ga...

Page 123: ... cup bore 12 Install the pinion rear bearing cup Fig 66 with Installer D l l l and Handle C 4171 Ensure the cup is correctly seated 13 If the depth of mesh has been followed accord ing to the instructions above good gear teeth contact should exist 14 Install the rear bearing and slinger if used on the pinion gear with Installer C 3095 A until completely seated Fig 71 15 Install pinion in housing b...

Page 124: ...bs torque SPECIAL TOOL C 452 J9102 31 Fig 75 Pinion Yoke Removal SPECIAL TOOL C 4735 SPECIAL TOOL C 3719 A DIFFERENTIAL HOUSING J9203 56 Fig 76 Pinion Seal Installation RING GEAR BACKLASH ADJUSTMENT 1 Place Master Differential Bearing D 343 D 117 on the case hubs Fig 78 2 Install a pilot stud at the right side of housing Attach Dial Indicator C 3339 to the pilot stud Load indicator plunger against...

Page 125: ...hick shim on this hub This will provide the required differential bearing preload torque 10 Install bearing on hub with Installer C 4025 A and Handle C 4171 Fig 79 11 Install new axle shaft oil seals in differential housing with Installer D 195 Apply lubricant to lip of seals 12 Match each bearing cup with bearing origi nal Install the cups on the bearings 13 Position Spreader D 167 with the tool ...

Page 126: ... gear Fig 82 Ring Gear Backlash Measurement away from the pinion gear Backlash correction is ac complished by transferring shims from one side to the other If the mesh and backlash steps have been followed in the procedures above good gear teeth contact pat terns should exist RING GEAR TEETH CONTACT PATTERN ANALYSIS The ring gear teeth contact patterns will show if the pinion gear depth shim s hav...

Page 127: ...ST SIDE OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH Fig 83 Gear T...

Page 128: ...er Suspension Arm Pivot Lower Ball Stud Nut 11 16 18 Bolt Lower Ball Stud Nut 3 4 16 Bolt Shock Absorber Upper Nut Shock Absorber Lower Bolt Stabilizer Bar Retainer Bolts Stabilizer Bar Link Nut Steering Arm to Knuckle 5 8 18 Bolt Nut Steering Arm to Knuckle 3 4 16 Bolt Nut 20 N m 180 in lbs 41 N m 30 ft lbs 305 N m 225 ft lbs 183 N m 135 ft lbs 237 N m 175 ft lbs 34 N m 25 ft lbs 23 N m 200 in lb...

Page 129: ...t lbs Ring Gear Bolts 61 to 81 N m 45 to 60 ft lbs Upper Ball Stud Nut 136 N m 100 ft lbs Upper Yoke Sleeve 54 N m 40 ft lbs J9202 110 DESCRIPTION TORQUE Bearing Cap Bolts Brake Splash Shield Spindle Differential Cover Bolts Fill Hole Plug Lower King Pin Cap Screws Pinion Yoke Nut Spindle Wheel Bearing Outer Lock Nut Ring Gear Bolts Grade 8 Ring Gear Bolts Grade 9 Upper King Pin Cap Upper King Pin...

Page 130: ...ted between the sensor and the wire harness connector The seal must be in plaee when the wire connector is connected to the sensor The RWAL brake exciter ring is press fitted onto the differential case against the flange A rear axle equipped with a Sure Grip differential is optionally available for both Ram Truck and Ram charger vehicles The Sure Grip has a two piece case that is interchangeable w...

Page 131: ... AND AXLE DIFFERENTIAL IDENTIFICATION DIFFERENTIAL FILL PLUG J9202 40 Fig 3 Model 60 and 70 Differential Cover Fig 1 Differential Cover 8 3 8 Inch Axle IDENTIFICATION TAG J9203 32 Fig 2 Differential Cover 9 1 4 Inch Axle ...

Page 132: ...Do not attempt to stop spring bushing noise by lubricating them Grease and mineral oil base lubricants will deterio rate the bushing rubber If the vehicle is used for severe off road operation the springs should be examined periodically Check for broken and shifted leafs loose and missing clips and broken center bolts VEHICLE LOADING AND WEIGHT DISTRIBUTION A vehicle should always be loaded so the...

Page 133: ...rber upward and position the upper end at the frame crossmember 4 Align and insert the bolt through the upper shock absorber eye and the crossmember Fig 1 5 Install the locknut on the upper bolt and tighten it finger tight 6 Remove the supports and lower the vehicle to the surface 7 Tighten the shock absorber nuts to 82 N m 60 ft lbs torque SPRINGS REMOVAL 1 Raise and support the frame until all w...

Page 134: ...sembly 4 Insert a long drift or punch into the center bolt hole and slowly release the vise jaws 5 Remove the spring from the vise Replace the broken defective leaf Insert a long drift or punch into the spring center bolt hole 6 Position the spring between vise jaws and slowly tighten the vise jaws Keep the spring leaves aligned with the long drift or punch 7 Remove the drift punch from the spring...

Page 135: ... the bearing surfaces This will result in noisy operation after repair Axle gear problem conditions are usually the result of Insufficient lubrication Incorrect or contaminated lubricant Overloading excessive engine torque Incorrect clearance or backlash adjustment Insufficient lubrication is usually the result of a housing cover leak It can also be from worn axle shaft or pinion gear seals Check ...

Page 136: ...oise is sensitive to inflation pres sure The pitch of tire noise changes when the vehi cle speed is varied Drive the vehicle over different road surfaces Note the changes in the noise If the noise changes the tires are the source of the noise Refer to Group 22 Wheels and Tires for additional information GEAR AND BEARING NOISE GEAR NOISE Axle gear noise can be caused by insufficient lubri cant Inco...

Page 137: ...ransmission transfer case mounts 9 Worn U joints Loose spring shackles or U bolts Loose pinion gear nut and yoke Excessive ring gear backlash Excessive differential side gear to case clearance A worn bushing in the transmission extension housing can also cause noise The source of a snap or a clunk noise can be deter mined with the assistance of a helper Raise the ve hicle on a hoist with the wheel...

Page 138: ...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 Replace broken axle shaft after inspecting for other possible causes Avoid erratic use of clutch d Replace broken axle shaft Inspect clutch and make necessary repairs or adjustments a Replace cracked c...

Page 139: ...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 as necessary e Readjust ring gear backlash and inspect gears for possible scoring a Replace gears Examine other gears and bearings for possible damage Replace parts as needed Avoid overloading of vehicle b Re...

Page 140: ...ing and cover mating surfaces Clean the mating sur faces with mineral spirits Apply a bead of MOPAR Silicone Rubber Sealant on the housing cover Fig 2 Allow the sealant to cure for a few minutes page Lubricant 11 Pinion Depth Measurement and Adjustment with Gauge Set 20 Pinion Seal Replacement 14 Install the housing cover within 5 minutes af ter applying the sealant If not installed the sealant mu...

Page 141: ...L HOUSING FRONT BEARING VENT FITTING SEAL AXLE AXLE SHAFT SHAFT BEARING TUBE BEARING CAP WASHER LOCK STUD SIDE GEAR CLIP NUT BOLT DIFFERENTIAL BEARING BEARING CUP ADJUSTER LOCK COVER BOLT PLUG HOUSING COVER BOLT J9003 109 Fig 1 8 3 8 Inch Or 9 1 4 Inch Axle ...

Page 142: ...ed N o r m a l bearing contact o n the shaft will be a dull gray a n d it could appear to be lightly dented ADJUSTER SIDE LOCK GEAR AXLE SHAFT C CLIP LOCK J9003 111 Fig 4 Axle Shaft C Clip Lock 10 If any of these conditions exist the axle shaft and bearing must be replaced The normal appearance will be a dull gray surface that could appear slightly dented AXLE SHAFT SEAL AND BEARING REMOVAL 1 Remo...

Page 143: ...t completely f failure of the rear axle REMOVAL 1 Raise and support tr 2 Mark the U joint pi for reference 3 Disconnect the drh yoke Secure the drive sha prevent damage to the re 4 Remove the rear w drums to prevent any dr false bearing preload torq 5 Use a Newton mete wrench to measure the p tate the pinion shaft sev wrench Note the indicate moved through several re 13 Install the brake drums 14 ...

Page 144: ...he differential case runout Remove the rear wheel anti lock RWAL sensor 5 Mark the differential housing and the differen tial bearing caps for installation reference Fig 12 6 Remove the bearing threaded adjuster lock from each bearing cap Loosen the bolts but do not remove the bearing caps 7 Loosen the threaded adjusters with Wrench C 4164 Fig 13 8 Hold the differential case in place Remove the be...

Page 145: ...g 16 Fig 16 Case Flange Runout Measurement 4 Rotate the differential case several times Ob serve the dial indicator pointer Mark the area of maximum flange runout The differential case flange runout must not exceed 0 003 inch 0 08 mm If the runout exceeds the amount replace the differential case You can reduce excessive ring gear runout by positioning the ring gear runout m a r k 180 de grees oppo...

Page 146: ...counterbores If replacement side gears or thrust washers are used refer to Differential Side Gear Clear ance Measurement And Adjustment 3 Position the thrust washers on the differential pinion gears Mesh the pinion gears with the side gears Ensure that the pinion gears are exactly 180 degrees opposite each other 4 Rotate the side gears to align the pinion gears and thrust washers Align these compo...

Page 147: ...OOL C 758 D6 SP 6018 SP 536 S Fig 21 9 1 4 Axle Pinion Adjustment Tools and Position Spacer SP 6017 over Shaft SP 526 Position pinion rear bearing on shaft Position tools with bearing in the housing Install Sleeve SP 1730 Install pinion front bearing Install Spacer SP 6022 Install Sleeve SP 535 A Washer SP 534 Nut SP 533 4 Prevent compression sleeve tool from turning with Wrench C 3281 Tighten the...

Page 148: ...n from the standard If the number is negative add that value to the required thickness of the depth shim s If the number is positive subtract that value from the thickness of the depth shim s If the number is 0 no change is necessary 11 Remove the tools from the differential hous ing 12 Position the depth shim s on the pinion gear Install the rear bearing Fig 24 Be sure the contact surfaces are cl...

Page 149: ...ts the face of the differential hous ing flange The outer perimeter of the seal is pre coated with a special sealant An additional application of sealant is not required 18 Install the pinion yoke with Remover Installer C 3718 and Wrench C 3281 19 Remove the tools Install the Belleville washer The convex side of the washer must face out ward Install the pinion nut 4 J9103 21 Fig 25 Pinion Yoke Ins...

Page 150: ... 285 N m 210 ft lbs torque If the preload torque is not within the specified range this is also unacceptable DIFFERENTIAL CASE INSTALLATION 1 Apply a coating of hypoid gear lubricant to the differential bearings bearing cups and threaded ad justers A dab of grease can be used to keep the ad justers in position Carefully position the assembled differential case in the housing 2 Observe the referenc...

Page 151: ... above Do this until the torque remains constant 9 Install the threaded adjuster locks Ensure the lock finger is engaged with the adjuster hole Tighten the lock screws to 10 N m 90 in lbs torque SIDE GEAR CLEARANCE MEASUREMENT AND ADJUSTMENT When measuring side gear clearance check each gear independently If it necessary to replace a side gear replace both gears as a matched set 1 Install the axle...

Page 152: ...nstalled to thrust washer thickness measured The sum will determine the required thickness of the replacement thrust washer 7 If clearance is 0 012 inch 0 305 mm or greater both side gears must be replaced matched set and the clearance measurements repeated 8 If clearance above continues to be 0 012 inch 0 305 mm or greater the case must be replaced RING GEAR TEETH CONTACT PATTERN ANALYSIS The rin...

Page 153: ...SIDE O F T O O T H BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN A N D TOP O F THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH Fig 34 G...

Page 154: ...m 9 25 in 23 50 cm Lubricant SAE 80W 90 Lube Capacity 76 oz 2 26 L Diff Case Clearance 0 005 in 0 12 mm Ring Gear Backlash 0 005 0 008 in 0 12 0 20 mm Pinion Bearing Preload 10 20 in lbs 1 2 Nnn Case Flange Runout 0 003 in 0 076 mm Ring Gear Runout 0 005 in 0 127 mm AXLE RATIO GEAR TEETH COMBINATION 3 55 1 39 11 3 90 1 39 10 TORQUE SPECIFICATIONS 8 1 4 AND 9 1 4 INCH REAR AXLE DESCRIPTION TORQUE 8...

Page 155: ... method of identification is by removing the housing cover fill hole plug Examine with a flashlight the differential case components through the lubricant fill hole SERVICE INFORMATION When Sure Grip differential service is necessary both rear wheels must be raised off the surface so they are free to rotate A Sure Grip differential case is not repairable If defective it must be replaced as a compl...

Page 156: ...sing hypoid gear design has the centerline of the pinion set below the centerline of the ring gear The axles are equipped with full floating axle shafts meaning that loads are supported by the axle housing tubes The full float axle shafts are retained by bolts attached to the hub The hub rides on two bearings at the outboard end of the axle tube The axle shafts can be removed without disturbing or...

Page 157: ...C O Fig 1 Model 60 and 70 Rear Axle ...

Page 158: ...e sealant must be removed a n d another bead ap plied 7 Install the cover on the differential Install the identification tag Tighten the cover bolts to 47 Ne m 35 ft lbs torque CAUTION Overfilling the differential can result in the lubricant foaming and overheating 8 Refill the differential housing with the speci fied quantity of MOPAR Hypoid Gear Lubricant With Trac Lok differentials add a contai...

Page 159: ...iced REMOVAL MODEL 60 1 Remove the axle shaft flange bolts 2 Slide the axle shaft out from the axle tube Fig 1 INSTALLATION MODEL 60 1 Clean 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 Fig 1 2 Install the bolts and tighten to 95 N m 70 ft lbs torque REMOVAL MODEL 70 1 Remove the axle shaft flange lock ...

Page 160: ...xle CAUTION Use care to prevent the inner wheel bear ing and bearing seal from contacting the axle threads during installation Otherwise the threads bearing and seal could be damaged 6 Carefully slide the hub onto the axle Install the outer wheel bearing the locktab and outer wheel bearing locknut 7 Tighten the adjustment nut to 163 190 Nnn 120 140 ft lbs torque while rotating the wheel 8 Loosen t...

Page 161: ...emove the differential bearing caps Fig 7 Bearing Cap identification 3 Position Spreader D 167 with the tool dowel pins seated in the locating holes Fig 8 Install the holddown clamps and tighten the tool turnbuckle fin ger tight SPECIAL TOOL DIAL MODEL 44 W 129 A INDICATOR Fig 8 Differential Housing Separation 4 Install a pilot stud at the left side of the differ ential housing Attach Dial Indicat...

Page 162: ...and Handle C 4171 16 Remove the depth shims from the housing bore Record the thickness of the depth shims 17 Remove the pinion rear bearing Fig 15 Model 60 use Puller DD 914 P Adapter Ring DD 914 9 and Plate C 293 37 Model 70 use Puller DD 914 P Adapter Ring DD 914 9 and Plate DD 914 95 18 Remove the differential side gears and thrust washers PINION YOKE WASHER SLINGER PINION PRELOAD SHIMS FRONT B...

Page 163: ...and mark them with hub identity for assembly refer ence Record the thickness of the shims PINION SPECIAL TOOL DD 914 9 SPECIAL TOOL G293 37 J9203 59 Fig 15 Pinion Rear Bearing Removal 22 Clamp the differential case in a vise equipped with soft jaws Use a pin punch to remove the pinion gear mate shaft lock pin Fig 17 23 Remove the mate shaft with a drift and ham mer Fig 18 24 Rotate the differentia...

Page 164: ...ng must be replaced as a matched sets only All machined surfaces in the housing and on bear ing caps should be smooth and without any raised edges Pinion gear front and rear bearing cup bores should be smooth Raised metal on shoulders of cup bores should be removed with a hand stone 4 Examine the differential pinion gear mate shaft pinion gears side gears and thrust washers for wear and damage Rep...

Page 165: ...er pin in two places If replacement gears and thrust washers were installed It is not necessary to measure the gear backlash Correct fit is due to close machining tolerances during manufacture 8 Place Master Differential Rearing D 343 D 117 on the case hubs Fig 24 9 Install a pilot stud at the right side of housing Attach Dial Indicator C 3339 to the pilot stud Load indicator plunger against the b...

Page 166: ...3 29 Fig 25 Differential Case End Play Measurement PRODUCTION NUMBERS DRIVE PINION GEAR DEPTH VARIANCE GEAR MATCHING NUMBER SAME AS RING GEAR NUMBER J9003 100 Fig 26 Pinion Gear ID Numbers The standard depth is the distance Fig 27 from the centerline of the axle shaft ring gear to the shoulder of the rear pinion bearing Model 60 axle the standard depth distance is 5 000 inches 127 00 mm Model 70 a...

Page 167: ...NG SHIM J9002 32 Fig 28 Shim Locations If equipped the oil slinger must be measured and the thickness included with the total shim pack thickness Depth shim thickness for the new pinion gear must be determined before installing differential case in housing PINION GEAR DEPTH MEASUREMENT AND ADJUSTMENT WITH TOOL SET D 116 The following gear depth measurement and adjust ment procedure involves using ...

Page 168: ...ce indicated plus or minus the variance etched in the gear is the re quired thickness for the depth shims Fig 31 Pinion Height Block Against Arbor Fig 32 Pinion Gear Depth Measurement 6 Measure the thickness of each depth shim with a micrometer and combine the shims necessary for total required pack thickness Include oil slinger thickness with the total shim pack thickness 7 Remove the measurement...

Page 169: ...37 The torque necessary to rotate the pinion gear should be Original Bearings 1 3 Nnn 10 20 in lbs New Bearings 2 5 Nnn 20 40 in lbs If the preload torque is not within the specified tol erance correct the shim thickness accordingly Fig 38 Increase the preload torque decrease the shim thickness Decrease the preload torque increase the shim thickness J9103 21 Fig 36 Pinion Yoke Installation 15 Remo...

Page 170: ...g cup with In staller C 4203 and Handle C 4171 Fig 43 REAR SUSPENSION AND AXLE 3 43 C 452 J9102 31 Fig 39 Pinion Yoke Removal SPECIAL TOOL C 4735 J9203 56 Fig 40 Pinion Seal Installation Assemble C 758 D6 Tool Set as described Fig 41 Position Spacer SP 5814 for Model 60 or SP 5587 for Model 70 over Shaft SP 526 Position pinion rear bearing on shaft Position tools with bearing in the housing Instal...

Page 171: ...al space exists at both ends Position the bearing caps on the arbor BEARING CUP DRIVER INSTALLATION TOOL C 4203 HANDLE Fig 44 Seating Pinion Bearings tool Install the attaching bolts Tighten the cap bolts to 14 N m 10 ft lbs torque 7 Trial fit depth shim s between the crossbore arbor and gauge block Fig 45 The depth shim s fit must be snug but not tight drag friction of a feeler gauge blade Depth ...

Page 172: ...inion gear with Installer C 3095 A until completely seated Fig 47 15 Install pinion in housing bore 16 Assemble preload shims onto pinion and in stall the pinion gear in housing PRESS DRIVE PINION GEAR SHAFT REAR BEARING INSTALLATION TOOL DRIVE PINION GEAR OIL SUNGER J9302 68 Fig 47 Pinion Rear Bearing Installation 17 Install pinion front bearing oil slinger yoke washer and nut Install the yoke wi...

Page 173: ...ew seal Fig 52 C 452 J9102 31 Fig 51 Pinion Yoke Removal Model 60 use Installer C 3719 A and Handle C 4735 Model 70 use Installer C 359 and Handle C 4735 SPECIAL TOOL C 4735 J9203 56 Fig 52 Pinion Seal Installation 22 Install the yoke with Installer C 3718 and Wrench C 3281 Fig 53 23 Install a new yoke nut and tighten to 339 366 N m 250 270 ft lbs torque RING GEAR BACKLASH ADJUSTMENT 1 Place Maste...

Page 174: ...al case hubs 8 Position the backlash shims with determined thickness on case hub ring gear side Install bear ing on the hub Model 60 use Installer C 4025 A and Handle C 4171 Fig 55 Model 70 HD use Installer C 4190 and Handle C 4171 Fig 55 Differential Bearing Installation 9 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 ...

Page 175: ...inch 0 05 mm between the points checked 19 Excessive backlash is corrected by moving the ring gear teeth closer to the pinion gear teeth Insuf ficient backlash is corrected by moving the ring gear away from the pinion gear Backlash correction is ac complished by transferring shims from one side to the other If the mesh and backlash steps have been followed in the procedures above good gear teeth c...

Page 176: ... SIDE O F T O O T H BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN A N D TOP O F THE T O O T H RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH J90...

Page 177: ... M 60 M 70 Axle Ratio to 1 Model 60 4 10 4 56 Model 7 0 3 07 3 54 4 10 4 56 Track Model 60 64 0 in Model 70 w dual rear wheels 73 0 in 68 0 in w single rear wheels 64 0 in GAWR lbs Mode 60 5800 6200 Mode 70 6900 7500 6200 denotes dual rear wheels Differential Bearing Preload Shim 0 38 mm 0 015 in Differential Side Gear to Case Clearance 0 00 0 18 mm 0 000 0 007 in Ring Gear Backlash 0 12 0 20 mm 0...

Page 178: ... 5 With a gradual throttle opening attempt to slowly drive the vehicle over the block of wood 6 If the Kraft paper slips out before the front wheel moves over the block of wood reposition the vehicle so paper and board are under the opposite rear wheel Attempt to drive over the block of wood the second time 7 If the front wheel moves over the block of wood the axle can be considered to be function...

Page 179: ...RD DIFFERENTIAL O N AXLE SHAFT 3 Position the differential case on the axle shaft Fig 3 4 Remove and discard the ring gear bolts They are not reusable 5 Remove the case from the fixture Remove the ring gear from the case by tapping it with brass drift and a hammer 6 Position the case on the fixture 7 Remove the pinion gear mate shaft retaining roll pin Fig 4 DIFFERENTIAL CASE PINION GEAR MATE SHAF...

Page 180: ...L C 4487 2 13 Loosen the forcing screw tool until the clutch pack tension is relieved 14 Insert Turning Bar C 4487 4 in case Rotate case with tool until pinion gears can be removed Fig 8 Remove tools from the case THREADED ROD C 4487 2 SPlCIAL tOOL C 4487 4 J9203 2 Fig 8 Pinion Gear Removal 15 Remove top side gear and clutch pack Keep plates in correct order during removal Fig 9 16 Remove case fro...

Page 181: ... Fig 10 3 Secure disc packs with retaining clips Fig 10 4 Position assembled clutch disc packs on the side gear hubs CLUTCH PACK RETAINER J8903 50 Fig 10 Clutch Disc Pack 5 Position case on fixture Fig 3 6 Install clutch pack and side gear in lower bore Fig 11 Be sure clutch pack retaining clips re main in position and are seated in the case pockets 7 Install lubricated Step Plate C 4487 1 on firs...

Page 182: ... if the chatter persists clutch disc damage could have occurred WARNING WHEN SERVICING VEHICLES WITH A POWER LOK DIFFERENTIAL DO NOT USE THE EN GINE TO ROTATE THE AXLE AND WHEELS BOTH REAR WHEELS MUST BE RAISED FROM THE SUR FACE AND THE VEHICLE SUPPORTED POWER LOK CAN EXERT ENOUGH DRIVING FORCE IF ONE WHEEL IS IN CONTACT WITH THE SURFACE TO CAUSE THE VEHICLE TO MOVE DIFFERENTIAL TEST 1 Drive the v...

Page 183: ... Lubrication and Maintenance for additional information FLANGE HALF CLUTCH RING J9203 73 Fig 3 Cover Half Removal DISASSEMBLY 1 Mark the ring gear half and cover half for in stallation reference Fig 2 2 Remove the case attaching bolts and remove the button cover half Fig 3 3 Remove the pinion mate gear side gear clutch ring and clutch pack shaft Fig 4 Keep these parts with the button cover half fo...

Page 184: ...cks must be replaced Lubricate each com ponent with gear lube before assembly and installa tion 2 Clamp one axle shaft in a vise with protective jaws Tighten shaft in vise with the splined end ex tending approximately 76 2 mm 3 0 inches upward Fig 5 Fig 5 Axle Shaft As Holding Fixture 3 Saturate the clutch plates with Hypoid Gear Lubricant or Additive Assemble clutch packs into the side gear plate...

Page 185: ...de gear Tighten body screws alternately and evenly Tighten screws to 89 94 N m 65 to 70 ft lbs torque Both axle shafts must be inserted ALL the way on each side to align BOTH splines If bolt heads have 7 radial lines stamped on the head tighten these to 122 136 N m 90 to 100 ft lbs torque 9 Remove differential assembly from axle shaft Inspect that each pinion mate cross shaft is tight on its ramp ...

Page 186: ...ad to Frame Aux 41 N m 30 ft lbs J9203 82 DESCRIPTION TORQUE 8 3 8 Axle Differential Bearing Cap Bolt 9 1 4 Axle Differential Bearing Cap Bolt Brake Backing Plate Differential Housing Cover Bolt Pinion Yoke Nut Minimum Torque Ring Gear Bolt RWAL Brake Sensor 95 N m 70 ft lbs 136 N m 100 ft lbs 64 N m 48 ft lbs 47 N m 35 ft lbs 2 8 5 N t t i 210 ft lbs 95 N m 70 ft lbs 24 N m 18 ft lbs J9203 69 MOD...

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Page 188: ...e is used on all models The valve consists of a front brake metering hold off valve and a front rear pressure differential switch A red brake indicator and warning light is used to alert the driver if a pressure differential exists be tween the front and rear hydraulic systems The light also alerts the driver when the parking brakes are applied The light is located at the left side of the instrume...

Page 189: ...OMPONENTS DO NOT C L E A N B R A K E C O M P O N E N T S WITH COM P R E S S E D AIR OR BY DRY BRUSHING U S E A VAC UUM C L E A N E R SPECIFICALLY DESIGNED FOR REMOVING B R A K E DUST THAT MAY A S B E S T O S FIBERS IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE CLEANING SHOULD B E DONE USING A WATER D A M P E N E D CLOTH DO NOT C R E A T E DUST BY SANDING GRINDING OR SHAVING B R A K E LININGS U N L...

Page 190: ...he power brake booster The electrical side of the switch is connected to the brake warning light The low vacuum switch monitors booster vacuum level whenever the engine is running If booster vac uum falls below 8 5 inches vacuum for a minimum of 10 seconds the switch completes the circuit to the warning light causing it to illuminate The warning light is designed to differentiate between a low vac...

Page 191: ...lve could also be faulty On diesel engine models high pedal effort may be the result of a low vacuum condition If the booster and check valve are OK the problem may be related to a vacuum pump hose hose connection hose fit ting pump diaphragm or drive gear Vacuum pump output can be checked with a standard vacuum gauge Vacuum output should range from 8 5 to 25 inches vacuum If vacuum pump output is...

Page 192: ...f severely worn brake lining If the lining has worn through to the brakeshoes in spots metal to metal con tact occurs If the condition is allowed to continue ro tors can become so scored that replacement is necessary Thump Clunk Thumping or clunk noises during braking are fre quently not caused by brake components In many cases such noises are caused by loose or damaged steering suspension or engi...

Page 193: ... 3 Clamp hose shut between vacuum source and check valve Fig 3 4 Stop engine and observe vacuum gauge 5 If vacuum drops more than one inch vacuum 33 millibars within 15 seconds either booster dia phragm or check valve are faulty SHORT CONNECTING CHECK VACUUM GAUGE J9005 81 Fig 3 Booster Vacuum Test Connections TESTING DIESEL ENGINE VACUUM PUMP OUTPUT On models with a Cummins turbo diesel engine a ...

Page 194: ...d to sep arate into distinct layers If contamination has oc curred the system rubber seals hoses and cups must be replaced and the system thoroughly flushed with clean brake fluid Remember that brake fluid tends to darken over time Do not confuse this normal condition with contamination REAR BRAKE ADJUSTMENT The rear drum brakes are equipped with a self ad justing mechanism Under normal circumstan...

Page 195: ...pidly in a reverse direction Fig 3 Rear Brake Adjustment With Tool C 3784 5 Have helper apply brakes firmly Firm applica tion will cause secondary shoe to move and engage rotating drum 6 Normal shoe wrap up effect should move sec ondary shoe enough to cause adjuster cable to pull adjuster lever up and turn star wheel BRAKE SYSTEM BLEEDING The brake system can be bled manually or with pressure equi...

Page 196: ...eeding operations at remaining wheel brake units 8 If pressure bleeding a Clean bleed screw on RWAL valve Then in stall bleed hose on bleed screw Insert end of hose in clear container partially filled with brake fluid Be sure hose end is immersed in brake fluid or air will be drawn back into valve b Open bleed screw at RWAL valve and allow fluid to flow through valve c Stop bleeding when only clea...

Page 197: ...of a front rear hydraulic system malfunction The reservoir compartments are designed to retain the necessary quantity of fluid needed to operate the functioning circuit Care must be exercised when removing installing the master cylinder connecting lines The threads in the fluid ports can be damaged if care is not prac ticed Start all brake line fittings by hand to avoid cross threading The aluminu...

Page 198: ...wards if care is not exercised Install the reservoir so the fluid fill information on the reservoir side is on the same side as the fluid outlet ports in the cyl inder body Fig 4 9 Start reservoir into grommets Then rock reser voir side to side until fully seated Reservoir bottom surface should touch grommets after installation 10 Bleed master cylinder before installing it in vehicle Refer to proc...

Page 199: ... primary piston in bore 5 Press pistons inward with wood dowel and in stall piston snap ring Be sure snap ring is fully seated 6 Install new gasket on cover if necessary 7 Install cover retaining wire on cylinder if re moved 8 Fill and bleed master cylinder on bench before installing it in vehicle Refer to following procedure BLEEDING NEW OR OVERHAULED MASTER CYLINDER A new or overhauled master cy...

Page 200: ...with brake fluid 4 Have helper press and hold brake pedal all the way down and observe warning light a If warning light illuminates switch is operat ing correctly b If light fails to illuminate check circuit fuse bulb and wiring Repair as necessary and repeat test steps 3 and 4 5 If warning light still fails to illuminate check brakelight and park brake switches and wiring with test lamp Repair or...

Page 201: ...ine and hose mating surfaces are Valve Mounting clean and free from nicks and burrs Also remember that right and left brake hoses are not interchange able Use new copper seal washers at all caliper connec tions Fig 9 Be sure brake line connections are properly made not cross threaded and tightened to recommended torque Brake line routing connections and tightening ref erence information is outline...

Page 202: ...Fig 9 Front Brake Lines ...

Page 203: ...Fig 10 Rear Brake Lines And RWAL Components ...

Page 204: ...AND SHIELD BRAKE HOSE AND RWAL SENSOR WIRING LET TORQUE LET POUNDS NEWTON METRES x 145 IN 16 X X 35 FT 47 170 IN 19 100 IN 11 125 IN 14 BRAKE VALVE TUBE TO RIGHT FRONT BRAKE HOSE VIEW IN DIRECTION OF ARROW A SCREW GASKET 8905 54 Fig 11 Brake Lines Two Wheel Drive Models ...

Page 205: ...RES 145 IN 16 125 IN 14 100 IN 11 170 IN 19 C SCREW RIGHT BRAKE A TUBE A RIGHT BRAKE TUBE C BRAKE HOSE BRAKE VALVE TUBE TO FRONT BRAKE HOSE VALVE VIEW IN DIRECTION OF ARROW B ASSEMBLY 8905 55 Fig 12 Brake Lines Four Wheel Drive Models ...

Page 206: ...with tool C 3478 A or an equivalent tubing cutter 2 Ream cut edges of tubing to ensure proper flare 3 Install replacement tube nut on section of tube to be repaired 4 Insert tube in flaring tool Center tube in area between vertical posts 5 Place gauge form A over the end of the tube Fig 13 6 Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diamete...

Page 207: ...manifold Power assist is produced by a combination of vac uum and atmospheric pressure to boost brake assist The power brake booster is not a repairable component The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred AD models with the Cummins diesel engine are equipped with a dual diaphragm power brake booster A separate vacuum pump assembly supplies the va...

Page 208: ...mounting studs fin ger tight 4 Install booster push rod on brake pedal pin and secure the rod with a new retaining clip 5 Tighten booster locknuts to 25 N t h 220 in lbs torque 6 Install master cylinder on booster Then install and tighten cylinder mounting nuts to 19 23 Nnn 170 200 in lbs torque 7 Connect vacuum hose to booster check valve BRAKE PEDAL REMOVAL 1 Disconnect booster push rod from ped...

Page 209: ...ed to the pump through an oil line at the underside of the pump housing The complete assembly must be removed in order to service either pump However the power steering pump can removed and serviced separately when necessary VACUUM PUMP SERVICEABILITY The vacuum pump is not a serviceable component If diagnosis indicates a pump malfunction the pump must be replaced as an assembly Do not disassemble...

Page 210: ...ted 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 5 to 25 inches vacuum If vacuum is consistently below 8 5 inches problem is with vacuum hoses or pump component If output is within specified limits con tinue testing 3 Check booster operation as described in diagno sis sec...

Page 211: ...ngage pump shaft from coupling if necessary 3 Inspect adapter O ring Fig 9 Replace O ring if cut or torn PUMP ASSEMBLY SOTTOM INIOAiD ADAPTER BRACKET NUT J9105 97 Fig 6 Adapter And Pump Mounting Fastener Location Fig 7 Removing Pump Assembly Upper Mounting Bolt 4 Lubricate adapter O ring with engine oil 5 Note position of drive slots in coupling Then rotate drive gear to align tangs on vacuum pump...

Page 212: ...g 10 Aligning Pump Shaft Drive Tangs PUMP ADAPTER REPLACEMENT 1 Remove coupling from adapter Fig 11 2 Remove remaining adapter attaching nuts and remove adapter from steering pump Fig 12 3 If steering pump will be serviced remove spacer from each inboard mounting stud on pump Fig 12 Fig 11 Removing Installing Pump Drive Coupling Fig 12 Steering Pump Mounting Stud Spacer Locations ...

Page 213: ... steering pump lines Start en gine and slowly turn steering wheel left and right to circulate fluid and purge air from system 13 Stop engine and top off power steering reser voir fluid level 14 Start engine and check brake and steering op eration Verify that power brake booster is providing vacuum assist and firm brake pedal is obtained Then verify that steering action is correct Do this before mo...

Page 214: ...9 General Information 27 Rotor Inspection and Service 34 Rotor Installation 35 Rotor Removal 34 SHIELD RK72 Fig 2 Chrysler Disc Brake Caliper Mounting Front View The outboard brake shoe has flanges that locate and position the shoe on the caliper fingers Fig 3 Braking force on this shoe is taken by the caliper The inboard shoe is held in position by the adapter and reacts directly on the adapter T...

Page 215: ...RK48 ...

Page 216: ... condition of the rotor brakeshoe lining caliper and brake hoses Front wheel bearing adjustment and condition can also be checked at this time The bearings should be repacked and adjusted if necessary Brakeshoes With the caliper and brakeshoes on the vehicle check running clearance between the rotor and brakeshoes The shoe lining should either be in very light contact with the rotor or have a maxi...

Page 217: ...ring from caliper adapter Fig 7 Removing Outboard Brakeshoe Fig 8 Removing Installing Inboard Brakeshoe CLEANING AND INSPECTION Replace bonded disc brakeshoes if the lining is worn to a thickness of 4 mm 3 16 in or less Re place riveted shoes if the lining is worn to within 1 5 mm 1 16 in of the rivet heads If shoe replacement is necessary replace the shoes on both sides at the same time Do not re...

Page 218: ...liper If shoe is difficult to install use C clamp to seat shoe Fig 11 OUTBOARD SHOE MACHINED Fig 9 Outboard Brakeshoe Positioned On Caliper Finger 4 Lubricate slide surfaces of caliper mounting adapter and machined ways on caliper with Mopar high temperature or multi mileage grease 5 Install O ring in adapter if removed 6 Carefully install caliper over rotor and into adapter Do not displace or dam...

Page 219: ...h wood pencil or plastic tool Fig 14 Do not use metal tools as they could scratch piston bore CLEANING AND INSPECTION Clean the caliper components Fig 15 with Mopar brake cleaner fresh brake fluid or denatured alcohol only Do not use gasoline kerosene thinner or any similar type of solvent These products can leave a residue that is damaging to pistons and seals Dry the caliper and piston with comp...

Page 220: ...boot on caliper piston Seat boot in piston groove 4 Start caliper piston in bore with a rotating mo tion When piston is started in seal push piston only part way into bore Fig 18 Maintain uniform pres sure on piston to avoid cocking it in bore Fig 17 Installing Caliper Piston Seal Fig 18 Installing Caliper Piston 5 Press caliper piston to bottom of bore and seat piston dust boot with Installer C 4...

Page 221: ...her and outer wheel bearing 5 Remove rotor from spindle 6 Remove rotor shield and seal if either is to be serviced ROTOR INSPECTION AND SERVICE rotor condition The rotor braking surfaces should not be refinished unless actually necessary Light surface rust and scale can be removed in a lathe equipped with dual sanding discs Rotor surfaces can be restored by machining in a disc brake lathe if surfa...

Page 222: ... ROTOR REFINISHING Rotor braking surfaces can be refinished by sand ing and or machining in a disc brake lathe The lathe must be capable of machining both rotor surfaces si multaneously with dual cutter heads Fig 22 A brake lathe capable of machining only one side at a time will produce a tapered rotor The disc brake lathe should also be equipped with a grinder attachment or dual sanding discs for...

Page 223: ...ck on bearing adjusting nut Align lock slots with cotter pin hole and secure nut and lock with new cotter pin 8 Clean grease cap Then coat interior of cap with wheel bearing grease 9 Install caliper wheel and tire assembly and lower vehicle 10 Check and adjust master cylinder fluid level 11 Apply brakes several times to seat brake shoes Be sure to obtain firm pedal before moving ve hicle ...

Page 224: ...ature of caliper operation is that the caliper is free to move laterally on the adapter slide surfaces Fig 3 Fig 1 Bendix Disc Brake Caliper page General Service Information 37 Rotor Inspection and Service 43 Rotor Installation 45 Rotor Removal 45 Fig 2 Caliper Mounting Adapter Attachment At brake application fluid pressure is exerted equally against the caliper piston and all surfaces of the cali...

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Page 226: ...ce is still ex cessive either the shoes are severely worn or the cal iper piston could be binding in the bore Hoses And Adapter Inspect condition of the brake lines and hoses Re place either front hose if cut torn or the reinforcing fabric is visible Check condition of the metal brake lines Replace any line that is badly rusted leaking or damaged in any way Clean and lubricate the adapter slide su...

Page 227: ...TION 1 Install anti rattle spring on inboard brakeshoe and install shoe in adapter Be sure spring remains in place and is positioned as shown Fig 9 Loop portion of spring should face away from the rotor BRASS ROD Fig 7 Removing Caliper Support Key And Spring Fig 8 Removing Installing Outboard Brakeshoe 2 Install outboard shoe in caliper Free play should not exist between shoe retaining flanges and...

Page 228: ... and lower vehi cle 10 Top off master cylinder fluid level 11 Pump brake pedal to seat shoes and restore normal pedal height Do not move vehicle until firm pedal is obtained CALIPER Fig 11 Caliper Installation CALIPER Fig 12 Installing Support Key And Spring CALIPER OVERHAUL CALIPER REMOVAL 1 Raise vehicle and support on hoist or jack stands 2 Remove wheel and tire assemblies 3 Clean brake hose an...

Page 229: ...ton surface by sanding Replace the piston if nec essary Very light scratches or corrosion in the piston bore can usually be cleaned up with a fiber brush or by polishing with a honing tool or crocus cloth How ever the caliper should be replaced if the bore is se verely corroded scored or if honing and polishing would increase bore diameter by more than 0 050 mm 0 002 in Dark brown or black stains ...

Page 230: ...d cocking piston Fig 16 10 Seat dust boot with suitable size installer tool if necessary CALIPER INSTALLATION 1 Install brakeshoes in caliper and adapter Fig 16 Installing Caliper Piston 2 Connect brake hose to brake line on frame bracket Tighten hose fitting to 13 20 N m 115 175 in lbs torque 3 Connect brake hose to caliper Use new seal washers when connecting fitting to caliper Do not tighten ho...

Page 231: ... shudder Measure rotor thickness at 6 to 12 points around the rotor face Fig 18 Position the micrometer ap proximately 25 4 mm 1 in from the rotor outer cir cumference for each measurement Figs 17 and 19 Thickness should not vary by more than 0 025 mm 0 001 in from point to point on the rotor Refinish or replace the rotor if necessary ROTOR RUNOUT Check rotor lateral runout with Dial Indicator C 3...

Page 232: ...move outer lock nut lock ring inner adjusting nut and outer bearing 11 Remove hub and rotor from spindle Fig 20 Removing Drive Flange Snap Ring 12 Remove seal and inner bearing from hub if bearing or seal requires service 13 If wheel bearing races require service remove them with suitable remover tools or with brass drift 14 Clean rotor and hub and wheel bearings in solvent ROTOR INSTALLATION 1 Re...

Page 233: ... 62 Fig 1 Eleven Inch Drum Brake Assembly BRAKE DRUM REMOVAL 1 Raise and support vehicle 2 Remove wheel and tire 3 Remove clip nuts securing brake drum to wheel studs 4 If drum is difficult to remove retract brake shoes as follows a Remove rear plug from access hole in support plate b Insert a thin screwdriver into access hole and push self adjusting lever away from adjuster screw star wheel c Ins...

Page 234: ...y Re place the assembly if the star wheel threads are damaged or the components are severely rusted or corroded Discard the brake springs and retainer components if worn distorted or collapsed Also replace the springs if a brake drag condition had occurred Over heating will distort and weaken the springs Inspect the brakeshoe contact surfaces on the sup port plate Fig 5 Remove light rust and scale...

Page 235: ...eed rates can produce taper and sur face variation Final finish cuts of 0 025 to 0 038 mm 0 001 to 0 0015 in are recommended and will gen erally provide the best surface finish Be sure the drum is securely mounted in the lathe before machining operations A damper strap should always be used around the drum to reduce vibration and avoid chatter marks BRAKE DRUM REFINISH LIMITS The maximum allowable...

Page 236: ...ng brake cable to lever on sec ondary shoe and install brakeshoes on support plate 8 Adjust brakeshoes to drum with brake gauge 9 Install brake drum and wheel and tire 10 Bleed brake system WHEEL CYLINDER REMOVAL 1 Raise vehicle and remove wheel and brake drum 2 Disconnect wheel cylinder brakeline 3 Remove brakeshoe return springs and move shoes out of engagement with cylinder push rods 4 Remove c...

Page 237: ...inder mounting surface of support plate 2 Connect brake line to cylinder Mount cylinder on support plate and install cylinder attaching bolts 3 Install wheel brake components 4 Install brake drum and wheel and bleed brakes DRUM BRAKES TWELVE INCH INDEX page Brake Drum Installation 54 Brake Drum Removal 52 Brake Drum Service 54 Brake Shoe Installation 53 Brakeshoe Removal 52 Cleaning and Inspection...

Page 238: ...NG ANTI RATTLE SPRING FLAT WASHER ANCHOR BOLT WHEEL CYLINDER BOLTS ADJUSTING HOLE COVER ANCHOR BOLT NUT SHOE HOLD DOWN PIN BACKING PLATE AUTOMATIC ADJUSTER CABLE ADJUSTER LEVER PIVOT PIN SECONDARY SHOE PARKING BRAKE LEVER ADJUSTER LEVER RETURN SPRING AUTOMATIC ADJUSTER LEVER RN326A Fig 1 Twelve Inch Drum Brake Assembly ...

Page 239: ...nhook adjuster lever from adjuster cable as sembly Fig 1 4 Remove shoe to shoe upper spring Fig 3 5 Remove shoe holddown springs Fig 4 6 Disconnect parking brake cable from parking brake lever 7 Remove both brakeshoes shoe to shoe lower spring and adjuster nut as assembly Fig 5 8 If support plate or wheel cylinder are to be ser viced remove anchor bolt and nut that attaches parking brake lever to ...

Page 240: ... anchor bolt and nut Fig 1 2 Coat contact pads on support plate Fig 6 with Mopar high temperature grease or equivalent 3 If both sets of brakeshoes were removed verify that adjusting nuts are installed on correct side of vehicle Pivot screw and adjusting nut have left hand threads on left side brake assembly and right hand threads on right side assembly 4 Lubricate and assemble adjusting nut and p...

Page 241: ...n oversize Always replace the drum if machining would cause drum diameter to exceed indicated size limit BRAKE DRUM RUNOUT Measure drum diameter and runout with an accu rate gauge The most accurate method of measure ment involves mounting the drum in a brake lathe and checking variation and runout with a dial indi cator Variations in drum diameter should not exceed 0 076 mm 0 003 in Drum runout sh...

Page 242: ...piston cup and piston 4 Install boots on each end of cylinder and insert push rods in boots 5 Install cylinder bleed screw WHEEL CYLINDER INSTALLATION 1 Start brakeline into cylinder 2 Position cylinder on support plate and install cylinder attaching bolts 3 Tighten brakeline fitting and cylinder attach ing bolts 4 Install anchor pin bushing cam plate adjuster cable parking brake lever spring wash...

Page 243: ... guides and retaining clips 10 Disconnect cable from equalizer and ratio le ver 11 Remove cable REAR CABLE INSTALLATION 1 Insert cable through support plate hole and seat cable 2 Connect cable to lever on secondary brakeshoe 3 Install brakeshoes parking brake strut and spring shoe return and holddown springs and self adjuster components 4 Install cable in cable guide and install cable re taining c...

Page 244: ... BRAKES 5 57 PAGE 1 OF 2 RR05E103 ...

Page 245: ...i i8 BRAKES CABLE INTERMEDIATE BRACKET BOLT VIEW E Fig 2 Parking Brake Cable Attachment ...

Page 246: ...sor located in the rear axle housing converts differential rotating speed into elec tronic signals The signals are transmitted to the electronic brake control module for processing The control unit determines rate of deceleration and wheel slip from these signals SYSTEM COMPONENTS Basic system components include an electronic brake control module a hydraulic pressure control valve a speed sensor a...

Page 247: ...he sensor is mounted at the top of the rear axle housing directly over the gear type exiter ring Fig 1 The exciter ring is pressed onto the differential case next to the ring gear The exciter ring is the sensor trigger mechanism As the ring rotates the teeth on the ring will inter rupt the magnetic field around the sensor pole The rate of interruption is converted into speed signals which are tran...

Page 248: ...to the isola tor valve solenoid which closes the valve Fig 6 Closing the valve prevents further fluid flow to the rear wheel cylinders This action isolates the rear brakes from the master cylinder The net effect is to decrease rear brake apply pressure to the point where the wheels will continue to rotate and not lock Additional Pressure Relief During Antilock Mode Braking The dump valve and accum...

Page 249: ...test feature The self test feature is activated whenever the ignition switch is turned to Accessory or Run position If a system fault is detected the control module il luminates the antilock light and stores the fault code in memory Fault codes are retained in memory even after turning the ignition switch to Off position FAULT CODES WITH TYPE II CONTROL MODULE The microprocessor in the electronic ...

Page 250: ...n speed exceeds 40 mph 12 Not used 13 Electronic control module phase lock loop failure 14 Electronic control module program check failure 15 Electronic control module RAM failure J9005 101 Fig 8 RWAL System Fault Codes ANTILOCK COMPONENT SERVICE GENERAL SERVICE INFORMATION The rear wheel antilock RWAL components are serviced as assemblies only The module hydraulic control valve speed sensor and e...

Page 251: ...wheel if both com ponents are out of tolerance SPEED SENSOR REPLACEMENT SENSOR REMOVAL 1 Raise vehicle on hoist 2 Remove bolt securing sensor to differential housing 3 Remove sensor shield and sensor from differen tial housing 4 Disconnect sensor wiring and remove sensor SENSOR INSTALLATION 1 Connect wires to sensor Be sure seal is se curely in place between sensor and wiring con nector 2 Install ...

Page 252: ...ti Rattle Spring Screw 25 N m 200 in lbs Caliper Retainer Screw keylock type 20 N m 15 ft lbs Master Cylinder Mounting Nuts 19 26 N m 170 230 in lbs RWAL Valve Bolts Nuts 22 34 Nrn 16 25 ft lbs Rear Brake Support Plate Bolts Nuts 7 16 101 N m 75 ft lbs 1 2 115 N m 85 ft lbs Rear Brake Support Plate Retainer Nut 8 3 8 axle 44 N m 33 ft lbs 9 1 4 axle 47 N m 35 ft lbs model 60 70 axle 115 N m 85 ft ...

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Page 254: ...MPONENTS The hydraulic linkage consists of a remote reser voir clutch master cylinder clutch slave cylinder and interconnecting fluid lines The clutch master cylinder is connected to the clutch pedal and the slave cylinder is connected to the clutch release fork The master cylinder is mounted on the drivers side of the dash panel adja cent to the brake master cylinder page CLUTCH SERVICE 11 CLUTCH...

Page 255: ...s clutch disc sticking and poor release Water and steam vapors can be absorbed by the clutch facing material If the vehicle sits idle for long page Inspection and Diagnosis Charts 5 periods after water contamination the force exerted by the pressure plate may cause the disc to bond it self to the flywheel or pressure plate Frequently the only remedy for the above condi tion is component replacemen...

Page 256: ... the bore Fig 3 Repeat the measurement at least twice for accuracy 9 Subtract each reading from the one 180 oppo site to determine magnitude and direction of runout Refer to Figure 3 and following example Bore runout example 0 000 0 007 0 007 in 0 002 0 010 0 012 in 0 004 0 005 0 009 in 0 001 0 001 0 002 in 0 002 inch In the above example the largest difference is 0 012 in and is called the total ...

Page 257: ...gs shown in Figure 6 If the low read ing was minus 0 004 in and the highest reading was plus 0 009 in total runout is actually 0 013 inch 5 Total allowable face runout is 0 010 inch If runout exceeds this figure runout will have to be corrected Refer to Correcting Clutch Housing Face Runout CORRECTING CLUTCH HOUSING FACE RUNOUT Housing face runout on gas or diesel engines can be corrected by insta...

Page 258: ...lutch housings are other causes of clutch failure Improper seating will produce misalignment and subsequent clutch 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 standard or low quality parts can also lead to problems and wear Use the recom mended f...

Page 259: ...t warped broken cracked Do not tamper with fac tory clutch spring setting Clutch problems will result 11 Check condition of clutch cover Replace clutch cover if plate surface is deeply scored warped worn or cracked Be sure cover is correct size and properly aligned on disc and flywheel 12 Inspect clutch housing Be sure alignment dowels are in position and bolts are tight Replace housing if cracked...

Page 260: ...nd transmission front bearing retainer if sleeve surface is damaged 4 Flywheel height incorrect Flywheel surface improperly machined Too much stock removed or surface is tapered Replace flywheel 5 Wrong disc or pressure plate installed Incorrect parts order or model number Replace with correct parts Compare old and new parts before installation 6 Clutch disc cover and or diaphragm spring warped di...

Page 261: ...in pockets over rivet heads in clutch disc Occurs as clutch cools down after use Drill 1 16 inch diameter hole through rivets and scuff sand disc facing with 180J 9r t paper 5 Clutch disc too thick Wrong disc installed Replace disc 6 Pilot bushing seized or loose a Bushing cocked during installation b Bushing defective c Bushing not lubricated d Clutch misalignment a b c d Lubricate and install ne...

Page 262: ...orroded a Replace both cylinders as assembly and reservoir 4 N o fault found with clutch components a Problem actually related to suspension or driveline component b Engine related problem a Further diagnosis required Check engine transmission mounts propeller shafts and U joints tires suspension attaching parts and other driveline components as needed b Check EFI and igniton systems 5 Partial eng...

Page 263: ...pecified torque Replace any clutch bolts that are damaged 4 Components appear overheated Hub of disc cracked or torsion damper springs are distorted or broken Frequent high load full throttle operation Replace parts as needed Alert driver to condition causes 5 Contact surface of release bearing damaged a Clutch cover incorrect or release fingers are bent or distorted causing damage b Release beari...

Page 264: ...r Fig 2 6 Insert clutch alignment tool in clutch disc and into pilot bushing Tool will hold disc 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 3 This relieves cover spring tension evenly to avoid warping 8 Remove cover bolts completely and remove cover disc and alignment tool CLUTCH COVER AN...

Page 265: ...n diameter bolts to 23 N m 17 ft lbs Tighten 3 8 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 contact surfaces and release lever pivot stud Fig 6 CLUTCH HOUSING COAT RELEASE FORK PIVOT BALL STUD WITH HIGH TEMP GREASE RELEASE FORK HIGH TEMP GREASE LUBE POINTS...

Page 266: ...Tighten bolt attaching strut to clutch housing first and engine bolt last 4 Install transmission and transfer case if equipped Refer to procedure in Group 21 RELEASE BEARING REPLACEMENT 1 Remove transmission 2 On models with gas engine and new style re lease fork remove clutch housing for access to re lease fork pivot stud and release bearing retainer springs 3 Disconnect release bearing from rele...

Page 267: ...h housing transmission and trans fer case on 4 wheel drive models CLUTCH LINKAGE SERVICE The clutch master cylinder remote reservoir slave cylinder and connecting lines are all ser viced as an assembly These components cannot be serviced separately The linkage cylinders and connecting lines are sealed units They are prefilled with fluid during manufacture and must not be disassembled nor disconnec...

Page 268: ...d reservoir on dash panel and install reservoir screws Tighten screws to 5 N m 40 in lbs torque 6 Install reservoir mounting bracket on dash panel if removed 7 Install replacement bushing on clutch pedal pin if necessary 8 Install clutch master cylinder push rod on clutch pedal pin Secure rod with wave washer flat washer and retainer ring 9 On diesel models disconnect clutch interlock start switch...

Page 269: ...IR PEDAL SHIFT CLUTCH FLUID LINE DIESEL ENGINE CLUTCH FLUID LINE GAS ENGINE SLAVE CYLINDER O I e HI O x CLUTCH HOUSING WITH GAS ENGINE CLUTCH HOUSING SLAVE CYLINDER WITH DIESEL ENGINE SHIELD J9206 1 Fig 14 Clutch Linkage And Pedal Components ...

Page 270: ...diesel flywheels Inspect the teeth on the starter ring gear If the teeth are worn or damaged the flywheel should be replaced as an assembly This is the recom mended and preferred method of repair In cases where a new flywheel is not readily avail able a replacement ring gear can be installed How ever the following precautions must be observed to avoid damaging the flywheel and replacement gear a M...

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Page 272: ...heating The cooling system also provides a means of heat ing the passenger compartment and cooling the auto matic transmission fluid if equipped The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system An optional factory installed maximum duty cool ing package is available on most models This pack age will provide additional cooling capacity f...

Page 273: ...ith water cooled intake manifolds are shown in figure 1 Coolant flow circuits for 5 9L V 8 Gas engines with water cooled intake manifolds are shown in fig ure 2 COOLING SYSTEM COMPONENTS DIESEL ENGINE Coolant flow circuits for 5 9L diesel engines with water cooled intake manifolds are shown in figure 3 The cooling system Fig 3 consists of a cross flow radiator engine driven cooling fan thermal vis...

Page 274: ...M 7 3 Fig 3 Diesel Engine Cooling System Typical 1 Coolant Flow from Cylinder Block 2 Coolant to Thermostat Housing Fig 4 Cylinder Block Coolant Routing Diesel Engine F i g 6 coolant Flow at Thermostat Diesel Engine ...

Page 275: ...s and or on a steep Loss grade Coolant Loss Hot Vehicle Not Engine Heat Damage Hot Carpet Seat Hot Catalytic Converter Smoke Burnt Odor Hot Engine Crackling Noise Hot Smell Severe Local Hot Spots Coolant Color Coolant Reserve Bottle Level Changes Coolant Not Returning To Radiator Improper refilling procedures can result in trapped air in the system Subsequent operation of the pressure cap and cool...

Page 276: ... not an indicator light switch 4 WARNING DO NOT REMOVE THE RADIATOR CAP OF A HOT PRESSURIZED ENGINE SERIOUS INJURY CAN RESULT FROM SCALDING COOLANT Inspect coolant level in the coolant reserve tank and radiator Inspect system for leaks 5 Inspect heater door controls Refer to Group 24 Heating and Air Conditioning TO TOP AMBIENT High Gauge Reading Hot Weather Heavy Load 1 Compare gauge reading to Hi...

Page 277: ...Coolant level low in radiator and coolant reserve tank 1 a Fill cooling system and vent trapped air b Inspect for leaks Repair as necessary c Ensure that pressure cap is completely shut and seals d If level is low in radiator but normal in the coolant reserve tank check the filler cap to coolant reserve bottle connection and pressure cap seal 2 Test coolant freeze point 2 Adjust coolant to 50 50 m...

Page 278: ...able Block Leak Tester cause the thermostat to open late b Check for coolant in engine oil c Inspect for white steam from exhaust system 4 Water pump impeller loose on shaft Loose accessory drive belt 4 Repair or replace as necessary 5 Air leak on the suction side of the water pump allows air to build 5 Find leak and repair up in cooling system causing thermostat to open late WARNING LIGHT GLOWS A...

Page 279: ...s found in system clean and flush system before replacing with 50 50 mixture of ethylene glycol and water COOLING SYSTEM HOSES COLLAPSE ON COOLDOWN 1 Inspect pressure cap vent valve 1 a Gasket swell can prevent valve from opening b Replace pressure cap 2 Coolant reserve tank hose plugged or kinked 2 Repair as necessary 3 Inside of pressure cap plugged 3 Clean cap or replace if necessary COOLING SY...

Page 280: ...liary heater vacuum water valve The valve should be open except when the climate controls are OFF or in the MAX A C mode 2 Is coolant level low 2 Fill cooling system and inspect for leaks Repair as necessary 3 Check On Board Diagnostics Is code 17 set in memory 3 If YES replace thermostat If NO inspect the auxiliary heater vacuum water valve The valve should be open except when the climate control...

Page 281: ...uge reading Is a high temperature reading indi cated 2 Gauge reading at H without signs of boiling 3 Low coolant level in radiator and coolant reserve tank MAXIMUM HOT WEATHER HEAVY LOAD MAXIMUM UP TO TOP AMBIENT High Gauge Reading Hot Weather Heavy Load 1 Compare gauge reading to High Gauge Reading Illustration above 2 Inspect for grounded gauge sending unit or circuit Refer to Group 8 Electrical...

Page 282: ...olant level low in radiator and coolant reserve tank 1 a Fill cooling system and vent trapped air b Inspect for leaks Repair as necessary c Ensure that pressure cap is completely shut and seals d If level is low in radiator but normal in the coolant reserve tank check the filler cap to coolant reserve bottle connection and pressure cap seal 2 Test coolant freeze point 2 Adjust coolant to 50 50 mix...

Page 283: ...stem will cause the thermostat to open late 3 a Test for leaking cylinder gasket leak with a commercially available Block Leak Tester b Check for coolant in enaine oil c Inspect for white steamfromexhaust system 4 Water pump impeller loose on shaft Loose accessory drive belt 4 Repair or replace as necessary 5 Air leak on the suction side of the water pump allows air to build up in cooling system c...

Page 284: ...ON COOLDOWN 1 Inspect pressure cap vent valve 1 a Gasket swell can prevent valve from opening b Replace pressure cap 2 Coolant reserve tank hose plugged or kinked 2 Repair as necessary 3 Inside of pressure cap plugged 3 Clean cap or replace if necessary COOLING SYSTEM SUSPECTED AS CAUSE OF INADE QUATE AIR CONDITIONING SYSTEM PERFORMANCE 1 Inspect for plugged radiator and or condenser D Clean with ...

Page 285: ...auxiliary heater vacuum water valve The valve should be open except when the climate controls are OFF or in the MAX A C mode 2 Is coolant level low 2 Fill cooling system and inspect for leaks Repair as neces sary 3 Thermostat failed in open position 3 If YES replace thermostat If NO inspect the auxiliary heater vacuum water valve The valve should be open except when the climate controls are OFF or...

Page 286: ...ivets that could have resulted from excessive vibration Replace fan if any of these conditions are found Also check condi tion of the thermal viscous fan drive Refer to Vis cous Fan Drive in this group 1 Disconnect negative battery cable from battery 2 Drain cooling system Refer to Draining Cool ing System in this group Do not waste reusable coolant If solution is clean drain coolant into a clean ...

Page 287: ...ove accessory drive belt as follows The drive belt is equipped with a spring loaded automatic tensioner Figs 4 or 5 3 9L 5 2L 5 9L LDC Gas Engines Relax the tension from the belt by rotating the tensioner clockwise as viewed from front Fig 4 When all belt tension has been relaxed remove accessory drive belt 5 9L HDC Gas Engines Relax the tension from the belt by rotating the tensioner counterclock...

Page 288: ...oose or rough turning bearing Also inspect ther mal fan drive Impeller rubs either the pump body or timing chain case cover INSTALLATION 1 Clean gasket mating surfaces 2 Using a new gasket install water pump to en gine as follows Guide water pump nipple into bypass hose as pump is being installed Install water pump bolts Fig 8 Tighten water pump mounting bolts to 40 N m 30 ft lbs torque 3 Spin wat...

Page 289: ...ill cooling system Refer to Refilling Cooling System in this group 14 Connect negative battery cable 15 Start and warm the engine Check for leaks WATER PUMPS 5 9L DIESEL The diesel engine water pump draws coolant from radiator outlet and circulates it through engine heater core and back to radiator inlet The crank shaft pulley drives the water pump via a serpentine drive belt Fig 12 An automatic b...

Page 290: ... refer to Testing Cool ing System for Leaks in this group FAN BLADE ASSEMBLY THREADED NUT WATER PUMP PULLEY PULLEY BOLTS WATER PUMP THREADED SHAFT WATER PUMP HUB VISCOUS FAN DRIVE CRANKSHAFT PULLEY J9307 32 Fig 15 Water Pump Bypass Hose Typical WITHOUT AIR CONDITIONING A C RE10WAL 1 Partially drain cooling system Refer to Drain ing Cooling System in this group Do not waste reusable coolant If the ...

Page 291: ... hose clamp at radiator Special Clamp Tool number 6094 Fig 16 may be used to remove the constant tension clamps Remove hose at radiator 4 Disconnect throttle cable from clip at radiator fan shroud 5 Unplug wiring harness from A C compressor 6 Remove the air cleaner assembly 7 Remove accessory drive belt Refer to Belt Re moval Installation in the Engine Accessory Drive Belt section of this group 8 ...

Page 292: ...ine bolts Figs 22 or 23 14 Lift and position generator and A C compres sor along with their common mounting bracket to gain access to bypass hose A block of wood may be Fig 21 Coolant Return Tube 5 9L HDC Gas Engine Fig 22 Bracket Bolts 3 9U5 2U5 9L LDC Gas Engine used to hold assembly in position 15 Loosen and position both hose clamps to the center of bypass hose Special Clamp Tool number 6094 F...

Page 293: ...elt the belt must be routed correctly If not the engine may overheat due to the water pump ro tating in the wrong direction Refer to Belt Schemat ics in the Engine Accessory Drive Belt section of this group for correct belt routing The correct belt with the correct length must be used 11 Install air cleaner assembly BELT TENSIONER DOWEL PIN J9307 63 Fig 24 Tensioner Dowel Pin 5 9L HDC Gas Engine F...

Page 294: ...rature An arrow plus the word U P is stamped on the front flange next to the air bleed The words TO RAD are stamped on one arm of the thermostat They indicate the proper installed position TESTING ALL ENGINES The computer On Board Diagnostics include a mode for a thermostat open too soon failure condi tion The Malfunction Indicator Light formerly called the Check Engine Light will not be lit by an...

Page 295: ...har ness located near rear of generator d Remove generator Position generator to gain access for thermostat gasket removal 4 Remove upper radiator hose clamp Special Clamp Tool number 6094 Fig 29 may be used to re move the constant tension clamps Remove upper ra diator hose at thermostat housing 5 Position the wiring harness behind the ther mostat housing to gain access to thermostat hous ing 6 Re...

Page 296: ...pump inlet through the by pass Fig 32 Fig 32 Thermostat Operation 5 9L Diesel When coolant temperature reaches 83 C 181 F the thermostat begins to open allowing coolant flow to the radiator This provides quick engine warm up and overall temperature control The thermostat is designed to provide a minimum engine operating temperature of 83 C 181 F and to be fully open for maximum coolant flow at app...

Page 297: ...gh the radiator and heater core fins The cool ant also removes heat from the automatic transmis sion fluid in vehicles equipped with an automatic transmission COOLANT PERFORMANCE The required ethylene glycol antifreeze and water mixture depends upon climate and vehicle operating conditions The coolant performance of various mix tures follows Pure Water Water can absorb more heat than a mixture of ...

Page 298: ...tank with a 50 50 mixture of ethylene glycol anti freeze containing Alugard 340 2 and water Re move the radiator cap only for testing or when refilling the system after service Removing cap un necessarily can cause loss of coolant and allow air to enter system This produces corrosion COOLANT LEVEL CHECK SERVICE The cooling system is closed and designed to main tain coolant level to the top of the ...

Page 299: ...VERSE FLUSHING CLEMMING Drain cooling system and refill with water Run engine with radiator cap installed until upper radia tor hose is hot Stop engine and drain water from system If water is dirty fill system with water run engine and drain system Repeat until water drains clean REVERSE FLUSHING Reverse flushing of cooling system is the forcing of water through the cooling system This is done usi...

Page 300: ...not obstructed Inspect cams on outside of filler neck If cams are bent seating of pressure cap valve and tester seal will be affected Bent cams can be reformed if done carefully Attach pressure tester 7700 or an equiva lent to radiator filler neck Fig 39 Operate tester pump to apply 103 4 kPa 15 psi pressure to system If hoses enlarge excessively or Remove lead away hose flushing gun water sup ply...

Page 301: ...ermostat opens Attach a Pressure Tester to filler neck If pressure builds up quickly it indicates a combustion leak exists This is usually the result of a cylinder head gasket leak or crack in engine Re pair as necessary If there is not an immediate pressure increase pump the Pressure Tester Do this until indicated pressure is within system range of 110 kPa 16 psi Fluctuation of gauge pointer indi...

Page 302: ...roud is equipped with T shaped slots to attach the tank TANK INSTALLATION 1 Snap tank into fan shroud 2 Install overflow hose to tank RADIATOR PRESSURE CAP Radiators are equipped with a pressure cap which releases pressure at some point within a range of 97 124 kPa 14 18 psi The pressure relief point in pounds is engraved on top of cap The cooling system will operate at pressures slightly above at...

Page 303: ... A M S T O P B E ING P U S H E D INTO TANK A N D S Y S T E M P R E S S U R E D R O P S R E M O V E RADIATOR C A P C O M P L E T E L Y PRESSURE TESTING RADIATOR CAPS Remove cap from radiator Be sure that sealing surfaces are clean Moisten rubber gasket with water and install cap on pressure tester 7700 or an equiv alent Fig 43 Operate tester pump to bring pressure to 104 kPa 15 psi on gauge If pres...

Page 304: ... from clip at radiator fan shroud 4 Remove hose clamps and hoses from radiator Special Clamp Tool number 6094 Fig 44 may be used to remove the constant tension clamps 5 Remove coolant reserve overflow tank hose from radiator filler neck nipple 6 If equipped with an automatic transmission except diesel disconnect oil cooler hoses at radiator lower tank 7 Remove fan shroud mounting bolts clips and p...

Page 305: ...hose clamps 5 Position fan shroud on radiator flange Install retaining clips 6 Place heater controls in full heat position 7 Fill cooling system with coolant Refer to Refill ing Cooling System in this group 8 Operate engine until it reaches normal temper ature Check cooling system RADIATOR DRAINCOCK SERVICE The radiator draincock is replaceable Unscrew the draincock in a clockwise direction and re...

Page 306: ...ooling System and Testing Cooling System 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 a dirty or plugged inlet filter If none of these conditions are found the transmission and torque convertor may not require reconditioning Re fer to Group 21 for...

Page 307: ... T shaped slots Do not disconnect hose or drain coolant from tank 4 The thermal Viscous Fan Drive Fan Blade As sembly is attached threaded to water pump hub shaft Fig 54 Remove fan blade viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front Threads on viscous fan drive are RIGHT HAND A Snap On 36 MM Fan Wrench number SP346 from Snap On Cummins Die...

Page 308: ...t reserve overflow tank to fan shroud Snaps into position 6 Install throttle cable to fan shroud 7 Connect negative battery cable COOLING SYSTEM FAN DIESEL ENGINE REMOVAL 1 Disconnect negative battery cable from battery 2 Remove the fan shroud mounting bolts Posi tion fan shroud towards engine CAUTION Do not remove the fan puHey bolts This pulley is under spring tension 3 The thermal viscous fan d...

Page 309: ... reduced rpm regardless of engine speed Only when sufficient heat is present in the air will the viscous fan drive clutch engage This air flowing through ra diator core will cause a reaction to thermostatic spring coil Fan speed will then increase to provide necessary additional engine cooling MOUNTING NUT TO WATER PUMP Fig 56 Viscous Fan Drive CAUTION If viscous fan drive is replaced because of m...

Page 310: ...Fig 57 Disconnecting End of Thermostatic Fig 58 Testing Spring and Shaft Rotation Typical Spring Typical ...

Page 311: ...use the schematics on Belt Routing Label This label is located in the engine compartment BELT TENSION ALL ENGINES Correct accessory drive belt tension is required to be sure of optimum performance of belt driven en gine accessories If specified tension is not main tained belt slippage may cause engine overheating lack of power steering assist loss of air conditioning capacity reduced generator out...

Page 312: ...uced friction 2 Replace belt and clean pulleys 3 Driven component bearing failure 3 Replace faulty component bearing 4 Belt glazed and hardened from heat and excessive slippage 4 Replace belt GROOVE JUMPING BELT DOES NOT MAINTAIN CORRECT POSITION ON PULLEY 1 Belt tension either too high or too low 2 Pulley s not within design tolerance 1 Adjust belt tension 2 Replace pulley s 3 Foreign object s in...

Page 313: ...tion 4 Driven component bearing failure 4 Replace faulty component bearing 5 Belt glazed and hardened from 5 Replace belt 5 heat and excessive slippage GROOVE JUMPING 1 Belt tension either too 1 Replace tensioner BELT DOES NOT 5 1 high or too low Replace tensioner MAINTAIN CORRECT high or too low POSITION O N PULLEY 2 Incorrect belt 2 Replace belt 3 Pulley s not within design 3 Replace pulley s to...

Page 314: ...ing serpentine accessory drive belt belt must be routed correctly If not en gine may overheat due to water pump rotating in COOLING SYSTEM 7 43 AUTOMATIC TENSIONER J9307 56 Fig 4 Belt Routing 5 9L HDC Gas Engine Without A C POWER STEERING PUMP IS NOT BELT DRIVEN Fig 5 Belt Routing 5 9L Diesel With A C wrong direction Refer to Fig 2 for correct engine belt routing The correct belt with correct leng...

Page 315: ...p Fig 8 Belt Tensioner 5 9L HDC Gas Engine 1 Attach a socket wrench to pulley mounting bolt of automatic tensioner Fig 8 The threads on this bolt are left hand 2 Relax the tension from the belt by rotating the tensioner counterclockwise as viewed from front Fig 8 When all belt tension has been relaxed re move belt from tensioner pulley first and other pul leys last INSTALLATION CAUTION When instal...

Page 316: ...er pump pulley 2 Attach a 3 8 inch ratchet to tensioner 3 Rotate ratchet and belt tensioner counterclock wise Place belt over water pump pulley Let ten sioner rotate back into place Remove ratchet Be sure belt is properly seated on all pulleys AUTOMATIC BELT TENSIONER Drive belts on all engines are equipped with a spring loaded automatic belt tensioner Figs 10 11 or 12 This belt tensioner will be ...

Page 317: ...TENSIONER UNIT I S S E R V I C E D A S A N A S S E M B L Y EXCEPT F O R PULLEY TENSIONER MOUNTING NUT INDEXING ARROW INDEXING MARK J9207 17 Fig 13 indexing Marks 3 9L 5 2L 5 9L LDC Gas Engine 5 Remove pulley bolt Remove pulley from ten sioner INSTALLATION 1 Install pulley and pulley bolt to tensioner Tighten bolt to 61 Nnn 45 ft lbs 2 Install tensioner assembly to mounting bracket An indexing tab ...

Page 318: ...15 in tensioner mount ing bracket Tighten bolt to 41 N m 30 ft lbs torque 3 Install drive belt Refer to Belt Removal Instal lation in this group 5 9L DIESEL ENGINE REMOVAL 1 Remove accessory drive belt Refer to Belt Re moval Installation in this group 2 Remove tensioner mounting bolt Fig 12 and remove tensioner WARNING B E C A U S E O F HIGH S P R I N G P R E S S U R E D O NOT ATTEMPT TO D I S A S...

Page 319: ...l outlet with a grounded three wire extension cord WARNING DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE THE POWER CORD MUST B E SECURED IN ITS RE TAINING CLIPS AND ROUTED AWAY FROM EX HAUST MANIFOLDS AND MOVING PARTS REMOVAL 1 Disconnect negative battery cable from battery 2 Drain coolant from radiator and cylinder block 3 Remove pow r...

Page 320: ...9L RAMCHARGER 4WD 15 0 14 0 5 9L W150 W250 W350 4WD 15 5 14 7 DIESEL ALL MANUAL 16 0 15 1 DIESEL ALL AUTOMATIC 17 0 16 1 J9207 41 TORQUE D I S C M P f l O N TORQUE TORQUi Automatic Belt Tensioner Pulley Bolt 3 9l 2 5L 5 9LLDC Gas Engine 61 N m 45ft lbs Automatic Belt Tensioner Pulley Bolt 5 9L HDC Gas Engine 88 N m 65ft lbs Automatic Belt Tensioner to Mounting Bracket 3 9L 5 2L 5 9L IDC Gas Engine...

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Page 322: ...ing and Charging Systems oper ate with one another and therefore must be thor oughly tested as a complete system In order for the vehicle to start and charge properly it must have a battery that will perform to specifications The starter motor generator wiring and electronics also must perform within specifications Group 8A covers Start ing Fig 1 and Charging Fig 2 System diagnostic procedures The...

Page 323: ...be measured with a hydrometer A factory in stalled battery has a built in test indicator to help determine state of charge The factory installed bat tery is also nonrefillable water can not be added The battery is vented to release gases that are cre page General Information 2 Ignition Off Draw IOD 4 State of Charge Test Using Test Indicator 3 Test Indicator 3 ated when the battery is being charge...

Page 324: ...YELLOW OR BRIGHT COLOR W A R N I N G D O NOT ATTEMPT TO C H A R G E TEST OR A S S I S T B O O S T BATTERY W H E N Y E L L O W O R BRIGHT C O L O R I S VISIBLE P E R S O N A L INJURY M A Y O C C U R A yellow or bright color indicates water electro lyte level in battery is below the test indicator Fig 5 Water can not be added to a maintenance free battery The battery must be replaced A low electro l...

Page 325: ...use or circuit breaker refer to Group 8 Wiring Diagrams until test light is either OFF or DIMLY lit This will eliminate the higher amperage draw If test light is still bright after disconnecting each fuse and circuit breaker disconnect the wiring har ness from the generator Refer to Generator Testing in this group Do not disconnect the test light After higher amperage IOD has been corrected low am...

Page 326: ... INDUCTION AMPMETER CLAMP POSITIVE CLAMP NEGATIVE CLAMP J908A 12 Fig 8 Volt Ammeter Load Tester Connections 3 Rotate the load control knob Carbon pile rheo stat to apply a 300 amp load for 15 seconds then control knob to off Fig 9 This will remove the sur face charge from the battery Fig 7 Volt Amps Load Tester Typical 898A 10 Fig 9 Remove Surface Charge from Battery 4 Allow the battery to stabili...

Page 327: ...ble before charging battery to avoid damage to electrical systems Do not exceed 16 0 volts while charging battery Battery electrolyte will bubble inside of case while being charged properly If the electrolyte boils vio lently or is discharged from the vent holes while charging immediately reduce charging rate or turn off charger and evaluate battery condition Some battery chargers are equipped wit...

Page 328: ...roperly followed a good battery may be needlessly replaced 1 Measure voltage at battery posts with a volt meter accurate to 1 10 volt Fig 11 If below 10 volts then charge current will be low and it could take some time before it accepts a current in excess of a few milliamperes Such low current may not be detectable on ammeters built into many chargers 2 Connect charger leads Some chargers feature...

Page 329: ... N T CRANK PROCEED TO STARTER TEST PROCEDURES ON VEHICLE IN THIS GROUP LOAD TEST DISCHARGE BATTERY AT 300 AMPERES FOR 15 SECONDS ALLOW BATTERY TO RECOVER FOR 15 SECONDS CONNECT VOLTMETER AND AMPERE LOAD EQUAL TO 1 2 THE COLD CRANKING AMPERE RATING OF THE BATTERY FOR 15 SECONDS OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON NOTE ESTIMATE TEMPERATURE OF BATTERY REFER TO LOAD TEST VOLTAGE CHART VOLTAGE A...

Page 330: ...tion switch Testing information can be found in the following pages If the following components are working properly remove the starter motor and follow procedures in the Testing Section battery wiring switch solenoid relay park neutral position switch COLD CRANKING TEST 1 Battery must first pass load and voltage drop tests and be fully charged before proceeding Refer to Battery Test Procedures 2 ...

Page 331: ...ER ASSEMBLY FAULTY CIRCUIT FAULTY FAULTY STARTER ASSEMBLY PARK NEUTRAL FAULTY STARTER ASSEMBLY POSITION STARTER SOLENOID ENGINE FAULTY SWITCH FAULTY SEIZED AUTO TRANS STARTER FAULTY OR STARTER MISADJUSTED STARTER ASSEMBLY IMPROPERLY FAULTY MOUNTED STARTER RELAY REFER TO FAULTY APPROPRIATE GROUP AND SECTION OF THIS MANUAL FOR PROPER STARTER ASSEMBLY SERVICE AND TEST FAULTY PROCEDURES FOR THE COMPON...

Page 332: ... block Fig 6 6 Rotate and hold the ignition with key in the START position If voltage reads above 0 2 volt cor rect poor contact at ground cable attaching point Voltage reading still above 0 2 volt replace ground cable ENGINE J P GROUND BATTERY 898A 18 Fig 6 Test Ground Circuit Resistance 7 Connect positive voltmeter lead to starter mo tor housing Connect negative lead of voltmeter to battery nega...

Page 333: ...HUT UNLOCK RELAY RELAY RELAY D O W N RELAY Fig 8 Starter Relay 1 Replace the relay as required 2 Test relay operation IGNITION SWITCH TEST After testing starter solenoid and relay and they check out okay trouble is probably with ignition switch or its wiring Check all wiring for opens and shorts and connec tions for being loose or corroded BENCH TESTING STARTER SOLENOID Refer to Group 8B Battery S...

Page 334: ...n receptacles They should be properly installed and tight Repair or replace as required Inspect generator mounting bolts for tightness Re place or torque bolt as required refer to Torque Specifications Inspect generator drive belt condition and tension Tension or replace belt as required Refer to Belt Tension Specifications Inspect connection at generator B output It should be clean and tight Repa...

Page 335: ... post Tighten to 5 to 6 Nnn 45 to 75 in lbs 5 Connect negative cable to battery 6 Use DRB II Scan Tool to erase diagnostic trou ble code CURRENT OUTPUT TEST Current output test determines whether or not gen erator is capable of delivering its rated current out put PREPARATION 1 Before starting any tests make sure vehicle has a fully charged battery Test and procedures on how to check for a fully c...

Page 336: ...ified and generator output wire resistance is not excessive the generator should be replaced Refer to Group 8B Generator Service for information 2 After current output test is completed reduce engine speed turn off carbon pile and turn off igni tion switch 3 Disconnect negative cable from battery 4 Remove test ammeter voltmeter tachometer and carbon pile 5 Remove Jumper Wire Fig 2 6 Connect genera...

Page 337: ...N UNS OR CHAF rEADY LOW K3ING TEST GENERATOR OUTPUT WIRE RESISTANCE CHARGING RESISTANCE TOO HIGH CORRODED OR SHORTED CABLES OR HIGH RESISTANCE ACROSS FUSIBLE LINK RESISTANCE O K TEST GENERATOR CURRENT OUTPUT CURRENT OUTPUT O K REFER TO USING ON BOARD DIAGNOSTIC SYSTEM o CHAR ER GING GROUNDED GENERATOR FIELD WIRE FIELD TERMINAL OR CONNECTIONS 1 NO 1 ALTERf ISY MATOR WORN OR FRAYED DRIVE BELT REFER ...

Page 338: ...s follows 1 Lamp on for 2 seconds then turns off 2 Lamp flashes 4 times pauses and then flashes 1 3 Lamp pauses for 4 seconds flashes 4 times pauses and then flashes 7 times The two codes are 41 and 47 Any number of codes can be displayed maximum of 8 faults can be stored as long as they are in memory The lamp will flash until all of them including 55 are displayed 55 End of test CHARGING SYSTEM F...

Page 339: ...Fields 4 No of Poles 4 Brushes 4 Drive Reduction Gear Train Free Running Test Voltage 11 Amperage Draw 73 Amps Minimum Speed rpm 3601 rpm Solenoid Closing Voltage 7 5 Volts Cranking Amperage Draw Test 125 200 Amps Engine should be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw J938B 14 REDUCTION GEAR STARTER Manufacturer Nippondenso Engine Appli...

Page 340: ...ONS TYPE PART N U M B E R PULLEY G R O O V E S ENGINE RATING NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS NIPPONDENSO 53008647 7 ALL GASOLINE 90 AMPS NIPPONDENSO 53008651 7 ALL GASOLINE 120 AMPS NIPPONDENSO 5234374 8 DIESEL 120 AMPS J938B 28 ...

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Page 342: ...ages The battery is equipped with a test indicator Fig 1 that display colored balls to indicate battery state of charge Green Indicator Full charge Black Indicator Discharged Yellow Indicator Battery replacement required Fig 1 Maintenance Free Battery BATTERY VISUAL INSPECTION AND SERVICE 1 Make sure ignition switch is on OFF position and all battery feed accessories are OFF 2 Disconnect and remov...

Page 343: ... Care should be taken to ensure that solution does not enter vent holes 5 Inspect battery case and cover for cracks or leakage If cracks or leakage is present battery must be replaced 6 Inspect battery tray for damage caused by loss of acid from battery If acid damage is present it will J928B 30 Fig 5 Cleaning Battery Post 8 Clean inside surfaces of terminal clamps with a suitable battery terminal...

Page 344: ...g sure that battery is properly positioned on battery tray Fig 2 11 Install battery hold down clamp making sure that it is properly positioned on battery Tighten bolt to 12 N m 100 in lbs 12 Place felt oil washer onto Positive battery post 13 Connect cable clamps to battery post making sure top of clamp is flush with top of post Fig 7 14 Tighten clamp nut securely ...

Page 345: ...pinion gear into ring gear At the same time the solenoid contacts close causing starter motor to crank As soon as engine starts running clutch pin ion gear overruns to protect starter armature from damage due to excessive speed Once the engine starts running the ignition key switch should be im mediately returned to the run position to prevent ex cessive starter motor damage W A R N I N G A L W A ...

Page 346: ...noid wire from solenoid 4 Remove starter motor mounting bolts Figs 1 and 2 INSTALLATION 1 Install starter motor Tighten bolts to 68 N m 50 ft lbs 2 Attach solenoid wire Tighten solenoid nut to 6 N m 55 in lbs 3 Attach battery cable to starter motor Tighten cable nut to 10 N m 90 in lbs 4 Connect negative cable to battery BATTERY STARTER GENERATOR SERVICE 8B 5 Fig 2 Remove Or Install Starter Motor ...

Page 347: ...ore information refer to Group 7 Cooling Belt Removal Installation REMOVAL 1 Disconnect negative cable from battery 2 Attach a socket wrench to pulley mounting bolt of automatic tensioner Fig 1 3 Rotate tensioner assembly clockwise as viewed from front until tension has been relieved from belt 4 Remove belt from idler pulley first 5 Remove belt from vehicle 6 Remove lower generator mounting bolt a...

Page 348: ...ioner 7 Connect negative cable to battery GENERATOR REPLACEMENT 5 9L HDC GAS ENGINE Drive belts on these engines are equipped with a spring loaded automatic belt tensioner Fig 4 This belt tensioner is used on all belt configurations For more information refer to Group 7 Cooling Belt Removal Installation REMOVAL 1 Disconnect negative cable from battery 2 Attach a socket wrench to pulley mounting bo...

Page 349: ...e belt over all pulleys except wa ter pump pulley 4 Attach a 3 8 inch rachet to tensioner 5 Rotate ratchet and belt tensioner counterclock wise Place belt over water pump pulley Let ten sioner rotate back into place Remove ratchet Be sure belt is properly seated on all pulleys 6 Connect negative cable to battery GENERATOR REPLACEMENT DIESEL ENGINE 1 Remove negative cable from battery 2 Remove gene...

Page 350: ...oltage 7 5 Volts Cranking Amperage Draw Test 125 200 Amps Engine should be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw J938B 14 R E D U C T I O N G E A R STARTER Manufacturer Nippondenso Engine Application 5 9L Part Number and Power Rating 4428221 3 kw Voltage 12 No of Fields 4 No of Poles 4 Brushes 4 Drive Conventional Gear Train Free Runnin...

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Page 352: ...l Instal lation section of this group For other useful information refer to On Board Di agnostics in the General Diagnosis sections of Group 14 Fuel System in this manual For operation of the DRB II Diagnostic Scan Tool refer to the appropriate Powertrain Diagnostic Proce dures service manual An Ignition specifications section is included at the end of this group A general Maintenance Schedule mil...

Page 353: ...switch low to 0 volts For component testing refer to the Diagnostics Ser vice Procedures section of this group For removal and installation of this component re fer to the Component Removal Installation section of this group CRANKSHAFT POSITION SENSOR The sensor is bolted to the top of cylinder block near the rear of the right cylinder head Fig 3 Fig 3 Crankshaft Position Sensor Typical Engine spe...

Page 354: ...ifugal or vac uum assisted advance Base ignition timing and all timing advance is controlled by the powertrain con trol module PCM Because ignition timing is con Fig 5 Sensor Operation 5 2L 5 9L Engine trolled by the PCM base ignition timing is not adjustable on any of these engines The distributor is held to the engine in the conven tional method using a holddown clamp and bolt Al though the dist...

Page 355: ...cal For component testing refer to the Diagnostics Ser vice Procedures section of this group For removal and installation of this component re fer to the Component Removal Installation section of this group INTAKE MANIFOLD CHARGE AIR TEMPERATURE SENSOR The sensor element extends into the intake mani fold air stream It provides an input voltage to the powertrain control module PCM indicating intake...

Page 356: ...led by the PCM Base ignition timing by rotation of distributor is not adjustable MANIFOLD ABSOLUTE PRESSURE SENSOR TORQUE CONVERTER CLUTCH RELAY ELECTRICAL J l p CONNECTOR g i s Fig 11 MAP Sensor Typical A C CLUTCH RELAY STARTER RELAY AUTO SHUTDOWN RELAY FUEL PUMP RELAY DATA LINK CONNECTOR POWERTRAIN CONTROL MODULE J9314 164 Fig 12 PCM Location Typical The PCM opens and closes the ignition coil gr...

Page 357: ...te range of from 1 volt at minimum throttle opening idle to 4 volts at wide open throttle Along with inputs from other sen sors the PCM uses the sensor input to determine current engine operating conditions It also will ad just fuel injector pulse width and ignition timing For component testing refer to the Diagnostics Ser vice Procedures section of this group For removal and installation of this ...

Page 358: ...ire harness connector For wire identification refer to Group 8W Wiring Diagrams page Ignition Timing 12 Intake Manifold Charge Air Temperature Sensor Test 12 Manifold Absolute Pressure MAP Sensor Test 12 Oxygen Sensor Tests 17 Powertrain Control Module PCM 14 Spark Plug Secondary Cables 16 Spark Plugs 14 Throttle Position Sensor Test 17 2 Connect the negative voltmeter lead into the ground wire Fo...

Page 359: ...N Remove the distributor cap and wipe it clean with a dry lint free cloth Visually inspect the cap for cracks carbon paths broken towers or damaged ro tor button Figs 3 and 4 Also check for white de posits on the inside caused by condensation entering VIEW LOOKING INTO CPS CONNECTOR J938D 7 Fig 2 Sensor Connector the cap through cracks Replace any cap that dis plays charred or eroded terminals The...

Page 360: ...Fig 7 Ignition Coil 5 9L HDC Gas Engine Inspect the ignition coil for arcing Test the coil ac cording to coil tester manufacturer s instructions Test the coil primary and secondary resistance Re place any coil that does not meet specifications Refer to the Ignition Coil Resistance chart If the ignition coil is being replaced the secondary spark plug cable must also be checked Replace cable if it h...

Page 361: ... ohmmeter The resis tance should be less than 1340 ohms at normal engine operating idle temperature For resistance values refer to the Sensor Resistance chart Replace the sensor if it is not within the range of resistance specified in the chart 3 Test continuity of the wire harness This is done between powertrain control module PCM wire harness connector terminal 2 and the sensor connec tor termin...

Page 362: ... 18 gauge jumper wire between the battery positive terminal and the coil positive termi nal WARNING BE V E R Y C A R E F U L WHEN THE ENGINE IS CRANKING D O NOT PUT YOUR H A N D S NEAR THE P U L L E Y S B E L T S O R T H E F A N D O NOT W E A R L O O S E FITTING CLOTHING 2 Rotate crank the engine with the starter mo tor and observe the cable terminal for a steady arc If steady arcing does not occu...

Page 363: ...e Pow ertrain Diagnostics Procedures service manual for operation of the DRB II Scan Tool INTAKE MANIFOLD CHARGE AIR TEMPERATURE SENSOR TEST To perform a complete test of this sensor and its circuitry refer to the DRB II diagnostic scan tool Also refer to the appropriate Powertrain Diagnostics Procedures manual To test the sensor only refer to the following 1 Disconnect the wire harness connector ...

Page 364: ...re that the harness wires are not damaged by the test meter probes AAAP SENSOR MOUNTING SCREWS RUBBER FITTING J9314 87 Fig 18 Rubber Fitting MAP Sensor to Throttle Body 2 Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B Fig 19 With the ignition switch ON and the en gine OFF output voltage should be 4 to 5 volts The voltage should drop to 1 5 to 2 1 volts wit...

Page 365: ...or gas fouled plugs generally cause hard starting but they will clean up at higher engine speeds Faulty plugs can be identified in a Fig 21 Heat Shields number of ways poor fuel economy power loss de crease in engine speed hard starting and in general poor engine performance Remove the spark plugs and examine them for burned electrodes and fouled cracked or broken por celain insulators Keep plugs ...

Page 366: ...on caused by chemical addi tives in certain fuels These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies Notice that accumula tion on the ground electrode and shell area may be heavy but the deposits are easily removed Spark plugs with scavenger deposits can be considered nor mal in condition and can be cleaned using standard procedures GR...

Page 367: ...es referred to as sec ondary ignition cables or secondary wires The cables transfer electrical current from the distributor to in dividual spark plugs at each cylinder The spark plug cables are of nonmetallic construction and have a built in resistance The cables provide suppression of radio frequency emissions from the ignition system Check the high tension cable connections for good contact at t...

Page 368: ...end of cable If resistance is not within specifications as found in the Spark Plug Cable Resistance chart remove the cable from the distributor cap Connect the ohmmeter to the termi nal ends of the cable If resistance is not within spec ifications as found in the Spark Plug Cable Resistance chart replace the cable Inspect the igni tion coil tower for cracks burns or corrosion For removal and insta...

Page 369: ...LAY FUEL PUMP RELAY DATA UNK CONNECTOR POWERTRAIN CONTROL MODULE J9314 164 Fig 1 Auto Shut Down Relay REMOVAL 1 Disconnect negative battery cable at battery 2 Remove the relay by pulling from connector INSTALLATION 1 Check the terminals in the relay connector for corrosion or damage before installation 2 Push the relay into the connector CAMSHAFT POSITION SENSOR The camshaft position sensor is loc...

Page 370: ...1 Position crankshaft position sensor to engine and install mounting bolts Tighten bolts to 8 N m 70 in lbs torque 2 Connect main harness electrical connector to sensor IGNITION SYSTEMS 8 0 1 9 Fig 4 Oil Pressure Sending Unit Removal Installation 3 Clean the EGR tube and exhaust manifold at EGR tube mounting point of any old gasket mate rial 4 Install a new gasket to exhaust manifold end of EGR tu...

Page 371: ... 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 removal 1 Disconnect negative battery cable at battery 2 Remove distributor cap from distributor two screws 3 Mark the position of distributor housing in relationship to engine or dash panel This is done to aid in installa...

Page 372: ... of distributor shaft with slot in distributor oil pump drive gear Position rotor to the number one spark plug cable position 5 Install distributor holddown 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 7 7 Tighten clamp holddown bolt Fig 8 to 22 5 N m 200 in lbs torque 8...

Page 373: ...ge air temperature sensor is located in right front side of intake manifold Figs 11 or 12 Fig 11 Sensor Location 3 9L Engine Typical 1 Disconnect electrical connector at sensor Figs 11 or 12 2 Remove sensor from intake manifold INSTALLATION 1 Install sensor to intake manifold 2 Tighten the sensor to 13 N m 10 ft lbs torque 3 Install electrical connector Fig 12 Sensor Location 5 2L 5 9L Engines Typ...

Page 374: ...ble Internal dam age to cable will result Fig 15 Heat Shields 2 Prior to removing the spark plug spray com pressed air around the spark plug hole and the area around the spark plug This will help prevent foreign material from entering the combustion chamber 3 Remove the spark plug using a quality socket with a rubber or foam insert 4 Inspect the spark plug condition Refer to Spark Plugs in the Dia...

Page 375: ...nes retainers Failure to route the cables properly can cause the radio to reproduce ignition noise It could also cause cross ignition of the plugs or short circuit the cables to ground When installing new cables make sure a positive connection is made A snap should be felt when a good connection is made between the plug cable and the distributor cap tower Spark plug cable boot heat shields are pre...

Page 376: ...e 7 terminal wiring connector Remove the connector from the ignition switch Fig 3 6 Release connector lock on the Key In Switch and Halo Light 4 terminal connector Fig 3 7 Remove the key cylinder from the ignition switch as follows Ignition Switch and Key Cylinder Service page 25 STEERING COLUMN IGNITION SWITCH 908D 14 Fig 2 Ignition Switch Screw Removal KEY IN SWITCH HALO LIGHT MULTIFUNCTION SWIT...

Page 377: ...tion switch is in lock position flag is parallel with the ignition switch terminals Fig 6 Apply a dab of grease to flag and pin Posi tion park lock link and slider to mid travel Position ignition switch against lock housing face Be sure pin is inserted into park lock link contour slot Tighten retaining screws to 2 N m 17 in lbs torque FASTENER LOCATIONS LOCATING PIN PARK LOCK DOWEL PIN IGNITION SW...

Page 378: ...icable IGNITION SWITCH CIRCUITS _ _ 1 2 3 4 5 6 7 I G N I T I O N SWITCH CONNECTOR L O O K I N G INTO SWITCH WIRE CAVITY WIRE COLOR APPLICATION 1 YELLOW STARTER RELAY 2 DARK BLUE IGNITION RUN START 3 WHITE BLACK BRAKE WARNING LAMP 4 PINK BLACK IGNITION SWITCH BATTERY FEED 5 BLACK ORANGE OR BLACK TAN RUN ACCESSORY 6 BLACK WHITE ACCESSORY 7 RED IGNITION SWITCH BATTERY FEED J938D 18 ...

Page 379: ...nostics Service Procedures section of this group for more informa tion IGNITION COIL C O i i TOYODSNSO Primary Resistance 95 1 20 Ohms 96 1 18 Ohms Secondary Resistance at 70 80 F 11 300 13 300 Ohms 11 300 15 300 Ohms SPARK PLUGS J918D 25 Engine Spark Plug Application G a p Tightening Torque Size Engine Original Equipment Replacement Application G a p Tightening Torque Size 3 9L 5 2L 5 9L RC12YC R...

Page 380: ...TION 1 8 4 3 6 5 7 2 Description Torque Crankshaft Position Sensor Distributor Hold Down Bolt Powertrain Control Module Mounting Screws Powertrain Control Module PCM Elect Connector Spark Plugs All Engines 8 N m 70 in lbs 23 N m 17ft ibs 1 N m 9 in lbs 4 N m 35 in lbs 41 N m 30ft lbs J9314 166 J9314 79 1 ...

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Page 382: ...he cluster also includes warning lamps for seat belt warning low oil pressure high beam left and right turn signals check engine J908E 66 Fig 11nstrument Cluster FUEL LEVEL INDICATING SYSTEM FIG 2 A hinged float arm in the fuel tank raises or lowers depending on the fuel level The float arm contacts a variable resistor in the gauge sending unit This pro vides a change of resistance in the fuel gau...

Page 383: ...ressure warning lamp in the in strument cluster causing the warning lamp to illumi nate GENERATOR INDICATING SYSTEM FIG 4 The voltmeter gauge senses the voltage of the elec trical system VOLTAGE GAUGE P J908E 49 Fig 4 Generator Indicating System SPEEDOMETER ODOMETER SYSTEM The speedometer odometer system consists of an electric speedometer and pushbutton reset odometer mounted in the cluster The s...

Page 384: ...udes warning lamps for the brake systems parking and service ABS brakes liftgate open Ramcharger only maintenance required O D BRAKE P 7 GATE OPEN MAINT REQD J938E 54 Fig 6 Message Center Gas Engine EMISSIONS MAINTENANCE REMINDER This system is designed to act as a reminder that scheduled vehicle emissions maintenance should be performed It is not intended to indicate a warn ing or that a state of...

Page 385: ... provides a reserve braking capability in the event of a failure to a portion of the hydraulic system Failure of either of the dual sys tem is indicated by the brake warning light which will glow when the service brake pedal is depressed The light will remain on until the cause is corrected The light will also come on when the parking brake is applied with the ignition in the ON position Refer to ...

Page 386: ...than a few seconds 2 With the ignition in the O N position a grounded input will cause the oil fuel or tempera ture gauge to read at or above maximum FUEL TANK SENDING UNIT TEST 1 Disconnect wire from terminal on fuel tank sending unit Fig 1 FUEL PUMP SUPPLY INPUT TO GAUGE SENDING UNIT GROUND FUEL PUMP GROUND J928E 49 Fig 1 Fuel Tank Sending Connector Terminals 2 Connect wire to a known good sendi...

Page 387: ...d Install properly d Mounting flange on fuel tank for sending unit deformed Feel for interference fit of sending unit to bottom of tank It is permissible to bend pick up tube down a little near mounting flange to gain interference fit e Fuel tank bottom deformed causing improper positioning of sending unit pick up tube Replace or repair tank and recheck sending unit Refer to Fuel Tank Section of G...

Page 388: ...Section 8M Seat Belt Warning Systems BRAKE SYSTEM WARNING LAMP FIG 6 The brake warning lamp illuminates when the parking brake is applied with the ignition key turned ON The same lamp will also illuminate should one of the two service brake systems fail when the brake pedal is applied To test the system turn the ignition key ON and apply the parking brake If the lamp fails to light inspect for a b...

Page 389: ...ensor and the temperature gauge sensor input pin Figs 7 8 and 9 3 With the ignition switch in the ON position check for battery voltage across the B pin and the Ground pin TURN IGNITION KEY ON DO NOT START ENGINE I RELEASE PARKING BRAKE I I WARNING LIGHT GOES I ON I 1 LIGHT SHOULD BE OFF X APPLY PARKING BRAKE WARNING LIGHT SHOULD GO ON BRAKE SYSTEM LEAKING FLUID X WARNING LIGHT FAILS TO GO ON GROU...

Page 390: ...pin and the Ground pin J908E 6i_ Fig 9 Temperature Gauge Pins TEMPERATURE OIL FUEL GAUGE DIAGNOSIS GAUGE INDICATES HIGHER OR LOWER THAN ACTUAL I FAULTY WIRING FAULTY SENDING UNIT FAULTY INSTRUMENT PANEL GAUGE ERRATIC GAUGE OPERATION TEST PROCEDURES DESCRIBED ARE IN APPROPRIATE SECTION OF SERVICE MANUAL LOOSE OR DIRTY ELECTRICAL CONNECTIONS FAULTY INSTRUMENT PANEL GAUGE J908E 52 FUEL GAUGE CIRCUIT ...

Page 391: ...ve voltage gauge Refer to Gauge Replace ment Fig 13 Oil Pressure Gauge Pins r FUEL PUMP SUPPLY 0 INPUT TO GAUGE SENDING UNIT GROUND FUEL PUMP GROUND J928E 49 Fig 14 Fuel Tank Sending Connector Terminals FUEL GAUGE INPUT GROUND y J908E 71 Fig 15 Fuel Gauge Pins 2 With the ignition switch in the ON position check for battery voltage across the B pin and the Ground pin Fig 16 The instrument panel vol...

Page 392: ...r input pin Fig 17 3 With the ignition switch in the ON position check for battery voltage across the B pin and the Ground pin INSTRUMENT PANEL AND GAUGES 8E 11 Fig 17 Speedometer Pins 4 Perform distance sensor test Refer to General Information Distance Sensor in this section 5 If all previous tests prove good replace speed ometer ...

Page 393: ...6 mounting screws page Lamp Bulbs 15 Printed Circuit Board 13 PRND21 Indicator 15 Specifications 15 Speedometer Odometer 14 5 Install map lamp 6 Remove tape from steering column 7 Connect negative cable to battery CLUSTER MASK AND LENS REMOVAL 1 Disconnect negative cable from battery 2 Remove cluster bezel 3 Remove 8 screws holding mask and lens 4 Remove mask and lens INSTALLATION 1 Position mask ...

Page 394: ...cket assemblies 3 Remove gauge mounting screws and remove gauges 4 Remove printed circuit board mounting screws 5 Remove printed circuit board from cluster hous ing HEADLAMP SWITCH BEZEL CLUSTER MASK AND LENS J928E 46 Cluster and Switches INSTALLATION CAUTION Do not overtighten mounting screws or damage to circuit board and or cluster housing will occur 1 Position printed circuit board on cluster ...

Page 395: ...ry to remove instrument clus ter from vehicle for speedometer replacement When removing speedometer Fig 4 from cluster gauge must be pulled straight out not twisted or damage to gauge pin and or printed circuit board may result 1 Disconnect negative cable from battery 2 Remove bezel Refer to Cluster Bezel Removal 3 Remove cluster mask and lens Refer to Cluster Mask and Lens Removal 4 Remove mounti...

Page 396: ... in panel See cluster installation 4 Connect battery negative cable LAMP BULB REPLACEMENT MESSAGE CENTER REMOVAL 1 Disconnect battery negative cable 2 Remove instrument cluster bezel assembly Re fer to Instrument Cluster removal 3 Twist lamp socket assembly and remove from printed circuit board 4 Remove bulb from socket INSTALLATION 1 Install bulb into socket assembly 2 Install lamp socket assembl...

Page 397: ...or bracket 7 Remove 2 nuts and washers attaching steering column bracket to instrument panel steering column support bracket 8 Allow column to lower and rest on seat STEERING COLUMN SUPPORT WASHER AND NUT Fig 1 Steering Column Mounting RAISING STEERING COLUMN 1 Raise steering column assembly against the in strument panel support bracket 2 Install 2 steering column bracket washers and nuts Finger T...

Page 398: ...IG 2 REMOVAL 1 Remove cluster bezel refer to Cluster Bezel Re moval 2 Reaching under instrument panel depress knob and stem release button located on bottom of switch housing At the same time pull knob and stem as sembly out of switch housing located on front of panel 3 Remove power mirror switch knob by pulling straight off 4 Remove bezel 5 From front of panel remove spanner nut mounting switch t...

Page 399: ...abs on switch and push it out of the instrument panel INSTALLATION 1 Hold wiring connector in switch opening 2 Push switch on to wiring connector 3 Continue to push until switch snaps into place 4 Install chime module on to bracket MAP LAMP SWITCH REMOVAL 1 Remove 2 attaching screws 2 Drop assembly down and remove wiring con nector then remove map lamp assembly INSTALLATION 1 Connect wiring connec...

Page 400: ...g tab on column cover down ward and lower fuse block The following components plug into the fuse block Fuses 30 amp circuit breakers Turn signal flasher Horn relay Hazard Warning Flasher INSTALLATION 1 Position fuse block to steering column cover 2 Push locking tab to lock fuse block in position HOOD RELEASE REMOVAL 1 Disengage cable from hood latch in engine com partment 2 Remove 4 screws holding...

Page 401: ...d tighten securely 3 Connect wiring to shell 4 Install lighter element 5 Install wires and close ash receiver ASH TRAY Fig 8 TRAY REMOVAL 1 Open ash tray 2 Remove ash tray bin INSTALLATION 1 Install ash tray bin 2 Push ash tray inward to closed position HOUSING REMOVAL 1 Remove ash tray bin 2 Disconnect electrical leads from cigar lighter 3 Remove 6 screws retaining housing to panel 4 Remove cigar...

Page 402: ... into cylinder 4 While holding tumbler down with wire in lock cylinder insert key 5 Remove wire and pull out lock cylinder 6 Remove latch mounting screws and remove as sembly INSTALLATION 1 Position latch assembly into place on glove box door install mounting screws and tighten securely 2 Depress retaining tumbler into lock cylinder and insert key 3 Position assembly so that it will be in the clos...

Page 403: ...ash receiver MAP LAMP BULB To replace bulb snap lens out replace bulb FOUR WHEEL DRIVE INDICATOR REMOVAL 1 Remove map lamp 2 Remove cluster bezel refer to Cluster Bezel Re moval 3 Remove bulb and socket INSTALLATION 1 Snap in bulb and socket 2 Replace cluster bezel 3 Install map lamp HEATER OR HEATER A C ILLUMINATION LAMP REMOVAL 1 Remove map lamp 2 Remove cluster bezel refer to Cluster Bezel Re m...

Page 404: ...e static A capacitor is mounted inside the generator and ground straps are utilized from cab to box and from the engine to cowl The previously mentioned Capacitor and Ground Straps should be securely mounted to a clean ground surface to work effectively Radio resistance spark plug wires complete the in terference suppression system Faulty or deteriorated spark plug wires should be replaced RADIO N...

Page 405: ...X54 X54 VIEWED FROM X56 WIRE END X56 E2 Ml X53 X53 X55 X55 L7 X12 LEGEND E2 ILLUMINATION X51 LEFT REAR FEED X55 LEFT DR RETURN L7 PARK LAMPS X52 RIGHT REAR FEED X56 RIGHT DR RETURN Ml BATTERY X53 LEFT DR FEED X57 LEFT REAR RETURN X12 ACC RUN X54 RIGHT DR FEED X58 RIGHT REAR RETURN J938F 8 T E S T P R O C E D U R E S RADIO DIAGNOSIS Turn Ign Key to ACC T Check AM FM and Tape Player Operation NOTE F...

Page 406: ...er Leaas Stop Yes Replace Radio No Send Original Radio for Service J928F 10 ANTENNA TESTING Antenna performance may be tested by substitut ing a known good antenna Check short or open cir cuits with an ohmmeter or continuity light once the antenna cable is disconnected from the radio as fol lows 1 Continuity should be observed between the tip of the mast and radio end pin Fig 1 2 No continuity or ...

Page 407: ...y or in the cable probably at the connector 3 Remove clip lead from connector pin and clip on outer shell of connector Connect other clip lead to antenna body assembly The lamp should LIGHT again If it does not Light antenna shielding has an open circuit Wiggle cable over its entire length to reveal in termittent short or open circuits during steps 1 2 and 3 REMOVAL 1 Disconnect negative cable fro...

Page 408: ...ve 13 Remove adapter on fender ADAPTER PR517 A Fig 7 Cap Nut and Adapter Fig 8 Removing or Installing Antenna Body INSTALLATION 1 Route antenna cable between fender and dash panel to A pillar area 2 Insert antenna mast through hole in fender and screw into antenna body 3 Pull assembly up and position into place and hold 4 Install adapter making sure tab indexes with opening in fender and antenna b...

Page 409: ...R DIAGNOSIS TAPE PLAYER DIAGNOSIS Turn Radio On Insert Tape Tape Inoperative Check Player For Obstruction Behind Doors Poor Performance 1 Try A Good Known Tape Yes Try A Known Good Tape Correct As Required Yes Advise Owner of Worn or Defective Tape Yes Remove Unit For Repair Advise Owner of Worn or Defective Tape NO EJECT Do Not Force Removal of Jammed Cassette J928F 5 ...

Page 410: ...map lamp if equipped 6 Connect negative cable to battery DOOR MOUNTED SPEAKER REMOVAL 1 Remove remote control handle 2 Remove window regulator handle if equipped 3 Remove pull strap if equipped 4 Remove screw at top of armrest 5 Using a trim stick or other suitable flat tool gently pry trim panel away from door 6 Remove screws holding speaker Fig 11 7 Disconnect speaker leads 8 Remove speaker Fig ...

Page 411: ...ector on speaker 2 Install retaining tab into clip 3 Install screws on the bottom of the speaker housing Fig 13 Club Cap Speaker Installation REAR SPEAKER RAMCHARGER 1 Remove screws holding the speaker and grille assembly to the mounting plate Fig 14 SPEAKER MOUNTING GRILLE ASSEMBLY J908F 12 Fig 14 Ramcharger Rear Speaker 2 Disconnect speaker connector and remove speaker 3 Remove screws holding sp...

Page 412: ... still intact and the horn re connected replace the horn If the lamp fails to illuminate check for a defective horn relay by substituting a known good horn relay in the circuit If the lamp illuminates when depress ing the horn switch the original relay is defective If the lamp fails to illuminate with a known good relay unplug that relay Connect a jumper wire from the battery terminal to the horn ...

Page 413: ...W N G O O D O N E FIG 3 TEST LIGHT ON FAULTY HORN RELAY SHORTED HORN RELAY WIRE TO H O R N BUTTON SWITCH G R O U N D E D OR H O R N BUTTON SWITCH G R O U N D E D REFER TO TEST PROCEDURES FAULTY HORN W R O N G FUSE SIZE TEST LIGHT ON FAULTY ORIGINAL RELAY TEST LIGIHT OFF UNPLUG REPLACEMENT RELAY FROM SOCKET A N D C O N N E C T A JUMPER WIRE BETWEEN RELAY SOCKET 1 A N D 2 SEE INSET DIAGRAM INSPECT F...

Page 414: ... of the radiator support Fig 5 1 Raise the hood 2 Disconnect the horn electrical connector 3 Remove bolt holding the horn bracket to the ra diator support and remove the horn 4 To install the horns reverse the removal proce dures Tighten the bolts to 200 in lbs HORN HI NOTE HORN LOW NOTE HORN MOUNTING BOLTS J908G 10 Fig 5 Horn Removal and Installation Gas Engine HORN REPLACEMENT DIESEL ENGINE The ...

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Page 416: ... TO ACTIVATE By pushing the ON OFF button to the depressed latched position ON the speed con trol function is now ready for use TO DEACTIVATE A soft tap of the brake pedal normal brake use or clutch pedal use while the sys tem is engaged will disengage speed control without erasing memory A sudden increase in engine R P M may be experienced if the clutch pedal is depressed while the speed control ...

Page 417: ... new desired speed This will allow the vehicle to continuously accelerate and set at a higher speed setting TAP UP When the speed control system is en gaged tapping the RESUME ACCEL button will in crease the speed setting by 2 mph 3 km h The system will respond to multiple tap ups TO ACCELERATE for PASSING Depress the accelerator as you would normally When the pedal is released the vehicle will re...

Page 418: ...E CONTROLLED T 1 i 1 N O W E E D CONTROL W H E N SET DECEL BUTTON IS PRESSED A N D RELEASED H U N T I N G S U R G E O R SPEED V A R I A T I O N S A T LOW SPEEDS EXCESSIVE S A G ON HILLS OR I N TRAILER T O W I N G SPEED SETTING AFTER LOCK IN T O O H I G H C3 t L O W 4 FUSE BLOWN LOCK UP TORQUE CONVERTER ROUGHNESS ENGINE PERFORMANCE V A C U U M LEAK f t f N O V A C U U M AT SERVO AMPLIFICATION OF EN...

Page 419: ...D SPEED VEHICLE RESUMES SPEED DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE NO SYSTEM DISENGAGEMENT WHEN MAKE PEDAL IS DEPRESSED DEFECTIVE OR IMPROPERLY ADJSUTED STOP LAMP AND SPEED CONTROL SWITCH yf SPEED CONTROL THROTTLE CABLE KINKED OR DAAAAGED 1 FAULTY ELECTRICAL CIRCUIT f DEFECTIVE SERVO NO RESUME WHEN BUTTON IS PRESSED SPEED CONTROL DISENGAGES DEFECTIVE SWITCH FAULTY ELECTRICAL CIRCUIT ...

Page 420: ...SET DECEL BUTTON IS PRESSED AND RELEASED FUSE BLOWN NO VACUUM AT SERVO T SPEED CONTROL THROTTLE CABLE DISCONNECTED IMPROPER STOP LAMP AND SPEED CONTROL SWITCH ADJUSTMENT FAULTY ELECTRICAL CIRCUIT T DEFECTIVE SERVO DEFECTIVE VACUUM PUMP HUNTING SURGE OR SPEED VARIATIONS AT LOW SPEEDS I LOCK UP TORQUE CONVERTER ROUGHNESS AMPLIFICATION OF ENGINE SURGE DEFECTIVE SERVO DEFECTIVE CABLE DEFECTIVE ENGINE ...

Page 421: ...LY MEMORIZED SPEED VEHICLE RESUMES SPEED DEPRESS BRAKE PEDAL SPEED CONTROL SHOULD DISENGAGE NO SYSTEM DISENGAGEMENT WHEN MAKE PEDAL IS DEPRESSED DEFECTIVE OR IMPROPERLY ADJSUTED STOP LAMP AND SPEED CONTROL SWITCH 11 SPEED CONTROL THROTTLE CABLE KINKED OR DAAAAGED 1 FAULTY ELECTRICAL CIRCUIT 1 DEFECTIVE SERVO SPEED CONTROL DISENGAGES DEFECTIVE SWITCH FAULTY ELECTRICAL CIRCUIT 1 NO SYSTEM DISENGAGE ...

Page 422: ...witch in ON position b After switch has been cycled 3 times observe Malfunction Indicator Lamp CHECK ENGINE on instrument cluster If a DTC is present the code page Speed Control Cable Attachment Servo 10 Stop Lamp Switch Test 9 Vacuum Supply Test 9 Vehicle Speed Control Switch Test 9 Vehicle Speed Control System Electrical Tests 7 Vehicle Speed Sensor Test 7 will be displayed in a series of flashe...

Page 423: ...egative lead of voltmeter to a good body ground near the module 3 For the following tests the ignition switch must be in the ON position Refer to Fig 4 for con troller terminal locations Touch the positive lead of the voltmeter to the terminal in cavity number 33 With the speed control switch in the OFF position the voltmeter should read 0 volts With the speed control switch in the ON position the...

Page 424: ...e switch from its mounting position Use an ohmmeter and refer to the Switch Continuity Chart to determine if continuity is correct If there is no continuity at any one of the switch positions replace the switch STOP LAMP SWITCH TEST 1 Disconnect connector at stop lamp switch Us ing an ohmmeter continuity may be checked at switch side of connector as follows Fig 5 a With brake pedal released there ...

Page 425: ...sual inspection will verify that the cable is securely attached If the cable is not attached the speed control system will be inoperative Refer to Ca ble Adjustment GAS ENGINE The clevis of the speed control cable is retained to the throttle body lever by slipping the clevis into the slot on the lever Visual inspection will verify that the cable is securely attached If the cable is not at tached t...

Page 426: ...hing nuts and tighten to 6 N m 50 in lbs 6 Connect vacuum hose to servo 7 Connect the electrical connector to servo termi nals SERVO THROTTLE CABLE ASSEMBLY GAS ENGINE REMOVAL 1 Remove air cleaner 2 Using finger pressure only remove speed con trol cable connector at bell crank by PUSHING con nector off the bell crank Fig 1 DO NOT try to pull connector off perpendicular to the bell crank 3 Squeeze ...

Page 427: ... Install cable end on bellcrank rod 8 Adjust cable as described under speed control cable adjustment 9 Install washer and hairpin clip on end of bell crank rod SPEED CONTROL SWITCH REPLACEMENT 1 Disconnect negative cable from battery 2 From underside of steering wheel remove horn pad mounting screws Fig 2 3 Pull pad up from wheel and disconnect electri cal leads 4 Remove pad 5 Unplug 4 way electri...

Page 428: ...tage at the Turn Hazard switch connector cavity 17 Meter should read battery volt age If OK replace Turn Hazard switch assembly If not repair open circuit in wiring between flasher and Turn Hazard switch connector HAZARD WARNING SYSTEM DESCRIPTION With the hazard switch OUT current flows through the hazard flasher canister hazard switch two front turn signal bulbs two rear turn signal bulbs both i...

Page 429: ...ning headlamp beam select headlamp optical horn windshield wiper pulse wipe windshield washer switching This integrated switch assembly is mounted to the left hand side of the steering column Should any function of the switch fail the entire switch assem bly must be replaced To test the switch 1 Disconnect negative cable from battery 2 Remove upper and lower column covers to gain access to the swi...

Page 430: ...U R E S REMOVAL 1 Disconnect negative cable from battery 2 Remove tilt lever Tilt column only 3 Remove both upper and lower steering column covers 4 Remove multifunction switch tamper proof mounting screws tamper proof torx bit Snap On TTXR20B2 or equivalent required 5 Gently pull switch away from column Loosen connector screw The screw will remain in the con nector 6 Remove wiring connector from ...

Page 431: ......

Page 432: ... Two Speed Wiper Switch Testing Procedures 4 TWO SPEED WIPER MOTOR TESTING PROCEDURES The following is a list of general wiper motor sys tem problems It contains the tests that are to be per formed to locate the faulty part and the corrective action to be taken The same motor is used for stan dard and optional systems If the malfunction in volves only the Delay mode switch or wiring refer to the I...

Page 433: ... O R S T O P S BLADES D O N O T P A R K P R O P E R L Y M O T O R W I L L N O T S T O P I W H E N S W I T C H IS T U R N E D O F F X LINKAGE NOT FASTENED PROPERLY TO MOTOR OUTPUT SHAFT J ARMS LOOSE ON PIVOT SHAFT BLADES CHATTER FOREIGN SUBSTANCE SUCH AS BODY POLISH ON GLASS OR BLADES OUTPUT SHAFT STATIONARY T REPLACE MOTOR JE OUTPUT SHAFT ROTATES t LOOSE MOTOR CRANK BAD LINKAGE CONNECTION ARMS LOO...

Page 434: ...If motor continues to draw more than 3 amps replace motor assembly 3 Check motor wiring harness for shorting be tween high and low speed wires as follows a Connect a voltmeter or test lamp to motor ground strap b Set wiper switch to LOW position c Connect other lead of voltmeter test lamp to terminal H of the wiring harness d If voltage is present there is a short in the wiring or wiper switch If ...

Page 435: ...and connect an ohmmeter or continuity tester between terminals L and P2 Fig 5 a If there is continuity between these termi nals the problem is a defective motor Fig 5 Ohmmeter Between Terminal L and P2 b If there is no continuity the problem is an open circuit in the wiper control switch or wiring harness MULTIFUNCTION TWO SPEED WIPER SWITCH TESTING PROCEDURES The multifunction switch contains cir...

Page 436: ...H C O N N E C T O R Fig 7 Multifunction Switch Connector KEY IN SWITCH H A L O LIGHT MULTIFUNCTION SWITCH I G N I T I O N SWITCH TURN S I G N A L SWITCH LEVER SPEED C O N T R O L J918J 2 Fig 8 Steering Column Connectors MULTIFUNCTION SWITCH PINS T W O S P E E D W I P E R S W I T C H C O N T I N U I T Y C H A R T SWITCH POSITION CONTINUITY BETWEEN OFF PARK PIN 1 PIN 2 LOW PIN 1 PIN 4 HIGH PIN 4 PIN...

Page 437: ...n at the in strument 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 that the wiring ground connections for the intermittent wipe control unit and the wiper switch are tight 4 If condition is not corrected replace control unit MULTIFUNCTION INTERMITTENT WIPER SWITCH TESTING...

Page 438: ...FF 2 Lift wiper arm to raise blade off glass 3 Remove blade assembly from arm and wiping element from blade depending on type as follows page Wiper Blades 7 Wiper Motor Replacement 8 Wiper Switch Replacement 9 TYPE A To remove blade assembly from arm insert a small screwdriver blade into release slot of wiper blade and pry slightly upward Fig 1 To remove wiping element from blade assembly pinch lo...

Page 439: ...RM REMOVAL 1 Remove wiper motor as previously described 2 Remove nut attaching crank arm to motor drive shaft 3 Remove crank arm INSTALLATION 1 Position crank arm on motor drive shaft mak ing sure slot is indexed properly Install mounting nut and tighten to 11 N m 95 in lbs torque 2 Install wiper motor DRIVE LINK ASSEMBLY LEFT PIVOT ASSEMBLY REMOVAL 1 Remove wiper arms 2 Remove screws attaching lo...

Page 440: ...tainer bushing by snapping together with channel lock pli ers 3 Position cowl cover into place install mounting screws and tighten securely 4 Install wiper arms WIPER SWITCH REPLACEMENT 1 Disconnect negative cable from battery 2 Remove tilt lever Tilt column only 3 Remove both upper and lower steering column covers 4 Remove multifunction switch tamper proof mounting screws 5 Gently pull switch awa...

Page 441: ...they are inserted di rectly into the cowl panel there is no adjustment re quired Fig 1 Windshield Washer System WINDSHIELD WASHER PUMP REPLACEMENT Fig 2 REMOVAL 1 Remove liquid from reservoir 2 Remove reservoir mounting screws and remove reservoir and pump assembly 3 Disconnect electrical lead and rubber hose from bottom of pump 4 Using an extension and deep well socket reach through reservoir fil...

Page 442: ... M P NOT P U M P I N G FLUID N O FLUID IN RESERVOIR NOZZLE JET UNDER COWL PANEL NOZZLE JETS PLUGGED BROKEN OR LOOSE HOSE FAULTY PUMP MOTOR R U N S P U M P P U M P I N G FLUID SYSTEM OPERATES INTERMITTENTLY LOOSE WIRING CONNECTIONS X FAULTY SWITCH t FAULTY MOTOR SYSTEM OPERATES WITHOUT INTERRUPTION IATES I T I ION j SYSTEM OUTPUT LOW NOZZLES AIMED LOW PINCHED OR LEAKY HOSES X LEAKY OR RESTRICTED PL...

Page 443: ......

Page 444: ... a given vehicle MULTI FUNCTION SWITCH TESTING PROCEDURES The multi function switch contains electrical cir cuitry for Headlamp Dimmer Switch Passing Lights Turn Signals Hazard Warning Windshield Wiper Pulse Wiper Windshield Washer HEADLAMPS HIM ENGINE IDLING OR IGNITION OFF TEST CHARGING SYSTEM HEADLAMP DIAGNOSIS SEALED BEAM OR BULB BURNS OUT FREQUENTLY TEST CHARGING SYSTEM HEADLAMPS DIM ENGINE R...

Page 445: ...itch as shown in the continuity chart Fig 4 9 Refer to Service Procedures for assembly UPPER SHROUD GROUND CLIP UPPER FIXED SHROUD SUPPORT BRACKET LOWER SHROUD LOWER FIXED SHROUD J9119 22 Fig 1 Steering Column Covers STEERING COLUMN ASSY J918J 1 TURN SIGNAL MULTI SWITCH AND FUNCTION LEVER SWITCH CONNECTOR Fig 2 Multi function Switch Connector KEY IN SWITCH HALO LIGHT MULTIFUNCTION SWITCH IGNITION ...

Page 446: ...and 1 down for the up down adjustment HEADLAMP ALIGNMENT PREPARATION 1 Verify headlamp dimmer switch and high beam indicator operation 2 Correct defective components that could hinder proper headlamp alignment 3 Verify proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is not heavily loaded 6 Fuel tank should be FULL Add 2 94 kg 6 5 lbs of weight over the fuel tank for each e...

Page 447: ... to side outboard edge of high in tensity pattern should be from 50 mm 2 in left to 50 mm 2 in right of headlamp centerline Fig 1 The preferred headlamp alignment is 0 for the up down adjustment and 1 down for the left right adjustment The high beam pattern should be correct when the iow beams are aligned properly Fig 2 To adjust headlamp aim rotate alignment screws to achieve the specified high i...

Page 448: ...e lamp and install screws CAB CHASSIS MODELS R E M O V A L 1 Remove 4 screws holding lens to lamp 2 Twist out bulb INSTALLATION 1 Install bulb 2 Position lens and install screws SPORT UTILITY MODELS REMOVAL 1 Remove screws and remove lamp assembly 2 Twist out socket 3 Replace bulb Fig 6 Tail Stop Turn Signal Rear Side Marker and Back Up Lamp LAMP ASSEMBLY PR1086 Fig 7 Tail Stop Turn Signal and Bac...

Page 449: ...ulb and lens assembly Figs 9 and 10 4 Connect electrical connector to new lamp and snap into housing J908L 73 Fig 9 Wheel Flare Clearance Lamp CAB CLEARANCE LAMPS To change bulb remove lamp as follows 1 Remove mounting screws Fig 11 2 Slide lens down and out of housing 3 Twist out socket and replace bulb Fig 10 Rear Clearance Lamps ...

Page 450: ...cedures LICENSE LAMP STANDARD BUMPER 1 Remove rear license plate 2 Remove 2 lamp mounting screws 3 Remove lamp assembly 4 Remove 2 screws attaching lamp lens to hous ing Fig 14 License Plate Lamp Standard Rear Bumper STEP BUMPER 1 Remove 2 lamp assembly mounting screws Fig 15 2 Remove lamp from bumper 3 Disconnect wire connector 4 Remove lens from lamp 5 Twist out bulb 6 To install reverse the rem...

Page 451: ...r to the lamp Fig 17 UNDERHOOD LAMP REPLACEMENT REMOVAL 1 Disconnect the wire connector from the lamp Fig 17 2 Rotate the bulb counter clockwise Remove it from the lamp base socket Fig 18 3 Remove the screw that attaches the lamp re flector and support bracket to the hood inner panel Fig 17 4 Remove the lamp from the hood inner panel INSTALLATION 1 Position the underhood lamp on the hood inner pan...

Page 452: ...less than 50 of normal intensity The Daytime Running Light Module is located on the right inner fender Fig 19 1 Remove the bolt holding the module and bracket to the vehicle 2 Disconnect the electrical connector 3 To install the module reverse the removal pro cedures Fig 19 Daytime Running Light Module ...

Page 453: ...TILITY 1 Squeeze the front and rear of the lens together and pull down to remove Fig 3 2 Pull bulb down to remove from socket READING LAMP SPORT UTILITY 1 Squeeze the front and rear of the lens together and pull down to remove Fig 4 J908L 66 Fig 2 Dome Lamp Extended Cab LAMPS LENS J918L 30 Fig 3 Dome Lamp Sport Utility 2 Remove 2 screws holding the dome and reading lamp assembly to the mounting br...

Page 454: ... lamps that can only be serviced by an Authorized Service Center ASC These components must be removed from the vehicle for service Contact local dealer for location of nearest ASC A C Heater Control 158 Ash Receiver 158 Gear Shift Selector PC194 Heater Control 158 Instrument Cluster PC 194 Radio ASC Snow Plow Control 158 INDICATOR LAMPS Service procedures for most of the lamps in the in strument p...

Page 455: ......

Page 456: ...tem for approximately 10 minutes or until either the control switch or ignition is turned off An indicating lamp illuminates a lens inlaid in the control switch TEST PROCEDURES SYSTEM TEST Electrically heated rear window defogger operation can be checked in vehicle in the following manner 1 Turn the ignition ON 2 Turn rear window defogger control switch ON 3 Monitor vehicle voltmeter With the cont...

Page 457: ...int C and Point B A reading of 10 14 volts indicates a break between Mid Point C and ground Point A Move toward break and voltage will change as soon as break is crossed CONTROL SWITCH TIMER MODULE TEST Control switch timer relay module may be tested in vehicle or bench tested In vehicle testing is ac complished in the following manner 1 Remove switch from instrument panel refer to Control Switch ...

Page 458: ... in repair kit for preparing damaged area 3 Remove package separator clamp and mix plas tic conductive epoxy thoroughly Fold in half and cut center corner to dispense epoxy 4 For grid line mark off area to be repaired with masking tape or a template Fig 4 5 Apply epoxy through slit in masking tape Overlap both ends of the break by at least 19mm 0 75 in 6 For a terminal or pigtail replacement mask ...

Page 459: ...module and twist it to remove it from the bracket 2 Squeeze rear window defogger switch retaining tangs and pull switch from rear of bezel 3 Remove connector from switch INSTALLATION 1 Connect electrical connector to switch 2 Insert switch into bezel making sure retaining tangs lock into position 3 Install chime module on to bracket ...

Page 460: ...y VOLTAGE TEST The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch After removing switch from trim panel for testing purposes carefully separate multiple terminal block on wiring harness from switch body Connect one lead of test light to black wire terminal and touch other test light lead to red wire terminal If the test light comes...

Page 461: ...emote handle 5 Using a device such as a trim stick pry trim panel away from door around perimeter 6 Roll door watershield away from lower rear cor ner of door to reveal inside panel access opening 7 Remove motor link at motor Fig 3 8 Disconnect motor lead wires 9 Remove 2 motor mounting bracket screws and remove motor assembly from mounting DOOR LOCK MOTOR J918P 9 Fig 3 Door Lock Motor Replacement...

Page 462: ...notch on forward end of switch housing Push screwdriver to depress locking tab Pull bezel out and forward to remove from door panel 2 Carefully separate multiple terminal block on wiring harness from switch body 3 Connect one lead of test light to black BK wire terminal Touch other test light lead to tan TN wire terminal If test light comes on the wiring cir cuit between the battery and switch is ...

Page 463: ...Y MAY RESULT BENCH TEST REGULATOR ASSEMBLY REMOVE MOTOR FROM REGULATOR I SYSTEM BINDING CORRECT BINDING CONDITION REGULATOR OPERATES CORRECTLY REGULATOR DOES NOT OPERATE I REINSTALL REGULATOR INTO DOOR CHECK ARM SECTOR ASSEMBLY FOR FREE MOVEMENT MISSING AND OR DAMAGED GEAR TEETH MISSING OR DAMAGED ROLLER OR BENT ARM ANY OF THESE CONDITIONS EXIST REPLACE ARM SECTOR ASSEMBLY PINION DOES NOT ROTATE R...

Page 464: ...CEDURES GEAR AND PINION REPLACEMENT AND LUBRICATION If gear and pinion assembly are replaced in gear box lubrication of gear box gear pinion and seal is necessary In the event there is no lubricant in gear box fill with MOPAR multi mileage lubricant or equivalent Apply a liberal amount of lubricant to inside area of seal and sealing surface at center area of gear and pinion coupling Also lubricate...

Page 465: ...previously described W A R N I N G S T E P S 2 A N D 3 A R E V E R Y IMPOR TANT IF NOT D O N E B E F O R E M O T O R R E M O V A L INJURY M A Y R E S U L T 2 Secure regulator in vise to prevent sector gear from rotating 3 Remove counter balance spring Must be done for safety before removing motor 4 Remove 3 motor attaching screws and remove motor Fig 5 Fig 5 Motor Attaching Screws 5 Inspect regula...

Page 466: ...l using wide blade screwdriver or similar tool Press in both inside corners to ensure hidden lip engages in channel 9 Install belt weatherstrip by aligning clips to holes in door and press in 10 Raise or lower vent to maintain a 1 6mm 06 in fore aft glass free play then with glass up tighten upper screws 11 Hold vent against glass glass down and tighten lower screws 12 Raise glass to full up posit...

Page 467: ......

Page 468: ...embly and cannot be serviced sepa rately page TEST PROCEDURES 1 Fig 1 Power Mirror and Headlamp Switches TEST PROCEDURES MIRROR MOTOR TEST PROCEDURE 1 Remove power mirror switch from mounting position refer to Service Procedures 2 Disconnect wiring harness at switch connector 3 Use 2 jumper wires Connect one to a 12 volt source and the other to a good body ground Refer to the MIRROR TEST CHART for...

Page 469: ...nt clus ter bezel to instrument panel Fig 2 Make sure the screw below the Heater C control is removed INSTRUMENT CLUSTER BEZEL J938E 51 Fig 2 Instrument Cluster Bezel 4 Place column shift lever in Position 1 5 Remove bezel by pulling top edge rearward to clear brow Disengage attaching clips around bottom of bezel and complete removal of bezel 6 If the bezel has a four wheel drive indicator re move...

Page 470: ...side panel access opening 7 Reach inside door and disconnect mirror wiring at connector Spray grommet on mounting bracket cover with silicone to avoid grommet coming off when cover is moved up on mirror stem 8 Remove mirror mounting bracket cover 1 screw and slide up on mirror stem Fig 4 Fig 4 Power Mirror Replacement 9 Remove 3 mirror mounting bracket nuts 10 Pull mirror loose from door and feed ...

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Page 472: ...NITION To sound the key in ignition alarm the module needs the ignition key warning switch must be closed the driver s door jamb switch must be closed These conditions ground pin 6 of the module These switches are closed when the driver s door is open and the key is in the ignition LIGHTS ON To sound the lights on warning the module needs the headlamp switch must be closed the driver s door jamb s...

Page 473: ... read open circuit if drivers seat belt is buckled If not repair short to ground or buckle switch may be defective Buzzer module connector pin 6 Open driver s door key in ignition in OFF position Meter should read zero ohms If not repair open to ground Buzzer chime module connector pin 6 Open driv er s door headlamp switch on meter should read zero ohms If not repair open to ground r i DOORSW 7 SH...

Page 474: ...tch Fig 7 KEY IN SWITCH HALO LIGHT MULTIFUNCTION SWITCH IGNITION SWITCH TURN SIGNAL SWITCH LEVER SPEED CONTROL J918J 2 Fig 7 Key In Switch And Halo Lamp Connector 7 Remove key cylinder from ignition switch as follows a Insert key in ignition switch and move switch to Lock position b Use a small screw driver to depress key cyl inder retaining pin flush with key cylinder surface Fig 8 IGNITION SWITC...

Page 475: ...id travel Position ignition switch against lock housing face making sure pin is in serted into park lock link contour slot Torque retain ing screws to 2 N m 17 in lbs 3 Assemble cover to the column with 3 screws Torque screws to 2 N m 17 in lbs 4 Tilt column only install tilt lever clockwise 5 Install negative cable to battery 6 Install key cylinder as follows 908D 18 Fig 11 Ignition Switch View F...

Page 476: ... CYLINDER ENGINE DISTRIBUTOR CLOCKWISE ROTATION FIRING ORDER 1 6 5 4 3 2 RN755 Fig 1 Secondary Ignition Wiring 3 9L Engine WIRING DIAGRAM SHEETS AND INDEXES The wiring diagram sheets are organized so that systems relating to the basic vehicle and all of its op tions are shown Add on or non factory options are SPARK PLUGS LEFT BANK EIGHT CYLINDER DISTRIBUTOR CLOCKWISE ROTATION FOR 318 AND 360 CUBIC...

Page 477: ...WT TN TAN WT DG DARK GREEN WT VT VIOLET WT GY GRAY BK WT WHITE BK LB LIGHT BLUE BK YL YELLOW BK LG LIGHT GREEN BK WITH TRACER 918W 136 Fig 4 Wire Color Code Chart LOCATING A SYSTEM OR COMPONENT To locate a system or component in the diagrams refer to the alphabetical index at the front of the di agrams Determine the diagram sheet number Sheet numbers are located at the lower right or left hand cor...

Page 478: ...ircuit information 3 Analyze the symptoms Use the wiring dia grams to determine what the circuit is doing where the problem most likely is occurring and where the diagnosis will continue 4 Isolate the problem area 5 Repair the problem 6 Verify proper operation For this step check for proper operation of all items on the circuit repaired Refer to the wiring diagram fuse application chart FUSIBLE LI...

Page 479: ...n together using rosin core type solder only Do not use acid core solder 8 Center 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 ones to prevent chafing or damage to the insulation 10 Connect battery and test all affected systems CONNECTOR REPLACEMEN...

Page 480: ...re to remove the termi nal from the connector Fig 9 5 Cut the wire 6 inches from the back of the con nector 6 Remove 1 inch of insulation from the wire on the harness side 7 Select a wire from the terminal repair assem bly that best matches the color wire being repaired 8 Cut the repair wire to the proper length and re move 1 inch of insulation 9 Place a piece of heat shrink tubing over one of sid...

Page 481: ...UT OPEN CONTACT 0 SINGLE FILAMENT LAMP M K CLOSED CONTACT 5 DUAL FILAMENT LAMP CLOSED SWITCH LE D LIGHT EMITTING DIODE OPEN SWITCH THERMISTOR CLOSED GANGED SWITCH GAUGE mi OPEN GANGED SWITCH SENSOR TWO POLE SINGLE THROW SWITCH FUEL INJECTOR PRESSURE SWITCH E 36 DENOTES WIRE GOES THROUGH BULKHEAD DISCONNECT 3i SOLENOID SWITCH STRG COLUMN DENOTES WIRE GOES THROUGH STEERING COLUMN CONNECTOR f r t MER...

Page 482: ...ER MIRRORS GLOVE BOX LAMP DOME LAMP READING LAMP MAP LAMP CARGO LAMP IGNITION SWITCH LAMP UNDERHOOD LAMP 20 AMP YL FUSE CAVITY 14 TAIL LAMPS PARKING LAMPS SIDE AAARKER LAMPS LICENSE LAMPS FRONT AND REAR CLEARANCE LAMPS RADIO INTENSITY HORNS 20 AMP YL STOP LAMPS KEY IN HEADLAMP ON BUZZER RWAL MODULE 30 AMP CIRCUIT BREAKER TURN SIGNAL FLASHER 20 AMP YL POWER DOOR LOCKS 15 AMP BL CIGAR LIGHTER 10 AMP...

Page 483: ...8W 8 WIRING DIAGRAMS ...

Page 484: ...ine Wiring 5 2L and 5 9L MPI Engine 24 Engine Wiring 5 9L Diesel Engine 25 Four Wheel Drive Wiring 20 Frame Wiring 2 Instrument Panel Wiring Right Side 13 Caption Fig Instrument Panel Wiring 12 Interior Wiring Sport Utility 6 Liftgate Wiring Sport Utility 4 Rear Clearance Lamp Wiring 3 Roof Wiring Sport Utility 5 Starter Wiring 19 Steering Column Wiring 11 Stop Lamp Switch Wiring 14 Tail Lamp Wiri...

Page 485: ...BACK UP LAMP J928W 169 Fig 1 Tail Lamp Wiring ...

Page 486: ...J908W 82 Fig 2 Frame Wiring ...

Page 487: ...J908W 84 GROUND Fig 4 L i f t g a t e Wiring Sport Utility ...

Page 488: ... DOME LAMP TO VIEW REAR DOME LAMP TO ROOF WIRING SPEAKER VIEWX J908W 85 Fig 5 Roof Wiring Sport Utility TO LIFTGATE GROUND TO DOME LAMP TO BODY WIRING TO REAR SPEAKER TO SEAT BELT WIRING J928W 170 Fig 6 Interior Wiring Sport Utility ...

Page 489: ...Fig 7 Cab Wiring Standard Cab ...

Page 490: ......

Page 491: ...MOTOR SPEAKER Fig 9 Door Wiring DOOR SWITCH CONNECTORS POWER WINDOW MOTOR CONNECTOR 2 CD 3 TO SPEAKER VIEW IN DIRECTION OF ARROW Z TO POWER MIRROR TO DOOR SWITCHES TO SPEAKER VIEW IN DIRECTION OF ARROW XWITH POWER MIRRORS J908W 88 ...

Page 492: ...ANEL WIRING TO DOOR WIRING J908W 89 Fig 10 Door Wiring Body Side KEY CYLINDER HALO LAMP CONNECTOR IGNITION SWITCH TO VEHICLE SPEED CONTROL SWITCH SEE VIEW Z MULTI FUNCTION SWITCH CONNECTOR TO INSTRUMENT PANEL WIRING WIRING TROUGH TO FOG LAMP WIRING J938W 95 Fig 11 Steering Column Wiring ...

Page 493: ...MP VIEW N CLUTCH PEDAL POSITION SWITCH CLUTCH PEDAL TO RADIO TO CIGAR LIGHTER TO CHASSIS CONN R W A L TO LEFT DOOR SWITCH INSTRUMENT PANEL INTERMITTENT WIPER CONTROL TO STOP LAMP BRAKE SW DIESEL TO TRANSMISSION OVERDRIVE SWITCH TO MESSAGE CENTER 4WD INDICATOR VIEW IN DIRECTION OF ARROW S VIEW P R W A L DATA LINK CONNECTOR VIEW IN DIRECTION OF ARROW R 25 n o a 2 m J938W 96 Fig 12 instrument Panel W...

Page 494: ...WHEEL ANTI LOCK DATA LINK CONNECTOR TO REAR WHEEL ANTI LOCK BRAKE CONTROL MODULE R W A L CONTROL VIEW IN DIRECTION OF ARROW Z INSTRUMENT PANEL RIGHT SIDE Fig 13 Instrument Panel Wiring Right Side J938W 97 PARK BRAKE SWITCH STEERING COLUMN SUPPORT CONNECTOR PARK BRAKE LEVER STOP LAMP SWITCH J908W 92 Fig 14 Stop Lamp Switch Wiring ...

Page 495: ... WIRING DIAGRAMS TRANSMISSION OVERDRIVE MODULE TRANSMISSION OVERDRIVE SWITCH GAS A C HEATER MODE SWITCH TO TRANSMISSION OVERDRIVE SWITCH DIESEL J938W 98 Fig 15 A C Heater Wiring Fig 16 Underhood Lamp Wiring ...

Page 496: ...CLUTCH RELAY AUTOMATIC SHUT DOWN RELAY FUEL PUMP RELAY BULKHEAD DISCONNECT A C LOW PRESSURE SWITCH SIDE MARKER LAMP TO UNDERHOOD LAMP WIRING VEHICLE SPEED CONTROL SERVO POWERTRAIN CONTROL MODULE A C CYCLING SWITCH TO BLOWER MTR WINDSHIELD WASHER MTR VIEW IN DIRECTION OF ARROW Z VIEW IN DIRECTION OF ARROW W a o o 30 2 m J938W 99 Fig 17 Engine Compartment Wiring 3 9L 5 2L and 5 9L Gas Engines ...

Page 497: ... BEYOND THIS POINT SEE VIEW Z DATA LINK CONNECTOR SIDE MARKER LAMP A C LOW PRESSURE SWITCH BULKHEAD DISCONNECT FUSIBLE LINKS POWERTRAIN CONTROL MODULE AIR HEATER RELAYS TO VEHICLE SPEED CONTROL A C CYCLING SWITCH VIEW IN DIRECTION OF ARROW W VIEW IN DIRECTION OF ARROW Z J938W 100 Fig 18 Engine Compartment Wiring 5 9L Diesel Engine ...

Page 498: ...WIRING DIAGRAMS 8W 23 J938W 101 Fig 19 Starter Wiring Fig 20 Four Wheel Drive Wiring ...

Page 499: ...IEW X VEHICLE SPEED SENSOR CONVERTER CLUTCH SOLENOID TO VEHICLE SPEED SENSOR BEYOND THIS POINT SEE MAIN VIEW TO HEATED OXYGEN SENSOR SEE VIEW X VIEW A 4X4 TRANSFER CASE TYPICAL VEHICLE SPEED SENSOR 1 a so w J938W 102 Fig 21 Transmission Wiring Gas Engines 2 ...

Page 500: ......

Page 501: ...ITION PURGE SENSOR SOLENOID IDLE AIR CONTROL MOTOR TO A C COMPRESSOR CLUTCH DISTRIBUTOR IGNITION COIL ENGINE COOLANT TEMPERATURE ENGINE COOLANT SENSOR PCM TEMPERATURE SENSOR GAUGE ENGINE OIL PRESSURE SENDING UNIT SWITCH DISTRIBUTOR C O N N E R N J E C T O R 1 INJECTOR 3 VIEW IN DIRECTION OF ARROW 1 FUEL INJECTOR 5 TO TRANSMISSION WIRING J938W 85 INS m a o o 2 m Fig 23 Engine Wiring 3 9L MPI Engine...

Page 502: ...NG PUMP ENGINE OIL PRESSURE SENDING UNIT SWITCH VIEW IN DIRECTION OF ARROW Y TO TRANSMISSION WIRING THROTTLE POSITION SENSOR IDLE AIR CONTROL MOTOR GENERATOR ENGINE COOLANT TEMPERATURE SENSOR PCM ENGINE COOLANT TEMPERATURE SENSOR GAUGE MAP SENSOR FUEL INJECTOR 3 EVAP PURGE SOLENOID FUEL INJECTOR 7 FUEL INJECTOR 5 FUEL INJECTOR 1 A C CLUTCH VIEW IN DIRECTION OF ARROW Z J938W 86 Fig 24 Engine Wiring...

Page 503: ...VIEW IN DIRECTION VIEW IN DIRECTION OF ARROW Z OF ARROW X J938W 104 Fig 25 Engine Wiring 5 9L Diesel Engine ...

Page 504: ...t Utility 3 L6 Club Cab 1 L7 Diesel Engine 6 L7 1 4 L7 2 3 L7 2 Sport Utility 3 L7 3 3 L7 4 3 L7 5 3 L50 4 M1 4 M1 1 Sport Utility 1 Splice Number Fit M2 4 M2 1 Sport Utility 1 P33 1 P34 1 T41 Gas Engine 9 V6 4 X2 Diesel Engine 6 X2 Gas Engine 5 X2 1 2 X2 4 3 X2 5 3 X2 6 3 X2 7 2 X53 4 X54 4 Z1 1 4 Z1 2 4 Z1 3 4 Z1 4 Diesel Engine 6 Z1 4 Gas Engine 5 Z1 5 Diesel Engine 6 Z1 5 Gas Engine 5 Z1 6 Die...

Page 505: ...Fig 2 Rear End Splices ...

Page 506: ......

Page 507: ...Fig 4 Instrument Panel Splices ...

Page 508: ......

Page 509: ......

Page 510: ...Fig 8 Heater A C Splices ...

Page 511: ...Fig 9 Engine Splices 3 9L 5 2L and 5 9L Engines ...

Page 512: ...Lamp Gas Engine 58 Brake Warning Indicator Lamp Switch Diesel Engine 34 Wiring Diagram Name Sheet Number Brake Warning Indicator Lamp Switch Gas Engine 32 Bulkhead Disconnect 50 Way 85 86 Buzzer Combined Headlamp Key In and Seat Belt 27 28 Bypass Jumper Clutch Pedal Position 8 Cargo Lamp 49 50 Cargo Lamp Switch 49 Charging System with Diesel Engine 5 6 Battery 5 Generator 6 Charging System with Ga...

Page 513: ...y Heater Motor Resistor Heater System Wiring Diagram Name Sheet Number Horn System 30 Identification Lamps Dual Rear Wheels 41 42 Identification Lamps Roof Mounted 40 Ignition Coil 16 Ignition Switch 2 10 Ignition Switch System 10 Ignition System Gas Engine 15 16 17 18 19 20 Automatic Shut Down Relay 16 Camshaft Position Sensor 20 Crankshaft Position Sensor 18 Data Link Connector 17 Engine Coolant...

Page 514: ...8 Oil Pressure Warning Lamp 59 Parking Brake Switch 31 33 Power Door Lock System 73 74 Left Door Motor 73 Left Door Switch 73 Right Door Motor 74 Right Door Switch 74 Power Mirrors 75 76 Fuse 75 Left Motor 75 Wiring Diagram Name Sheet Number Right Motor 76 Switch 76 Powertrain Control Module 11 12 14 15 16 17 18 19 20 21 22 23 24 35 37 Powertrain Control Module Connector 83 84 Power Window System ...

Page 515: ... 52 61 63 65 75 Splice M1 1 51 Splice M2 49 Splice M2 1 51 Splice P33 74 Wiring Diagram Name Sheet Number Splice P34 74 Splice T41 9 Splice V6 54 55 Splice X2 30 Splice X2 1 79 81 Splice X2 4 41 Splice X2 5 41 Splice X2 6 41 Splice X2 7 80 81 Splice X53 65 Splice X54 65 Splice Z1 1 48 Splice Z1 2 48 52 Splice Z1 3 48 Splice Z1 4 44 46 Splice Z1 5 43 45 Splice Z1 6 11 23 Splice Z1 7 41 79 Splice Z1...

Page 516: ...3 Speaker Left 62 64 Speaker Right 62 64 Stereo Radio Dual Speakers 65 Temperature Sending with Diesel Engine 27 Temperature Sending Unit with Gas Engine 28 Trailer Tow Wiring 81 Transmission Overdrive Solenoid 12 14 Transmission Overdrive System 12 14 Wiring Diagram Name Sheet Number 2 Speed Wiper Motor 55 Washer Pump Motor 55 Switch 55 Turn Signal System 56 Flasher 56 Fuse 56 Lamps Front 43 44 4...

Page 517: ...R WHEEL ANTI LOCK SH 3 1 3 3 FUSE 15 10 AMP L7 18BK YL 3 FUSE 14 D 3 A M P E2 200R X CLUSTER LAMPS SH 59 RADIO LAMPS SH 6 1 6 3 6 5 A C AND HEATER CONTROL LAMP SH 48 ASH RECEIVER LAMP SH 48 TACHOMETER LAMP SH 48 T R A N S M I S S I O N OVERDRIVE INDICATOR LAMP SH 12 HEATED REAR WINDOW SWITCH LAMP SH 39 PARKING LAMPS SH 4 3 4 4 4 5 4 6 T A I L LAMPS SH 7 9 8 0 L I C E N S E LAMP SH 80 FRONT S I D E...

Page 518: ...W FUSE 9 120 AMP V6 18DB WINDSHIELD WIPER SYSTEM SH 54 55 RADIO AND CLOCK SH 61 63 65 L5 18RD i TURN SIGNAL FLASHER SH 56 TACHOMETER PROVISIONS SH 48 REAR WHEEL ANTI LOCK MODULE SH 31 33 AUTOMATIC SHUT DOWN RELAY SH 16 22 TRANSMISSION OVERDRIVE SOLENOIDS SH 12 14 FUEL PUMP RELAY SH 16 GENERATOR SH 4 VACUUM SENSOR SH 34 AIR SWITCHING SOLENOIDS SH 16 PMC SH 16 AIR HEATER CONTROLLER SH 21 WOT RELAY S...

Page 519: ... LEFT FRONT OF ENGINE BLACK REAR OF BATTERY FUSIBLE LINK HYPALON WIRE TO HAZARD FLASHER SEE SH 56 REAR OF BATTERY BLACK TO FUSE 15 SEE SH 49 AND TO 8 SPLICE SPORT UTILITY ONLY SEE SH 39 AO 6BK I O D CONNECTOR NATURAL FRONT LEFT SIDE SHIELD AO 6BK A4 18GY TO ENGINE STARTER K MOTOR r SEE SH 9 FUSIBLE LINK HYPALON WIRE AOA 12RD AD 3 CHARGING SYSTEM WITH GAS ENGINES J938W 11 ...

Page 520: ...GINE All 6BK RIGHT FENDER SIDE SHIELD All 6BK FUSIBLE LINK HYPALON WIRE All 10DG A2 200R TO WIDE OPEN C26 14BR 1 THROTTLE RELAY SEE SH 68 50 A2 12PK BK A2 12PK BK FUSIBLE LINK HYPALON WIRE Al 200R FUSIBLE LINK HYPALON WIRE 4 9 m Al 12RD Al 12RD TO IGNITION SWITCH SEE SH 10 A14 22WT k A 1 C D n T0 FUEL PUMP RELAY A M 16RD 1 SEE SH 16 TO A3 SPLICE SEE SH 47 AOA 12RD A3 18GY A3 12RD WT A3 12RD WT 1 J...

Page 521: ...0 RD Al 2 0 RD I A4 14BK RD TO FUSE 15 SEE SH 49 A3 14PK Al 2 0 RD TO HAZARD r FLASHER y SEE SH 56 23 I O D CONNECTOR NATURAL FRONT LEFT SIDE SHIELD A15 16PK T40 14BR A15 16PK T40 14BR A15 22WT TO ENGINE STARTER MOTOR SEE SH 7 BLACK REAR OF BATTERY TO ENGINE STARTER RELAY SEE SH 7 FUSIBLE LINK HYPALON WIRE AD 5 CHARGING SYSTEM WITH DIESEL 5 9L ENGINE J938M 11 ...

Page 522: ...All 6BK RIGHT FENDER SIDE SHIELD FUSIBLE LINK HYPALON WIRE AOA 12RD FUSIBLE LINK HYPALON WIRE A2 200R C26 14BR 50 TO ENGINE STARTER T O WIDE 1 f J l c h J n J OPEN THROTTLE SEE SH 7 RELAY SEE SH 70 Al 200R FUSIBLE L I N K HYPALON WIRE A2 12PK BK A l 1 2 R D A2 12PK BK A l 12RD 49 A14 22WT A14 16RD A14 16RD A3 18GY A3 12RD WT A3 12RD WT TO IGNITION SWITCH SEE SH 10 TO AUTOMATIC SHUT DOWN RELAY SEE ...

Page 523: ...TER RELAY LEFT SIDE SHIELD TO CHARGING SYSTEM SEE SH 5 6 TO v A 9 1 u n Q f IGNITION A 2 1 1 4 0 8 5 SWITCH SEE SH 10 ENGINE STARTER MOTOR LEFT LOWER REAR OF ENGINE AD 7 5 3 L D I E S E L E N G I N E S T A R T E R S Y S T E M J938W 11 ...

Page 524: ... SH 10 A41 1 6 Y L S21 14YL BK 31 MANUAL TRANSMISSION BLACK J 18BK C L U K H 18BK PEDAL POSITION SWITCH ON CLUTCH ROD BYPASS JUMPER TAPED TO WIRE HARNESS SWITCH CLOSES WHEN CLUTCH IS DEPRESSED J938W 11 5 9 L D I E S E L ENGINE STARTER SYSTEM AD 8 ...

Page 525: ...YL r Z 1 1 8 B K T41 18BR YL 14 ENG TO POWERTRAIN CONTROL MODULE I I PCM I I AUTO TRANS CAVITY 30 S E E SH 19 T41 20BR YL T41 18BR YL jt _ _ _ _ j 1 b i MANUAL TRANS ONLY Zl 14BK H E N G h Zl 14BK TO A C COMPRESSOR CLUTCH S E E SH 6 8 T 0 Z 1 4 1 S P L I C E S E E SH 4 4 4 6 L I 18VT BK FUSE 3 20 AMP F20 18WT TO HEATED REAR WINDOW SWITCH S E E SH 3 9 TO BACK UP LAMPS S E E SH 7 9 TO _A 2i 1 4 D B ...

Page 526: ...SE 11 30 AMP TO AIR CONDITIONING AND HEATER FEED SEE SH 6 6 6 7 6 9 12BK 0R FUSE 12 30 AMP CIRCUIT BREAKER CI 12DG F21 12TN TO POWER WINDOWS SEE SH 71 Gil 20WT BK Gil 20WT BK 20PK BK A41 14YL A21 14DB Gil 20WT BK Gil 20WT BK A2 12PK BK A22 12BK 0R A3 14BK WT Al 12RD FUSE 7 15 AMP FUSE 8 10 AMP F30 16RD TN X12 20RD WT FUSE 9 20 AMP FUSE 10 20 AMP 18DB 5 18DB 5 14RD TO MESSAGE CENTER SEE SH 57 DIESE...

Page 527: ...LAMP GROUND CENTER DASH PANEL 4 11 18BK Zl TO TRANSFER 18 BK CASE SWITCH SEE SH 13 Zl 14BK T0 Z124j SPLICE SEE SH 44 46 EMCC SOLENOID 3 SPEED AUTO TRANS MOUNTED ON TRANSMISSION LEFT SIDE T22 T22 HOB 14DB W T WT AD 1 1 EMCC SYSTEM 3 S P E E D AUTOMATIC TRANSMISSION J938W 11 ...

Page 528: ...OR E2 200R 1 8 UNG j POWERTRAIN 10 CONTROL MODULE I I 37 PCM I I CONNECTOR SEE SH 84 55 T6 200R WT T61 20BK 0R 54 K 5 4 200R BK T 0 A 2 1 SPLICE T60 S 200R SEE SH 16 LG 44 T6 200R WT 17 ON T R A N S M I S S I O N EMCC SOLENOID K54 20QR BK A21 14DB A21 14DB A21 14DB T60 200R LG J 3 9 L T R A N S M I S S I O N T R O A V N E B n 5 9 L E N G I N E S o v e r d r i v e s y s t e m ON TSSSION A U T O T R...

Page 529: ...SEE SH 31 33 r 3 31 3 BLACK REAR OF ENGINE X4 20LG BR Z12 18BK TN BLACK ON TRANSFER CASE V X4 20LG BR Z l 18BK BLACK ON TRANSFER CASE X4 20LG BR Z l 1SBK 241 TRANSFER CASE LEFT SIDE FRONT AXLE Gl 20DG GY Gl 20DG GY r X4 20LG BR DIESEL TO SPLICE SEE SH 24 X4 20LG BR BLACK LEFT SIDE DASH PANEL FOUR WHEEL DRIVE INDICATOR LAMP 40 GAS ENGINE TO V E H I C L E SPEED CONTROL SERVO SEE SH 35 Zl 18BK 1 TO Z...

Page 530: ... T6 200R WT T61 20BK 0R 3r Ji Zl 18BK Zl 18BK G5 20DB WT 24 TO Z1 1 SPLICE SEE SH 48 T61 20BK OR c o c o c _p I i POWERTRAIN CONTROL 10 MODULE I I q 7 PCM I I J CONNECTOR SEE SH 83 55 T6 200R WT T61 20BK 0R 44 T6 200R WT T60 200R LG TO A21 21 SPLICE SEE SH 24 J938W 11 A21 14DB DARK GRAY REAR OF ENGINE T60 200R LG TRANSMISSION OVERDRIVE SYSTEM DIESEL ENGINES PCM TRANSMISSION OVERDRIVE SOLENOID II A...

Page 531: ...6 15 14 13 38 58 17 18 I N J INJ INJ INJ INJ I N J INJ INJ 1 Ml 3 4 5 6 Ul 8 POWERTRAIN CONTROL MODULE I I PCM I I 19 I G N I T I O N COIL DRIVER 57 ASD B CONNECTOR S E E SH 84 LEFT FENDER S I D E S H I E L D AD 15 IGNITION SYSTEM GAS MFI ENGINES J938W 11 ...

Page 532: ...8 TO CHARGING SYSTEM S E E SH 4 A H 16RD ENGT A21 14DB A21 H O B A21 H O B A H 16RD K51 20DB YL TO DATA L I N K S CONNECTOR S E E SH 17 TO T R A N S M I S S I O N OVERDRIVE SOLENOID S E E S H 12 A21 H D B K52 20PK BK EVAP PURGE S O L E N O I D K 3 5 L E F T REAR 2 0 G Y OF E N G I N E YL EGR S O L E N O I D RIGHT REAR OF E N G I N E 3 5 1 9 52 35 BATTERY ASD I G N I T I O N EVAP EGR RELAY FEED PUR...

Page 533: ...5 25 DATA S I G N A L DATA LINK GROUND LINK R E C E I V E TRANSMIT I1 1 I 2 I POWER GROUND 23 41 HEATED OXYGEN SENSOR POWERTRAIN CONTROL MODULE I I PCM I I CONNECTOR S E E SH 84 LEFT FENDER S I D E S H I E L D AD 17 IGNITION SYSTEM GAS MFI ENGINES J 9 3 8 W U ...

Page 534: ... THROTTLE P O S I T I O N SENSOR ON THROTTLE BODY T 0 K 6 S P L I C E S E E SH 20 rtM KB 20VT WT K4 1 8 B K L B TO 8 x S P L I C E S E E SH 20 TO A C AND HEATER SYSTEM S E E SH 68 K22 180R DB E N G h 25 F N G C20 18BR C13 20DB OR 24 22 27 34 R E F T P S A C W O T PICKUP CYCLING RELAY SWITCH POWERTRAIN CONTROL MODULE I I PCM I I CONNECTOR S E E SH 84 LEFT FENDER S I D E S H I E L D J938U 11 IGNITIO...

Page 535: ...AMP MODULE CANADA ONLY SEE SH 46 G7 20WT OR G7 8 20WT 0R H G3 20BK PK 38 13 G7 20WT OR 43 TO MESSAGE CENTER SERVICE REMINDER INDICATOR SEE SH 58 G24 22 GY PK 42 G3 20BK PK ENGf TO CHARGING SYSTEM SEE SH 4 T K20 18DG T G24 20GY PK 33 HENG 24 ETTGI G7 20WT 0R G3 20BK PK G24 20GY PK 30 PARK NEUTRAL SWITCH 40 60 39 20 32 IAC IAC IAC GENERATOR MIL FIELD POWERTRAIN CONTROL MODULE I I PCM II 56 SRI CONNE...

Page 536: ...HARGE A I R TEMP 2 ECT 44 CMP 7 8 VOLT INPUT 4 SENSOR RETURN 6 5 VOLT SUPPLY 47 V E H I C L E SPEED SENSOR 1 MAP SENSOR POWERTRAIN CONTROL MODULE I I PCM I I CONNECTOR S E E S H 8 4 LEFT FENDER S I D E S H I E L D J938H 11 IGNITION SYSTEM GAS MFI ENGINE AD 20 ...

Page 537: ...ten AIR INTAKE HEATER ON INTAKE UNDER INLET PIPE TO ENGINE STARTER RELAY SEE SH 7 T T41 20BR YL J L 1 S21 18YL BK A21 MDB T0 2 SPLICE SEE SH 23 TO CHARGING SYSTEM SEE SH 6 K20 18DG 30 PARK NEUTRAL POSITION SWITCH 16 HEATER 1 RELAY 20 GENERATOR FIELD 15 HEATER 2 RELAY IGNITION FEED POWERTRAIN CONTROL MODULE I I PCM I I CONNECTOR SEE SH 83 LEFT FENDER SIDE SHIELD AD 21 D I E S E L CONTROL SYSTEM J93...

Page 538: ...1 14DB AUTOMATIC SHUT DOWN RELAY LEFT SIDE SHIELD A14 16RD TO GENERATOR SEE SH 6 G3 20BK PK G21 20GY LB A142 16DG OR K51 A142 20DB 16DG YL OR 16 A14 16RD G3 20BK PK G21 20GY LB 51 57 3 32 43 A S D A S D BATTERY MIL TACH RELAY BATTERY FEED POWERTRAIN CONTROL MODULE I I PCM I I CONNECTOR SEE SH 83 LEFT FENDER S I D E S H I E L D J938W 11 DIESEL CONTROL SYSTEM AD 22 ...

Page 539: ...ESSOR 71 1 4 B K C C L U T C H v Zl j S E E SH 70 T 0 Z l 1 8 B K A UNDERHOOD LAMP SEE SH 29 TO VACUUM SENSOR S E E SH 34 A21 1408 TO LEFT HEADLAMP GROUND S E E SH 4 3 4 5 G86 20DG WT G85 20TN OR 11 TO DAYTIME RUNNING LIGHTS MODULE SEE SH 46 Z l l 18BK WT 20 E5 K31 20DG 20BK WT PK DATA LINK CONNECTOR RIGHT REAR OF ENGINE COMPARTMENT 020 20LG 56 54 W A I T T O W A T E R I N START LAMP FUEL LAMP POW...

Page 540: ... SH 13 Z12 18BK TN T41 18BR YL i TO ENGINE STARTER RELAY MANUAL TRANS ONLY A 2 i SEE SH 7 HOB FUEL HEATER ON TOP OF FUEL WATER SEPARATOR BLACK I 1 THERMO SWITCH A21 14DB FUEL SOLENOID LEFT FRONT OF ENGINE A21 18BL EIZZll COLD START ADVANCE K S B MOTOR ON PUMP FRONT OF ENGINE J938W 11 D I E S E L CONTROL SYSTEM AD 24 ...

Page 541: ...ERATURE SENSOR IN INTAKE LEFT SIDE TO LEFT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 60 TO DAYTIME RUNNING LIGHT MODULE CANADA ONLY SEE SH 46 47 7 2 1 21 24 28 VEHICLE 8 VOLT ECT WATER 1N INTAKE CKP THERMO SPEED SENSOR INPUT SENSOR FUEL AIR TEMP PICK UP SWITCH PICK UP SENSOR CONNECTOR POWERTRAIN CONTROL MODULE I I PCM I I SEE SH 83 LEFT FENDER S I D E S H I E L D AD 25 D I E S E L CONTROL SYSTEM J938...

Page 542: ... G7 20WT OR A B L A C K LEFT REAR OF ENGINE O o oo O O 9 9 9 O V E H I C L E SPEED SENSOR ON REAR OF T R A N S M I S S I O N AUTOMATIC TRANS 2 W D ONLY K22 180R DB TO A C SYSTEM S E E SH 70 K4 18BK LB K6 20VT WT C 1 3 20DB OR C20 18BR 22 4 6 T P S SENSOR 5 VOLT RETURN SUPPLY POWERTRAIN CONTROL MODULE I I PCM I I 34 27 W O T A C RELAY COMPRESSOR CLUTCH CONNECTOR S E E SH 8 3 L E F T FENDER S I D E ...

Page 543: ... YL TO RIGHT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 60 BLACK REAR OF ENGINE LEFT SIDE G60 20GY YL G60 20GY YL ENGINE OIL PRESSURE SENDING UNIT AND SWITCH G20 20VT YL G6 20GY G6 20GY LEFT SIDE OF BLOCK CENTER G60 2 0 G Y Y L G6 20GY ENGINE TEMPERATURE SENDING UNIT LEFT REAR OF CYLINDER HEAD AD 27 OIL PRESSURE AND TEMPERATURE SYSTEM FOR D I E S E L ENGINE jsaew n ...

Page 544: ...NG G60 20GY YL G6 20GY TO LEFT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 60 17 G20 20VT YL 26 ENG h G20 ENGINE OIL PRESSURE SENDING UNIT AND SWITCH REAR OF INTAKE MANIFOLD CENTER ENGINE TEMPERATURE SENDING UNIT RIGHT SIDE FRONT OF ENGINE OIL PRESSURE AND TEMPERATURE SYSTEM FOR ELECTRONIC U938W H FUEL INUECTION IGNITION AD 28 ...

Page 545: ... 18PK BLACK TO BOOY WIRING SEE SH 50 RIGHT SIDE COWL PANEL BLACK Zl 1BK GAS DIESEL Ml 18PK TO Z1 4 SPLICE SEE SH 44 46 TO M SPLICE SEE SH 49 T0 Z1 6 SPLICE SEE SH 23 Zl 18BK Ml 18PK UNDERHOOD LIGHT CENTER OF HOOD INNER PANEL MERCURY SWITCH AD 29 UNDERHOOD LAMP J938W 11 ...

Page 546: ...RN HIGH NOTE HORN LEFT SIDE OF RADIATOR SUPPORT GAS LEFT SIDE SHIELD DIESEL BLACK X2 18DG RD RIGHT SIDE OF RADIATOR SUPPORT GAS LEFT SIDE SHIELD DIESEL BLACK X2 18DG RD NOTE HORNS ON DIESEL ARE ON LEFT SIDE NEAR BATTERY 32 X2 18DG RD X3 20BK RD CLOCK SPRING OR HORN RING IN COLUMN I N STEERING COLUMN HORN SWITCH STEERING COLUMN GROUND THROUGH CENTER SHAFT J938W 11 HORN SYSTEM AD 30 ...

Page 547: ...H 13 TWISTED PAIR ROLLS TEST CONNECTOR IN PLANT USE ONLY pa 3 D D 3 D 2 J 3 B114 18WT VT L50 18WT TN F32 20PK DB G9 20GY BK B102 180R A N T I L O C K LAMP IGN FEED Gil 20WT BK B112 18BK WT 12 18BK LG TO INTERMITTENT WIPER MODULE SEE SH 54 GRAY L50 18WT TN Gil 20WT BK G9 20GY BK Gl 2QDG GY L5 14RD B102 180R B101 16LG BK B113 18RD VT B114 18WT VT B112 18BK WT B i l l 18LB 12 18BK LG F32 20PK DB B108...

Page 548: ... LEFT FRONT FRAME R A I L TO HAZARD L50 18WT TN F L A S H E R SWITCH S E E SH 5 6 R W A L SENSOR I N REAR D I F F E R E N T I A L TO POWERTRAIN CONTROL MODULE I I CAVITY 29 S E E SH 3 5 O STOP LAMP AND V E H I C L E SPEED CONTROL SWITCH WITH SPEED CONTROL STOP LAMP SWITCH WITHOUT V E H I C L E SPEED CONTROL J 9 3 8 W 1 1 REAR WHEEL ANTI LOCK BRAKE SYSTEM GAS ENGINE AD 32 ...

Page 549: ... SH 13 B114 18WT VT TWISTED PAIR ROLLS TEST CONNECTOR m IN PLANT USE ONLY B114 18WT VT L50 18WT TN F32 20PK DB Gil 20WT BK B102 180R A N T I LOCK LAMP BRAKE LAMP G9 20GY BK Bl12 18BK WT Z2 18BK LG TO INTERMITTENT WIPER MODULE SEE SH 54 GRAY L50 18WT TN Gil 20WT BK G9 20GY BK Gl 20DG GY L5 14RD B102 180R B101 16LG BK to g S B113 18RD VT B114 18WT VT B112 18BK WT B i l l 18LB Z2 18BK LG F32 20PK DB ...

Page 550: ...18WT TN F32 20PK DB TO BUZZER S E E SH 77 GROUND S P L I C E S E E SH 48 B l 1 3 18RD VT B114 18WT VT TO HAZARD L50 18WT TN FLASHER SWITCH S E E SH 56 TAPED TO HARNESS NEAR CONNECTOR 8113 B l 1 4 18RD 18RD VT VT F32 18PK DB Zl 18BK 150 20WT TN Zl 20BK V40 18WT PK TO DATA LINK CONNECTOR S E E SH 23 RESISTOR 41 20PK 18WT V40 18WT PK i TO POWERTRAIN CONTROL MODULE I I CAVITY 29 SEE SH 37 TWISTED P A ...

Page 551: ...ICE S E E SH 1 1 31 E N G V35 20LG RD 30 E N G Zl 20BK V30 20DB RD V36 20TN RD V35 20LG RD D I R E C T 7 CONNECTION 12 ENG 29 HENGV V32 20YL RD 27 E N G V31 2 0 B R R D V33 20WT LG V30 2 0 D B R D TO REAR WHEEL ANTI LOCK CONTROL MODULE S E E SH 3 1 TO SEAT BELT F WARNING S Y S T E M y S E E S H 7 8 FUSED BATTERY FEED F 3 2 2 0 P K D B F 3 2 18PK DB V40 18WT PK V E H I C L E SPEED CONTROL SERVO UND...

Page 552: ... G N I T I O N f SWITCH S E E SH 10 STOP LAMP AND VEHICLE SPEED CONTROL SWITCH WITH V E H I C L E SPEED CONTROL J938W 11 GAS ENGINES VEHICLE SPEED CONTROL SYSTEM V E H I C L E SPEED CONTROL SWITCH I N S T E E R I N G WHEEL AD 36 ...

Page 553: ...ICE y SEE SH 43 45 Zl 20BK V40 18WT PK V36 20TN RD V35 20LG RD V31 20BR RD V33 20WT LG V30 20DB RD TO REAR WHEEL ANTI LOCK CONTROL MODULE SEE SH 33 TO SEAT BELT f WARNING SYSTEMr SEE SH 77 FUSED BATTERY FEED F32 18PK DB F32 18PK DB V40 18WT PK DIRECT CONNECTION TO SERVO VEHICLE SPEED CONTROL SERVO LEFT FENDER SIDE SHIELD AD 37 5 9 L D I E S E L ENGINE VEHICLE SPEED CONTROL SYSTEM J938W 11 ...

Page 554: ... I O N f SWITCH y S E E SH 10 STOP LAMP AND V E H I C L E SPEED CONTROL SWITCH WITH V E H I C L E SPEED CONTROL J938W 11 5 9 L DIESEL ENGINE VEHICLE SPEED CONTROL SYSTEM V E H I C L E SPEED CONTROL SWITCH I N S T E E R I N G WHEEL AD 38 ...

Page 555: ... SPLICE J SEE SH 48 ILLUM LAMP FEED ON jz OFF OF MECHANICAL OFF ON SWITCH HEATED REAR WINDOW DEFOGGER SWITCH INSTRUMENT PANEL L E D TIMER BLACK CIS 12BK WT E2 220R Zl 20BK F20 18WT e A4 12BK RD CIS 12BK WT BLACK LEFT C P I L L A R LEFT SIDE KICK PANEL TO FUSIBLE LINK SEE SH 3 A4 12BK RD 48 A4 12BK RD TO FUSE BLOCK FUSE 15 SEE SH 49 ELECTRICALLY HEATED REAR WINDOW AD 39 SPORT U T I L I T Y vJ938w n...

Page 556: ...NT PANEL BLACK cur AT LAMP L7 18BK CLEARANCE LAMP L7 18BK YL L7 18BK YL L7 18BK YL L7 18BK YL BLACK C D X AT LAMP BLACK an AT LAMP BLACK an AT LAMP BLACK an AT LAMP L7 18BK L7 18BK IDENTIFICATION LAMP IDENTIFICATION LAMP L7 18BK IDENTIFICATION LAMP L7 18BK CLEARANCE LAMP J938W 11 FRONT CLEARANCE AND I D E N T I F I C A T I O N LAMPS ROOF AD 4 0 ...

Page 557: ...AMS L7 18BK YL L7 18BK YL CLEARANCE LAMP IDENTIFICATION LAMP IDENTIFICATION LAMP IDENTIFICATION LAMP CLEARANCE LAMP X2 18GY X2 18GY L7 18BK YL L7 18BK YL AD 41 CLEARANCE AND IDENTIFICATION LAMPS DUAL REAR WHEELS J938W 11 ...

Page 558: ... LEFT S I D E X2 18GY L7 1 8 B K Y L L7 16BK X2 16GY an an L7 16BK X2 16GY L7 16BK X2 16GY L7 16BK X2 16GY BLACK REAR UNDERBODY RIGHT S I D E LEFT FENDER CLEARANCE LAMPS arr 7 f an am an RIGHT FENDER CLEARANCE LAMPS an y TN an FENDER CLEARANCE LAMPS DUAL REAR WHEELS AD 42 ...

Page 559: ...18TN L61 18LG L61 18LG 26 L3 14RD 0R L7 I8BK YL L7 18BK YL L4 16VT WT Zl 22BK 21 GAS L61 18LG L3 14RD 0R L7 18BK YL 5 Z1 1 L 4 16VT WT TO n t r r r VEHICLE SPEED DIESEL CONTROL SERVO SEE SH 37 DIESEL ONLY i Zl 20BK L7 18BK YL Zl 18BK L61 18LG L7 18BK YL L7 18BK YL L7 18BK YL Zl Zl 18BK 18BK N8 LEFT HEADLAMP GROUND LEFT FENDER SIDE SHIELD Z12 14BK TN LEFT REAR RADIATOR YOKE PANEL GAS ENGINE ONLY TO...

Page 560: ...SH PANEL SPLICE SEE SH 11 GAS ENGINE ONLY Zl 22BK L4 16VT WT L3 14RD 0R 3 d RIGHT HEADLAMP Zl 14BK Zl 14BK f TO ENGINE WIRING j SEE SH 9 GAS ENGINE ONLY TO BLOWER MOTOR A SEE SH 66 67 GAS ENGINE ONLY RIGHT SIDE MARKER LAMP RIGHT PARK AND TURN SIGNAL LAMP TO UNDERHOOD LAMP SEE SH 2 9 GAS ENGINE ONLY RIGHT REAR RADIATOR YOKE GAS ENGINE ONLY 18TN J 9 3 8 W 1 1 FRONT END LIGHTING AD 44 ...

Page 561: ... SEE SH 47 26 L3 14RD 0R L7 18BK YL L7 18BK YL L4 16VT WT Zl 22BK 21 GAS I L3 14RD OR L7 18BK YL L 4 16VT WT L61 j 5 Z 1 k n T F F 1 VEHICLE SPEED l DIESEL CONTROL SERVO SEE SH 37 DIESEL ONLY i Zl 20BK 18LG L7 18BK YL Zl 18BK L61 18LG L7 18BK YL L7 18BK YL I i L7 18BK YL Zl 18BK LEFT HEADLAMP GROUND LEFT FENDER SIDE SHIELD Z12 14BK TN LEFT REAR RADIATOR YOKE PANEL GAS ENGINE ONLY TO Z12 1 S P L I ...

Page 562: ...P SWITCH SEE SH 47v LEFT PARK AND TURN SIGNAL LAMP TO BLOWER MOTOR SEE SH 66 67 GAS ENGINE RIGHT HEADLAMP GROUND CENTER DASH P A N E L J938W 11 SPLICE SEE SH 23 DIESEL ENGINE SPLICE SEE SH 11 GAS ENGINE FRONT END LIGHTING CANADA AD 46 ...

Page 563: ... LINK j SEE SH 4 6 FUSE 14 3 AMP 616 20BK LB JG16 20BK LB G26 20LB G26 20LB IF33 18PK RD M2 20YL L2 14LG jD cb B3 H P A BlLH A3 12RD WT L7 18BK YL AD 47 TO DAYTIME RUNNING LAMP MODULE f L 2 0 20LG WT JanadaH oJEJ h e a d l a m p s w i t c h J938W 11 ...

Page 564: ...ORT U T I L I T Y ONLY TO RADIO SEE SH 6 1 6 3 6 5 P R O V I S I O N FOR TACHOMETER NEAR FUSE BLOCK O I E S E L BLACK TO PCM I I SEE SH 22 TO TURN SIGNAL FLASHER SEE SH 56 BLACK J M O TO MESSAGE CENTER D I E S E L S E E SH 57 GROUND TO BRAKE SWITCH S E E SH 3 2 3 4 3 6 3 8 J 9 3 8 W U TO MAP LAMP AND READING S E E SH 49 TO POWER DOOR LOCKS S E E SH 73 TO POWER MIRRORS S E E SH 75 TO POWER WINDOWS ...

Page 565: ...SW 90 WIRING DIAGRAMS TO COMBINED BUZZER SEE SH 7 7 7 8 L30 18BR YL Zl 20BK Ml 18PK BLUE AD 49 MAP LAMP AND CARGO LAMP msu n ...

Page 566: ...Ml 18BK 18BK YL PK BLACK NEAR LAMP V Y L6 L6 180R 180R VT VT BLACK NEAR LAMP fcLJSL LEFT S I D E OF STEERING COLUMN BLACK M2 18BK YL Ml 18BK PK BLACK STANDARD CAB CLUB CAB M2 20YL Mi 18PK L30 18BR YL Ml 18PK TO UNDERHOOD 4 LAMP SEE SH 29 BLACK M2 20YL TO BODY WIRING SPORT U T I L I T Y ONLY S E E SH 51 J938W 11 DOME LAMP AND CARGO LAMP AD 50 ...

Page 567: ...K YL M2 18BK YL Ml 18PK PK FRONT DOME READING LAMP BLACK C 3 3 Z BLACK UNDER BULKHEADJ CONNECTOR LIFTGATE AJAR SWITCH L I F T G A T E LATCH M2 G78 18BK 18TN YL BK TO UNDERHOOD LAMP S E E SH 29 DIODE AND MOLD ASSEMBLY LEFT C P I L L A R M4 18TN BK Z l 12BK BOOY GROUND LEFT REAR C P I L L A R BLACK LEFT C P I L L A R AD 51 LIFTGATE AJAR WARNING SYSTEM AND REAR DOME LAMPS SPORT U T I L I T Y ONLY JSM...

Page 568: ...D V SEE SH 3 5 A4 12BK RD GLOVE BOX LAMP AND SWITCH CIGAR LIGHTER n n t n t U U 1 CENTER OF INSTRUMENT PANEL BLACK TO HEADLAMP SWITCH SEE SH 47 TO IGNITION SWITCH SEE SH 10 J938W 11 CIGAR LIGHTER ASH RECEIVER LAMP AND GLOVE BOX LAMP AD 52 ...

Page 569: ...0BR 3 V6 18DB V8 18VT INTERMITTENT WIPER SWITCH ON STEERING COLUMN V9 18WT BK X V3 18BR WT V4 18RD YL V7 18DG WT 18DG YL STEERING COLUMN CONNECTOR SEE SH 87 V3 18BR WT V17 18DG YL Zl 12BK VIO 18BR V8 18VT V9 18WT BK V7 18DG WT Z2 18BK LG V6 18DB V3 18BR WT V4 18RD YL JTO Jlj2 AD 53 SPLICE PANEL GROUND SEE SH 48 RIGHT OF STEERING COLUMN INTERMITTENT WIPER SYSTEM J938W 11 ...

Page 570: ...ITTENT WIPER 7 CONTROL UNIT 2 8 1 6 3 4 5 MOUNTED ON BRACKET UNDER STEERING COLUMN TO I G N I T I O N SWITCH S E E SH 10 V 1 0 18BR V 8 18VT V9 18WT BK V7 18DG WT 12 18BK LG V6 18DB V3 18BR WT 4 18RD YL 1 INTERMITTENT WINDSHIELD WIPER MOTOR I N PLENUM LEFT S I D E t C4 V3 18BR WT K t V6 18DB NC4 V5 18DG YL K M V 4 18RD YL PARK SWITCH J938W 11 INTERMITTENT WIPER SYSTEM AD 54 ...

Page 571: ...SW 96 WIRING DIAGRAMS WINDSHIELD WIPER SWITCH F0R__CONNECTOR SEE SH 88 LO W PARK ft w _ HI T V HI TO A C 8LOWER MOTOR S E E SH 6 6 6 7 6 9 AD 5 5 WINDSHIELD WIPER SYSTEM J938W 11 ...

Page 572: ...RAKE SWITCH SEE SH 3 6 3 8 L50 18WT TN L50 18WT TN L50 18WT TN GRAY CL50 HAZARD FLASHER SWITCH CONNECTOR S E E SH 8 7 8 8 TO REAR WHEEL ANTI LOCK i RWAL MODULE S E E SH 3 2 3 4 L61 18LG L61 18LG 11 L 6 G 18TN TO REAR L I G H T I N G SEE SH 79 TURN SIGNAL SWITCH ON STEERING COLUMN L63 18DG RD L62 18BR RD 0 0 0 4 5 6 TO LEFT PRINTED C I R C U I T BOARD CONNECTOR S E E SH 60 21 22 L61 18LG 5 L S I 18...

Page 573: ...TEST SEE SH 10 Gil 20WT BK BRAKE WARNING SWITCH AND VACUUM SWITCH SEE SH 33 Gil 20WT BK REAR WHEEL ANTI LOCK BRAKE MODULE SEE SH 33 G86 20DG WT WAIT TO START SWITCH SEE SH 23 B102 180R ANTI LOCK MODULE SEE SH 33 G5 20DB WT IGNITION 12V FEED SEE SH 58 Zl 22BK GROUND Z 1 1 S P L I C E SEE SH 48 G40 20LB BK FUEL TANK LOW FUEL SWITCH SEE SH 77 AD 57 MESSAGE CENTER D I E S E L J938W 11 ...

Page 574: ...RIVE SWITCH S E E SH 12 GAS ONLY GRAY G5 20DB WT G i l 20WT BK SEE SH 10 G i l 20WT BK B102 180R BLACK TO I G N I T I O N SWITCH GROUND TO REAR WHEEL ANTI LOCK MODULE S E E SH 31 TO COMBINED BUZZER S E E SH 7 7 7 8 G24 22GY PK S E R V I C E REMINDER INDICATOR S E E SH 19 G78 20TN BK GATE OPEN LAMP S E E SH 51 G9 20GY BK TO REAR WHEEL A N T I L O C K MODULE S E E SH 31 G9 20GY BK TO BRAKE LAMP WARN...

Page 575: ...N LAMP LOW ENGINE O I L PRESSURE LAMP RIGHT TURN SIGNAL LAMP LOW ENGINE O I L PRESSURE GAUGE ILLUMINATION LAMP ENGINE COOLANT TEMPERATURE GAUGE ILLUMINATION LAMP MALFUNCTION INDICATOR LAMP VEHICLE SPEED SENSOR E L E C T R I C SPEEDOMETER HIGH BEAM INDICATOR LAMP ILLUMINATION LAMP FUEL GAUGE AD 59 CLUSTER PRINTED CIRCUIT BOARD J938W 11 ...

Page 576: ...N F E E D 1 2 VOLTS S E E SH 58 LEFT CONNECTOR BLACK E2 200R ILLUMINATION LAMP FEED S E E SH 48 Zl 20BK GROUND S E E SH 48 G4 20DB FUEL GAUGE SENDING UNIT SEE SH 7 7 7 8 G6 20GY ENGINE O I L PRESSURE LAMP SWITCH S E E SH 2 7 2 8 G5 20DB WT I G N I T I O N F E E D 1 2 VOLTS S E E SH 5 8 7 7 7 8 G34 16RD GY HIGH BEAM INDICATOR LAMP S E E SH 4 3 4 5 L60 18TN RIGHT TURN SIGNAL LAMP SEE SH 56 G60 20GY ...

Page 577: ...31 14BK WT TO BATTEF FEED S E E SH 3 5 s FUSE 8 10 AMP qoc Y N SEE X12 2 0 R D W T Ml 20PK GRAY BEHIND RADIO X56 18DB RD X55 18BR RD X58 18DB 0R X57 18BR LB X 5 4 18VT X53 18DG X52 18DB WT X 5 1 18BR YL GRAY BLACK aTl FOR 2 SPEAKERS WIRING S E E SH 65 STEREO RADIO AD 61 STEREO RADIO 4 SPEAKERS J938W 11 ...

Page 578: ...X58 18DB 0R X57 18BR LB X54 18VT X53 18DG X52 18DB WT X51 18BR YL X52 18DB WT X58 18DB 0R BELOW BULKHEAD Lb dl CONNECTOR GREEN X56 18DB RD X53 18DG X55 18BR RD RIGHT REAR SPEAKER BLACK COWL TOP RIGHT S I D E LEFT FRONT DOOR SPEAKER RIGHT FRONT DOOR SPEAKER J938W 11 STEREO R A D I O 4 SPEAKERS AD 62 ...

Page 579: ... qoc T 7 TO BATTERY FUSE 14 3 AMP FEED S E E SH 3 5 S E E SH 48 X12 20RD WT Ml 20PK E2 200R GRAY BEHIND RADIO X56 18DB RD X55 18BR RD X58 18DB 0R X57 18BR LB X 5 4 18VT X53 18DG X52 18DB WT X 5 1 18BR YL GRAY BLACK T FOR 2 SPEAKERS WIRING SEE SH 65 STEREO RADIO AD 63 STEREO R A D I O 4 SPEAKERS SPORT U T I L I T Y J938W 11 ...

Page 580: ...18DB 0R X57 18BR LB X54 18VT X53 18DG X52 18DB WT X51 18BR YL 9 RIGHT REAR SPEAKER X 5 8 18DB 0R X52 18DB WT X57 18BR LB LEFT B P I L L A R X52 18DB WT X58 18DB 0R GREEN LEFT FRONT DOOR SPEAKER RIGHT FRONT DOOR SPEAKER J938W 11 STEREO RADIO 4 SPEAKERS SPORT U T I L I T Y AD 64 ...

Page 581: ...8W 106 WIRING DIAGRAMS S E E SH 49 STEREO RADIO AD 65 STEREO RADIO DUAL SPEAKERS Jaasw ...

Page 582: ...c SWITCH Y SEE SH 10 A22 12BK 0R CI 12DG FUSE 11 30 AMP HEATER BLOWER MOTOR RIGHT S I D E DASH PANEL TO WINDSHIELD WASHER V MOTOR SEE SH 5 3 5 5 S P L I C E S P L I C E S E E SH 23 S E E SH 4 4 4 6 D I E S E L ONLY GAS ONLY J938W 11 HEATER AD 66 ...

Page 583: ...FUSE 11 30 AMP C6 14LB 7 7 C3 12WT DG C7 12DG 5 2 C4 12TN TO I G N I T I O N SWITCH S SEE SH 10v HEATER BLOWER MOTOR RIGHT S I D E DASH PANEL S P L I C E SEE SH 44 46 TO WASHER MOTOR S E E SH 5 3 5 5 AD 67 A C AND HEATER GAS ENGINES J938W 11 ...

Page 584: ...TO IGNITION SWITCH SEE SH 10 4ENG 2 TO FUSIBLE LINK SEE SH 4 SEE SH 18 Zl 14BK TO EMCC RELAY SEE SH 11 A21 14DB I A 2 1 14DB 34 ENG T0 Z1 4 SPLICE SEE SH 44 46 TO A21 SPLICE SEE SH 16 C21 18DB 0R C3 14DB BK r TO DAYTIME A21 14DB RUNNING LIGHTS MODULE SEE SH 46 A21 14DB WIDE OPEN THROTTLE CUTOUT RELAY LEFT FENDER SIDE SHIELD C21 18DB 0R f A C LOW PRESSURE SWITCH RIGHT FENDER SIDE SHIELD A21 14DB PR...

Page 585: ...G C6 14LB T T C3 12WT DG C7 12DG 2 C4 12TN FUSE 11 30 AMP TO I G N I T I O N SWITCH SEE SH 10 HEATER BLOWER MOTOR RIGHT S I D E DASH PANEL S P L I C E S E E SH 23 TO WASHER MOTOR S E E SH 5 3 5 5 AD 69 A C AND HEATER D I E S E L ENGINES J938W 11 ...

Page 586: ...POWERTRAIN CONTROL MODULE I I CAVITY 27 34 SEE SH 26 r T C20 18BR BI DIRECTIONAL ZENER DIODE WIDE OPEN THROTTLE CUTOUT RELAY LEFT FENDER SIDE SHIELD C13 14DB BK Zl 14BK TO SPLICE SEE SH 23 C21 18DB 0R TO A21 SPLICE SEE SH 23 SPLICE SEE SH 21 A C LOW PRESSURE SWITCH RIGHT FENDER SIDE SHIELD A21 14DB PROBE RIGHT SIDE SHIELD A C CYCLING SWITCH C2 18DB 0R A21 14DB C20 18BR C20 18BR J938W H A C AND HEA...

Page 587: ...GHT FRONT UP RIGHT FRONT DOWN FEED AND GROUND Qll 14LB Q21 14WT A Aflk 4 W V 4 6 21 14BK Q16 14BR WT Q26 14VT WT F21 14TN UP FORWARD CONNECTOR GAGE LEFT FRONT DOOR MASTER SWITCH TO IGNITION 11 SWITCH 1 2 B K 0 R SEE SH 10 1 DN UP 14VT i 14DG LEFT DOOR WINDOW LIFT MOTOR DOWN 7 XX 026 14VT WT LEFT DOOR WINDOW SWITCH AD 71 POWER WINDOW SYSTEM J938W 11 ...

Page 588: ...M MASTER SWITCH UP FROM MASTER SWITCH FEED RED Q26A 14VT Q26 14VT WT 1 FORWARD IN CAR Q16 14BR WT F21 12TN Q16A 14BR UP RIGHT FRONT WINDOW LIFT SWITCH CONNECTOR 1 1 DN UP L i 14VT 14DG RED AT MOTOR RIGHT DOOR WINDOW LIFT MOTOR BLACK OVER HEATER OR A C UNIT Q16A 14BR Q26 14VT WT 016 14BR WT F21 12TN Q26A 14VT SWITCH VIEW FROM TERMINAL END J938W 11 POWER WINDOW SYSTEM AD 72 ...

Page 589: ...OR SWITCH CONNECTOR LEFT FRONT DOOR SWITCH VIEW FROM TERMINAL END 1 F35 16RD 1 TO POWER MIRROR SWITCH S E E SH 75 P37 160R VT LOCK Zl 16BK r G R A Y Zl 16BK F35 16RD FEED P36 16PK VT UNLOCK FORWARD TERMINAL END UP P36 16PK VT P35 160R VT P34 16PK BK P33 160R BK F 3 5 16RD P36 16PK VT LEFT FRONT DOOR MOTOR RIGHT DOOR COWL TOP DISCONNECT OVER HEATER OR A C U N I T F35 16RD P36 16PK VT P35 160R VT P3...

Page 590: ... tUP y R I G H T F R O N T DOOR S W I T C H V I E W FROM T E R M I N A L E N D B L A C K fTOPl VLK P 3 6 P 3 4 1 6 P K 1 6 P K VT BK F 3 5 1 6 R D P36 16PK VT J P35 1 6 0 R V T P 3 3 1 6 0 R B K P 3 4 1 6 P K B K J 9 3 8 W 1 1 P 3 4 1 6 P K BK F 3 5 16RD P 3 5 1 6 0 R VT P 3 3 1 6 0 R B K P34 1 6 P K B K POWER DOOR LOCKS RIGHT FRONT DOOR MOTOR LK X U N L K t o AD 74 ...

Page 591: ...T UP DN VERTICAL P74 18DB Zl 12BK Ml 18PK BLACK RIGHT OF STEERING COLUMN P72 18YL BK P70 18WT Zl 12BK Ml 20PK Ml 18PK S l l 18DG Ml SEE SH 49 P74 20DB WT P72 2 0 Y L Ml Zl 20PK 12BK TO BATTERY FEED SEE SH 3 5 LEFT MIRROR MOTORS T FUSE 15 10 AMP A4 14BK RD TO ZJS SPLICE SEE SH 48 AD 75 POWER MIRRORS J938W 11 ...

Page 592: ... 0 2 0 W T B K P 7 2 2 0 Y L L H u p I i is A UP L T O P L E F T M I R R O R G M U P A L E F T M I R R O R LT D R I G H T M I R R O R RT B D N C V I E W OF S W I T C H I N D E X I N G F R O M F R O N T O F S W I T C H R I G H T M I R R O R P 7 5 2 0 D B P 7 4 2 0 D B W T r P J R C RT POWER M I R R O R S W I T C H F U N C T I O N L E V E R P O S I T I O N C I R C U I T M I R R O R D I R E C T I O N...

Page 593: ...ADLAMP SWITCH SEE SH 47 49 TO LEFT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 60 G13 20DB RD TO MESSAGE CENTER DIESEL SEE SH 57 TZ7 n e r a c c QC at BLACK BLACK G10 18LG RD LEFT BASE OF STEERING COLUMN DD DP DD G40 20LB BK LEFT SIDE UNDER I P I DD DD 3 GROUND SPLICE SEE SH 48 G4 18DB YL Zl 16BK Zl 16GY BK TO Z1 71 GROUND SPLICE SEE SH 79 5 21 1 6 B K H T A61 16DG BK b o c b o ppoc o Zl 18BK SEAT BELT...

Page 594: ...E SH 3 2 3 5 TO HEADLAMP S SWITCH SEE SH 47 GRAY TO LEFT PRINTED C I R C U I T BOARD CONNECTOR S E E SH 60 G13 20DB RD TO FUEL PUMP H i 4 1 16DG BK A MOTOR FEED S E E SH 16 G10 Zl LEFT BASE OF 18BK S T E E R I N G COLUMN I 18BK Zl 8BK AT SEAT 18LG B E L T 18BK B L U E r LEFT S I D E UNDER I N S T R P A N E L G4 18DB YL TO Z 1 3 GROUND S P L I C E SEE SH 48 Zl 16BK XL Zl 16GY BK TO Z1 7 GROUND S P ...

Page 595: ...3 S P L I C E SEE SH 48 SPORT UTILITY LEFT TAIL STOP i TURN X2 SIGNAL 18GY LAMP LEFT BACK UP LAMP CAB I CHASSIS SWEPT LINE BOX LEFT T A I L STOP I TURN SIGNAL LAMP LEFT BACK UP LAMP LEFT T A I L STOP I TURN Y 9 SIGNAL ppv LAMP 1 8 f Y LEFT BACK UP LAMP BLUE LEFT SIDE UNDER I P TO Z 1 8 1 S P L I C E SEE SH 77 78 B2 18VT BK AD 79 REAR LIGHTING J938W 11 ...

Page 596: ... L62 18BR RD Zl 18BK L I C E N S E LAMP WITHOUT BUMPER L I C E N S E LAMP L I C E N S E LAMP STEP BUMPER L I C E N S E LAMP STANDARD BUMPER RIGHT T A I L STOP I X2 TURN 18GY SIGNAL LAMP B2 18VT BK RIGHT BACK UP LAMP RIGHT T A I L STOP I TURN SIGNAL LAMP RIGHT BACK UP LAMP RIGHT T A I L STOP I TURN SIGNAL LAMP RIGHT BACK UP LAMP SPORT U T I L I T Y CAB I C H A S S I S SWEPT L I N E B O X J938W 11 R...

Page 597: ...HOWN AND MAKE CONNECTION TO TRAILER CONNECTOR AS REQUIRED L7 18BK YL Zl 18BK LI 18VT BK L2 18BR YL Zl 18BK LEFT TAIL STOP ft TURN SIGNAL LAMP LEFT BACK UP LAMP LI 1 8 B K BACK UP LAMPS Zl 18WT BODY GROUND 62 18DG RIGHT STOP ft TURN SIGNAL LAMP r7 1 P Y LEFT STOP ft TURN L63 18YL SIGNAL LAMP L7 18BR TAIL I RUNNING LAMPS WIRE ENDS SEALED AND UNTERMINATED PROVISIONS FOR TRAILER CONNECTOR L7 18BK YL 5...

Page 598: ...X2 18DG RD_ A15 16PK A22 12BK 0R V6 18DB V6 18DB HAZARD FLASHER SEE SH 56 HORN RELAY SEE SH 30 FUSE NO AMPS COLOR SHEET 1 2 GRAY 2 3 6 3 8 2 5 TAN 2 10 1 2 1 3 1 4 5 8 7 7 7 8 3 20 YELLOW 2 7 9 1 0 3 9 4 20 YELLOW 1 30 47 5 20 YELLOW 1 77 78 6 20 YELLOW 1 73 7 15 LT BLUE 1 10 52 8 10 RED 2 1 0 6 1 6 3 6 5 9 20 YELLOW 2 1 0 3 1 3 3 5 6 10 20 YELLOW 2 1 0 5 4 5 5 11 30 GREEN 2 1 0 6 6 6 7 6 9 12 30 ...

Page 599: ...0PK DATA LINK TRANSMIT 23 26 27 J C20 18BR A C COMPRESSOR CLUTCH INPUT 26 28 T25 20LG RD TRANSMISSION THERMO SWITCH 25 29 V40 18WT PK BRAKE SENSE 37 30 rTTF 18BR YL PARK NEUTRAL POSITION SWITCH 21 31 32 G3 20BK PK MALFUNCTION INDICATOR LAMP 22 33 V36 20TN RD VEHICLE SPEED CONTROL VACUUM 37 34 CI3 20DB 0R W O T CUTOUT RELAY 26 35 36 37 T61 20BK 0R TRANSMISSION OD LAMP SIGNAL 14 38 39 40 41 42 43 G2...

Page 600: ... SWITCH INPUT 18 28 _ 29 V40 18WT PK BRAKE SENSE 35 30 T41 20BR YL PARK NEUTRAL P O S I T I O N SWITCH 19 31 32 G3 20BK PK MALUNCTION INDICATOR LAMP 19 33 V36 20TM RD V E H I C L E SPEED CONTROL VACUUM 35 34 C13 20DB OR W O T CUTOUT RELAY 18 35 K35 20GY YL EGR SOLENOID 16 36 37 TBI 20BK 0R T R A N S M I S S I O N OD LAMP SIGNAL 12 38 K15 18PK BK INJECTOR DRIVER 5 15 39 40 K39 18GY RD IDLE A I R CO...

Page 601: ...SWITCH A C AND HEATER BLOWER MOTOR FUEL PUMP FEED GAS ONLY HEADLAMP LOW BEAM 2 WIRES HEADLAMP HIGH BEAM 2 WIRES VEHICLE SPEED CONTROL VEHICLE SPEED CONTROL VEHICLE SPEED CONTROL VEHICLE SPEED CONTROL WAIT TO START LAMP DIESEL QNLYr HIGH BEAM INDICATOR LAMP HIGH BEAM FEED TACHOMETER SIGNAL DIESEL ENGINE COOLANT TEMPERATURE SENDING UNIT ENGINE OIL PRESSURE SWITCH ENGINE OIL PRESSURE SENDING UNIT WAT...

Page 602: ...L PRESSURE LAMP ENGINE O I L PRESSURE GAUGE SEND UNIT WATER IN FUEL LAMP D I E S E L LEFT FRONT TURN SIGNAL LAMP RIGHT FRONT TURN SIGNAL LAMP HAZARD FLASHER TRANSMISSION OVERDRIVE INDICATOR LAMP BACK UP LAMPS PARKING LAMPS BACK UP LAMP FEED WINDSHIELD WASHER MOTOR I G N I T I O N START I G N I T I O N START D I E S E L HORNS UNDERHOOD LAMP E L E C T R I C VACUUM SENSOR D I E S E L WINDSHIELD WIPER...

Page 603: ...CH 7 V7 18DG WT INTERMITTENT WIPER MODULE 8 V17 18DG YL INTERMITTENT WIPER MODULE 9 V3A 18BR WT WIPER SWITCH 10 11 L60 18TN RIGHT FRONT TURN SIGNAL 12 L62 18BR RD RIGHT REAR TURN SIGNAL 13 L19 18PK HAZARD FLASHER FEED 14 L50 18WT TN STOP LAMP FEED 56 15 L63 18DG RD LEFT REAR TURN SIGNAL 16 L61 18LG LEFT FRONT TURN SIGNAL 17 L6 18RD WT TURN SIGNAL FLASHER FEED 18 L4 14VT WT LOW BEAM HEADLAMPS 19 L2...

Page 604: ... 18RD YL WIPER MOTOR HIGH SPEED 55 6 7 8 9 10 11 L60 18TN RIGHT FRONT TURN SIGNAL 56 12 L62 18BR RD RIGHT REAR TURN SIGNAL 56 13 L19 18PK HAZARD FLASHER FEED 56 14 L50 18WT TN STOP LAMP FEED 56 15 L63 18DG RD LEFT REAR TURN SIGNAL 56 16 L61 18LG LEFT FRONT TURN SIGNAL 56 17 L6 18RD WT TURN S I G N A L F L A S H E R FEED 56 18 L4 14VT WT LOW BEAM HEADLAMPS 47 19 L2 14LG HEADLAMP FEED 47 20 L3 14RD ...

Page 605: ...E STARTER RELAY COIL 9 15 G60 20GY YL ENGINE OIL PRESSURE SEND UNIT 28 16 G6 20GY ENGINE OIL PRESSURE SWITCH 28 17 T6 200R WT TRANSMISSION OD OVERRIDE 12 18 T61 20BK 0R TRANSMISSION OD LAMP SIGNAL 12 19 20 F20 18WT BACK UP LAMP SWITCH 9 21 22 T22 14DB WT EMCC 11 23 24 G24 20GY PK SRI LAMP 19 25 C13 20DB 0R A C COMPRESSOR CLUTCH RELAY 18 26 G20 20VT YL ECT SEND UNIT 28 27 V31 20BR RD VEHICLE SPEED ...

Page 606: ...c type gasket material cures in the absence of air when squeezed between smooth machined metallic surfaces It will not cure if left in the uncovered tube DO NOT use on flexible metal flanges page Hydrostatic Lock 4 Measuring with Plastigage 3 Repair Damaged or Worn Threads 4 SURFACE PREPARA TION Parts assembled with form in place gaskets may be disassembled without unusual effort In some in stance...

Page 607: ...roblem in the cylinder The recommended compression pressures are to be used only as a guide to diagnosing engine problems An engine should NOT be disassem bled to determine the cause of low compression unless some malfunction is present 4 Clean or replace spark plugs as necessary Ad just gap refer to Group 8D Ignition System for gap adjustment and torque 5 Test resistance of spark plug cables refe...

Page 608: ...l and No 3 main bearing ALL ENGINES When checking No 3 main bear ing shim No 2 and No 4 main bearing 5 2L 5 9L AND 5 9L DIESEL EN GINES When checking No 4 main bearing shim No 3 and No 5 main bearing 3 9L ENGINE When checking No 4 main bear ing shim No 3 main bearing 5 2L AND 5 9L ENGINES When checking No 5 main bearing shim No 4 main bearing 5 9L DIESEL E N G I N E W h e n checking No 5 main bear...

Page 609: ...his repair consists of Drilling out worn or damaged threads Tapping the hole with a special Heli Coil Tap or equivalent Installing an insert into the tapped hole This brings the hole back to its original thread size CAUTION Be sure that the tapped holes maintain the original center line Heli Coil tools and inserts are readily available from automotive parts jobbers HYDROSTATIC LOCK When an engine ...

Page 610: ...rge or replace as necessary 2 Clean and tighten battery connections Apply a coat of light mineral grease to the terminals 3 Refer to Group 8A Battery Starter Charging System Diagnostics 4 Wipe wires and cap clean and dry 5 Replace any cracked or shorted cables 6 Test and replace if necessary refer to Group 8D Ignition System 7 Set gap refer to Group 8D Ignition System 8 Refer to Group 8D Ignition ...

Page 611: ...tall new parts as necessary 12 Replace any cracked or shorted cables 13 Test and replace as necessary refer to Group 8D Ignition System ENGINE MISSES ON ACCELERATION 1 Dirty or gap set too wide in spark plug 2 Incorrect ignition timing 3 Dirt in fuel system 4 Burned warped or pitted valves 5 Faulty coil 1 Clean spark plugs and set gap refer to Group 8D Ignition System 2 Refer to Group 8D Ignition ...

Page 612: ...efer to Group 0 Lubrication and Maintenance 2 Check engine oil level Inspect oil pump relief valve and spring 3 Change oil to correct viscosity 4 Measure bearings for correct clearance Repair as necessary 5 Check No 3 main bearing for wear on flanges 6 Grind journals or replace crankshaft 7 Tighten to correct torque OIL PRESSURE DROP 1 Low oil level 2 Faulty oil pressure sending unit 3 Low oil pre...

Page 613: ...eck for loose wires and verify that the valve is functioning Check to be sure manual shutoff lever is in the run position Remove the obstruction Drain fuel water separator and replace fuel filter Check fuel flow bleed fuel system Visually check fuel delivery with an externally connected injector to one of the pump outlets Replace the pump if fuel is not being delivered Time the pump refer to Group...

Page 614: ...or the fuel supply is inadequate Fuel waxing due to extremely cold weather Contaminated fuel Adjust the idle speed Visually check for exhaust restriction and inspect the air intake Repair replace restricting parts Check the flow through the filter and bleed the system Locate and eliminate the air source Verify by inspecting the fuel filter Clean the system and use climatized fuel Replace fuel wate...

Page 615: ...ump delivery valves Replace injection pump Camshaft out of time Check correct gear train timing alignment Damaged camshaft or tappets Inspect camshaft valve lift Replace camshaft and tappets ENGINE RPM WILL NOT REACH RATED SPEED Engine overloaded Verify high idle speed without load Investigate operation to be sure correct gear is being used Improperly operating tachometer Verify engine speed with ...

Page 616: ...s in the air crossover tube hoses gaskets and around mounting capscrews or through holes in the manifold cover Exhaust leak at the manifold or turbocharger Check correct leaks in the manifold or turbocharger gaskets If manifold is cracked replace manifold Improperly operating turbo charger Inspect replace turbocharger Valve clearance incorrect Check adjust valves Injection pump improperly operatin...

Page 617: ...T TEMPERA TURE ABOVE NORMAL Low coolant level a Check coolant level Add coolant if necessary b Locate and correct the source of the coolant leak Refer to troubleshooting logic for coolant loss Incorrect improperly operating pressure cap Replace cap with the correct rating for the system High lube oil level Check drain oil to correct level Loose drive belt on water pump fan Check replace belt or be...

Page 618: ...oad rating is not being exceeded COOLANT TEMPERA TURE BELOW NORMAL Too much air flow across the radiator Incorrect thermostat broken thermostat jiggle pin or contamination in thermostat Temperature sensor or gauge inoperative Coolant not flowing by temperature sensor Check repair viscous fan as required Check and replace thermostat Verify that the gauge and sensor are accurate If not replace gauge...

Page 619: ...stuck open Check replace valve Plugged oil filter Change oil filter Oil filter change interval may need to be revised If cooler was replaced shipping plugs left in cooler Check remove shipping plugs If pump replaced four cylinder oil pump installed in a six cylinder engine Verify that the correct pump is installed If not install an oil pump for a six cylinder engine Loose or missing cup plugs Chec...

Page 620: ... c Review reduce the oil change intervals Oil cooler leak Check and replace the oil cooler High blow by forcing oil out the breather Check the breather tube area for signs of oil loss Perform the required repairs Turbocharger leaking oil to the air intake Inspect the air ducts for evidence of oil transfer Repair as required Worn valve seals Inspect and replace the valve seals Piston rings not seal...

Page 621: ...nsioner and inspect the drive belt Make sure water pump tensioner pulley fan hub and alternator turn freely Intake air or exhaust leaks Refer to Excessive Exhaust Smoke Engine Diagnosis Performance Excessive valve lash Adjust valves Make sure the push rods are not bent and rocker levers or adjusting screws are not severely worn Replace bent or severely worn pads Turbocharger noise Check turbocharg...

Page 622: ...num Alloy w Strut Connecting Rods Forged Steel J9309 29 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 from front to rear 1 3 5 on the left bank and 2 4 6 on the right bank The firing order is 1 6 5 4 3 2 Fig 2 The engine serial number is stamped into a ma chined pa...

Page 623: ...o 41 N m 30 ft lbs torque 6 Install insulator stud nuts and washers Tighten the stud nuts to 102 N m 75 ft lbs torque 7 Lower the vehicle 8 Remove lifting fixture ENGINE REAR MOUNT REMOVAL 2WD 1 Raise the vehicle on a hoist 2 Position a transmission jack in place 3 Remove rear mount insulator through bolt and nut Fig 6 4 Raise rear of transmission and engine SLIGHTLY 5 Remove the flange nuts from ...

Page 624: ...to the insulator mounting plate Fig 8 Re move the bolts and nuts holding the engine rear sup port plate to the insulator mounting plate Fig 8 5 MANUAL TRANSMISSION Remove the nuts and bolts holding the insulator mounting plate to the transfer case Fig 9 6 Remove insulator mounting bolts spacers washers and upper lower insulators Figs 8 and 9 Fig 6 Rear Engine Support 2WD 7 Remove the insulator mou...

Page 625: ... torque 6 Install the skid plate 7 Lower the vehicle ENGINE ASSEMBLY REMOVAL 1 Scribe hood hinge outlines on hood Remove the hood 2 Remove the battery 3 Drain cooling system refer to Group 7 Cooling System for the proper procedure 4 Remove the air cleaner 5 Disconnect the radiator and heater hoses Re move radiator refer to Group 7 Cooling System 6 Set fan shroud aside 7 Remove the vacuum lines 8 R...

Page 626: ...ket install MPI throttle body Tighten the throttle body bolts to 23 N m 200 in lbs torque 16 Connect the accelerator linkage 17 Connect the starter wires 18 Connect the oil pressure wire 19 Install the distributor cap and wiring 20 Connect the vacuum lines 21 Connect the fuel lines 22 Install the radiator refer to Group 7 Cooling System Connect the radiator hoses and heater hoses 23 Install fan sh...

Page 627: ... the valves REMOVAL 1 Disconnect the negative cable from the battery 2 Drain cooling system refer to Group 7 Cooling System for the proper procedures 3 Remove the heat shields Fig 4 SPARK SPARK INTAKE PLUGS PLUG VALVE EXHAUST INTAKE EXHAUST VALVE VALVES VALVES J9309 35 Fig 3 Cylinder Head Assembly Fig 4 Exhaust Manifold Heat Shields 4 Remove the intake manifold to generator bracket support rod Rem...

Page 628: ...cylinder head gaskets onto the cylinder block 3 Position the cylinder heads onto head gaskets and cylinder block 4 Starting at top center tighten all cylinder head bolts in sequence to 68 N m 50 ft lbs torque Fig 6 Repeat procedure tighten all cylinder head bolts to 143 N m 105 ft lbs torque Repeat procedure to confirm that all bolts are at 143 N m 105 ft lbs torque CAUTION When tightening the roc...

Page 629: ...ue 12 Install exhaust manifolds Tighten the bolts and nuts to 34 N m 25 ft lbs torque FRONT OF ENGINE J9209 59 Fig 9 Intake Manifold Bolt Tightening Sequence 13 Adjust spark plugs to specifications refer to Group 8D Ignition System Install the plugs and tighten to 41 N m 30 ft lbs torque 14 Install coil wires 15 Connect heat indicator sending unit wire 16 Connect the heater hoses and bypass hose 1...

Page 630: ...1 c Move valve to and from the indicator The to tal dial indicator reading should not exceed 0 432 mm 0 017 inch Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored Service valves with oversize stems are available Fig 12 Slowly turn reamer by hand and clean guide thor oughly before installing new valve R e a m the valve guides...

Page 631: ...060 inch The width of the exhaust seats should be 1 524 2 032 mm 0 060 0 080 inch Fig 15 Refacing Valve Seats VALVE SPRING INSPECTION Whenever valves have been removed for inspection reconditioning or replacement valve springs should be tested As an example the compression length of the spring to be tested is 1 5 16 inch Turn table of Valve Spring Tester Tool C 647 until surface is in line with th...

Page 632: ...oil pressure gauge install a reliable gauge at the pressure sending unit The pressure should be be tween 207 552 kPa 30 80 psi at 3 000 RPM Check the oil level after the engine reaches normal operating temperature Allow 5 minutes to stabilize oil level check dipstick The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick Either of these 2 conditions coul...

Page 633: ...at are unfit for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear in stall a new tappet assembly If valve is pitted or valve seat on end of plunger is prevented from seat ing install a new tappet assembly 4 Assemble tappets Fig 17 INSTALLATION 1 Lubricate tappets PLUNGER SPRING CHECK BALL PLUNGER RETAINER SPRING CLIP ROLLER TAPPET BODY RETAINER I PLUNGER CHECK VALVE...

Page 634: ...ING CHAIN COVER REMOVAL 1 Disconnect the negative cable from the battery 2 Drain cooling system refer to Group 7 Cooling System 3 Remove the serpentine belt refer to Group 7 Cooling System 4 Remove water pump refer to Group 7 Cooling System 5 Remove power steering pump refer to Group 19 Steering 6 Remove vibration damper 7 Remove fuel lines refer to Group 14 Fuel Sys tem 8 Loosen oil pan bolts and...

Page 635: ...ignment of Timing Marks 11 Install the camshaft bolt Tighten the bolt to 68 Nnn 50 ft lbs torque 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 new thrust plate CLEANING Be sure mating surfaces of chain case cover and cylinder block are clean and fr...

Page 636: ... 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 crankshaft seal surface of cover 5 Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 Fig 6 Seat the oil seal in the groove of the tool 6 Position the seal and tool onto the crankshaft Fig 7 7 ...

Page 637: ...xt 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 Installed Position 3 Hold tool in position with a distributor lock plate bolt This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block Tool should remain installed until the ca...

Page 638: ...into the bore 2 Drive bushing and tool into position using a hammer Fig 15 3 As the burnisher is pulled through the bushing the bushing is expanded tight in the block and bur nished to correct size Fig 16 DO NOT ream this bushing DISTRIBUTOR TIMING Before installing the distributor and oil pump drive shaft time engine as follows Fig 16 Burnishing Distributor Driveshaft Bushing 1 Rotate crankshaft ...

Page 639: ...ply small amount of Mopar Silicone Rubber Adhesive Sealant or equivalent in the corner of the cap and the cylinder block 4 Slide the one piece gasket over the dowels and onto the block 5 Position the oil pan over the dowels and onto the gasket 6 Install the oil pan bolts Tighten the bolts to 23 N m 200 in lbs torque Fig 2 Position of Dowels in Cylinder Block 7 Remove the dowels Install the remaini...

Page 640: ...eplaced STRAIGHT EDGE COVER RH175 Fig 5 Checking Oil Pump Cover Flatness Measure thickness and diameter of outer rotor If outer rotor thickness measures 20 9 mm 0 825 inch or less or if the diameter is 62 7 mm 2 469 inches or less replace outer rotor Fig 6 RH176 Fig 6 Measuring Outer Rotor Thickness If inner rotor measures 20 9 mm 0 825 inch or less replace inner rotor and shaft assembly Fig 7 RH1...

Page 641: ...hten cover bolts to 11 N m 95 in lbs torque 3 Install the relief valve and spring Insert the cotter pin 4 Tap on a new retainer cap 5 Prime oil pump before installation by filling ro tor cavity with engine oil INSTALLATION 1 Install oil pump During installation slowly ro tate pump body to ensure driveshaft to pump rotor shaft engagement 2 Hold the oil pump base flush against mating surface on No 4...

Page 642: ...and confirm ring side clearance a Install oil rings being careful not to nick or scratch the piston b Install the compression rings using Installa tion Tool C 4184 The top compression may be in stalled with either side up The second compression ring must be installed with the identification mark face up toward top of piston and the chamfer should face down An identification mark on the ring is a d...

Page 643: ... connecting rod bolt protectors on rod bolts the long protector should be installed on the numbered side of the connecting rod 5 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Be sure connecting rod and cylinder bore number are the same Insert rod and piston into cylinder bore and guide rod over the crankshaft journal 6 Tap the piston down in cylinder bo...

Page 644: ...allow the seal ant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant applica tion 7 To align the bearing cap use cap slot align ment dowel and cap bolts Do not remove excess ma terial after assembly Do not strike rear cap more than 2 times for proper engagement 8 Clean and oil all cap bolts Install all main bearing caps Install all cap bolts and alternatel...

Page 645: ... can only be installed with the rear main bearing cap removed UPPER SEAL REPLACEMENT CRANKSHAFT REMOVED 1 Remove the crankshaft Discard the old upper seal 2 Lightly oil the new upper seal lips with engine oil 3 Install the new upper rear bearing oil seal with the yellow paint facing towards the rear of the en gine 4 Position the crankshaft into the cylinder block 5 Lightly oil the new lower seal l...

Page 646: ...ne oil 6 Install a new lower seal in bearing cap with yellow paint facing the rear of engine 7 Apply 5 mm 0 20 in drop of Loctite 515 or equivalent on each side of the rear main bearing cap Fig 16 Do not over apply sealant or allow the seal ant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant applica tion 8 To align the bearing cap use cap slot align ment...

Page 647: ...a drift or a screw driver and a hammer strike the bottom edge of the cup plug Fig 22 2 With the cup plug rotated grasp firmly with pliers or other suitable tool and remove plug Fig 22 CLEANING Thoroughly clean inside of cup plug hole in cylin der block or head Be sure to remove old sealer Make certain the new plug is cleaned of all oil or grease RH157 Fig 21 Location of Cup Plugs in Oil Galleries ...

Page 648: ...0015 in Nos 2 3 and 4 0 0127 0 0508 mm 0 0005 0 0020 in Max Allowable Nos 2 3 4 0 0635 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 63 487 63 513 mm 2 4995 2 5005 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cylinder Bore Diameter 99 314 99 365 mm 3 910 3 912 in Out of Round Max 0 127 mm 0 0...

Page 649: ... 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 25 001 mm 0 9841 0 9843 in End Play NONE Length 75 946 76 454 mm 2 990 3 010 in Piston Rings Ring Gap Compression Rings 0 254 0 508 mm 0 010 0 020 in Oil Control Steel Rails 0 254 1 270 mm 0 010 0 050 in Ring Sid...

Page 650: ...e Overlap 26 J9309 33 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS C O N D I T I O N IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R o r M M 2 3 etc indicating no 2 and 3 main bearing journal a n d o r R l 4 etc indicating no 1 and 4 connecting rod journal Steel stamped near notch on no 6 crankshaft counterweight HYDRAULIC TAPPETS OVERSIZE 0 2032 mm...

Page 651: ...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 Rear Insulalor to Bracket Through Bolt 2WD 68 N rn 50 ft lbs Rear Insuiator to Crossmember Support Bracket Nut 2WDJ 41 N m 30 ft lbs Rear Insulator Mounting Plate to Rail Assembly Nuts 4WD 41 N m 30 ft lbs Rear Support Bracket to Crossmember Flange Nuts 41 N m 30 ft lbs Rear Support Plate to lnsulator ...

Page 652: ...inum Alloy w Strut Connecting Rods Forged Steel J9309 41 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 from front to rear 1 3 5 7 on the left bank and 2 4 6 8 on the right bank The firing order is 1 8 4 3 6 5 7 2 Fig 2 The engine serial number is stamped into a ma ...

Page 653: ... crossmember sport utility or from the transmission support bracket Fig 5 4 Remove the flange nuts from the crossmember support bracket Fig 5 5 Raise rear of transmission enough to provide insulator to crossmember clearance Remove the in sulator flange nuts and remove the insulator Fig 5 6 If necessary remove the attaching bolts hold ing the transmission support bracket to the transmis sion Fig 5 ...

Page 654: ...case Fig 7 Install the bolts and tighten to 41 N m 30 ft lbs torque 2 If removed position the transmission support spacer automatic transmission to the extension as sembly Fig 7 Install the bolts and tighten to 68 Nnn 50 ft lbs torque 3 Install insulator mounting plate mounting bolts spacers washers and upper lower insulators to the rail assembly Figs 7 and 8 Tighten the mount ing bolt nuts to 204...

Page 655: ... hoses 16 Disconnect the power steering hoses if equipped INSULATOR MOUNTING PLATE SPACER UPPER L f INSULATOR NUT RAIL ASSEMBLY LOWER INSULATOR l6f f RAIL I J9109 245 Fig 8 Rear Engine Support 4WD with Manual Transmission 17 Remove starter motor refer to Group 8B Bat tery Starter Generator Service 18 Remove the generator refer to Group 8B Bat tery Starter Generator Service 19 Raise and support the...

Page 656: ...ng a new gasket install MPI throttle body Tighten the throttle body bolts to 23 N m 200 in lbs torque 16 Connect the accelerator linkage 17 Connect the starter wires 18 Connect the oil pressure wire 19 Install the distributor cap and wiring 20 Connect the vacuum lines 21 Connect the fuel lines 22 Install the radiator refer to Group 7 Cooling System Connect the radiator hoses and heater hoses 23 In...

Page 657: ...up 7 Cooling System for the proper procedures 3 Remove the heat shields Fig 4 4 Remove the intake manifold to generator bracket support rod Remove the generator 5 Remove closed crankcase ventilation system 6 Disconnect the evaporation control system 7 Remove the air cleaner 8 Disconnect the fuel lines 9 Disconnect accelerator linkage and if so equipped the speed control and transmission kick down ...

Page 658: ... 105 ft lbs torque CAUTION When tightening the rocker arm bolts make sure the piston in that cylinder is NOT at TDC Contact between the valves and piston could occur 5 Install push rods and rocker arm assemblies in their original position Tighten the bolts to 28 N m 21 ft lbs torque 6 Place the 4 plastic locator dowels into the holes in the block Fig 7 Fig 6 Cylinder Head Bolt Tightening Sequence ...

Page 659: ...ting strap bolt to 23 N m 200 in lbs torque Refer to Group 7 Cooling Sys tem for adjusting the belt tension 22 Install the intake manifold to generator bracket support rod Tighten the bolts 23 Place the cylinder head cover gaskets in posi tion and install cylinder head covers Tighten the bolts to 11 N m 95 in lbs torque 24 Install closed crankcase ventilation system 25 Connect the evaporation cont...

Page 660: ...lve seat Step 1 Ream to 0 0763 mm 0 003 inch Step 2 Ream to 0 381 mm 0 015 inch REFACING VAL WES WAL WE SEATS The intake and exhaust valves have a 43 1 4 to 43 3 4 face angle and a 44 1 4 to 44 3 4 seat angle Fig 13 CONTACT A SEAT WIDTH INTAKE 1 016 1 524 mm 0 040 0 060 in EXHAUST 1 524 2 032 mm 0 060 0 080 in B FACE ANGLE INTAKE EXHAUST 437 4 3 3 C SEAT ANGLE INTAKE EXHAUST 447 447 D CONTACT SURF...

Page 661: ...til ping is heard Take reading on torque wrench at this instant Multiply this reading by 2 This will give 9209 37 Fig 16 Testing Valve Spring for Compressed Length with Tool C 647 INSTALLATION 1 Coat valve stems with lubrication oil and insert them in cylinder head 2 If valves or seats are reground check valve stem height If valve is too long replace cylinder head 3 Install new seals on all valve ...

Page 662: ...e to aeration it may be in termittent or constant and usually more than 1 tap pet will be noisy When oil level and leaks have been corrected operate the engine at fast idle Run engine for a sufficient time to allow all of the air inside the tappets to be bled out TAPPET NOISE DIAGNOSIS 1 To determine source of tappet noise operate en gine at idle with cylinder head covers removed 2 Feel each valve...

Page 663: ...m 7 Install cylinder head cover 8 Start and operate engine Warm up to normal operating temperature CAUTION To prevent damage to valve mechanism engine must not be run above fast idle until all hy draulic tappets have filled with oil and have become quiet VALVE TIMING 1 Turn crankshaft until the No 6 exhaust valve is closing and No 6 intake valve is opening 2 Insert a 6 350 mm 1 4 inch spacer betwe...

Page 664: ...1 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 surface of cover Fig 3 Fig 3 Removal of Front Crankshaft Oil Seal TIMING CHAIN STRETCH 1 Place a scale next to the timing chain so that any movement of the chain may be measured 2 Place a torque wrench and socket over cam shaft sprocket attaching bolt Apply torque in the...

Page 665: ...ce the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 Fig 6 Seat the oil seal in the groove of the tool 3 Position the seal and tool onto the crankshaft Fig 7 4 Using the vibration damper bolt tighten the bolt to draw the seal into position on the crankshaft Fig 8 5 Tighten chain case cover bolts to 41 Nnn 30 ft lbs torque Tighten oil pan bolts to 24 Nnn 215 in lbs tor...

Page 666: ...rankshaft Fig 8 8 Remove the vibration damper bolt and seal in stallation tool 9 Install the vibration damper 10 Connect the negative cable to the battery CAMSHAFT This procedure requires that the engine is removed from the vehicle The camshaft has an integral oil pump and distrib utor drive gear Fig 9 5 2L ENGINE 9 61 J9309 71 Fig 9 Camshaft and Sprocket Assembly REMOVAL 1 Remove intake manifold ...

Page 667: ...olt cup washer Tighten bolt to 68 N m 50 ft lbs torque 11 Measure camshaft end play Refer to Specifi cations for proper clearance If not within limits in stall a new thrust plate 12 Each tappet reused must be installed in the same position from which it was removed When camshaft is replaced all of the tappets must be replaced DISTRIBUTOR REMOVAL Refer to Group 8D Ignition Systems for the proper pr...

Page 668: ...spirals into place it will index with the oil pump shaft The slot in top of drive gear should be aligned towards left front intake manifold attaching bolt hole Fig 17 Fig 17 Position or Installed Distributor Drive Gear INSTALLATION Refer to Group 8D Ignition Systems for the proper procedure OIL PAN REMOVAL 1 Disconnect the negative cable from the battery 2 Remove engine oil dipstick 3 Raise vehicl...

Page 669: ...engine to transmission strut 10 Install exhaust pipe 11 Lower vehicle 11 Install dipstick 12 Connect the negative cable to the battery 13 Fill crankcase with oil to proper level OIL PUMP REMOVAL 1 Remove the oil pan 2 Remove the oil pump from rear main bearing cap DISASSEMBLE 1 Remove the relief valve as follows a Remove cotter pin Drill a 3 175 mm 1 8 inch hole into the relief valve retainer cap ...

Page 670: ...nd pump body Fig 8 If clearance is 0 356 mm 0 014 inch or more replace oil pump as sembly Install inner rotor and shaft into pump body If clearance between inner and outer rotors is 0 203 mm 0 008 inch or more replace shaft and both ro tors Fig 9 Place a straightedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm Fig 7 Measuring Inner Rotor Thickness Fig 8 Measuring O...

Page 671: ...ce fit of the piston pin in the connecting rod REMOVAL 1 Remove the engine from the vehicle 2 Remove the cylinder head 3 Remove the oil pan 4 Remove top ridge of cylinder bores with a reli able ridge reamer before removing pistons from cyl inder block Re sure to keep tops of pistons covered during this operation 5 Be sure the connecting rod and connecting rod cap are identified with the cylinder n...

Page 672: ...ing land Fig 13 Clearance should be 0 038 0 076 mm 0 0015 0 0030 inch for the compression rings The steel rail oil ring should be free in groove but should not exceed 0 203 mm 0 0080 inch side clearance d Pistons with insufficient or excessive side clearance should be replaced 3 Arrange ring gaps 90 apart as shown in Fig RING GROOVE J9209 136 Fig 13 Measuring Piston Ring Side Clearance OIL RING SP...

Page 673: ...e No 2 main journal are 0 025 mm 0 Q01 in undersize When a crankshaft is replaced all main and con necting rod bearings should be replaced with new bearings Therefore selective fitting of the bearings is not required when a crankshaft and bearings are replaced REMOVAL 1 Remove the oil pan 2 Remove the oil pump from the rear main bear ing cap 3 Identify bearing caps before removal Remove bearing ca...

Page 674: ...s are not interchangeable and should be marked at removal to ensure correct assembly Upper and lower bearing halves are NOT inter changeable Lower main bearing halves of No 2 and 4 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 18 Bearing shells are available in st...

Page 675: ...cone Rubber Adhesive Seal ant or equivalent at bearing cap to block joint to provide cap to block and oil pan sealing Fig 17 Ap ply enough sealant until a small amount is squeezed out Withdraw nozzle and wipe excess sealant off the oil pan seal groove 12 Install new front crankshaft oil seal 13 Immediately install the oil pan UPPER SEAL REPLACEMENT CRANKSHAFT INSTALLED 1 Remove the oil pan 2 Remov...

Page 676: ...l C 119 The cylinder block should be bored and honed with new pistons and rings fitted if The cylinder bores show more than 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 ordinated with the fitting of pistons and rings so specified clearances m a y be m...

Page 677: ...oat edges of plug and core hole with 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 drive plug drive 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 cooling syste...

Page 678: ...e No 1 0 0127 0 0381 mm 0 0005 0 0015 in Nos 2 3 4 and 5 0 0127 0 0508 mm 0 0005 0 0020 in Max Allowable Nos 2 3 4 5 0 0635 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 63 487 63 513 mm 2 4995 2 5005 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cylinder Bore Diameter 99 314 99 365 mm 3 910 3...

Page 679: ... 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 25 001 mm 0 9841 0 9843 in End Play NONE Length 75 946 76 454 mm 2 990 3 010 in Piston Rings Ring Gap Compression Rings 0 254 0 508 mm 0 010 0 020 in Oil Control Steel Rails 0 254 1 270 mm 0 010 0 050 in Ring Side Cl...

Page 680: ...ion 240 Valve Overlap 26 J9309 33 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in RorM M 2 3 etc indicating no 2 and 3 main bearing journal and or R l 4 etc indicating no 1 and 4 connecting rod journal Milled flat on no 8 crankshaft counterweight HYDRAULIC TAPPETS OVERSIZE 0 2032 mm 0 008 in Diamo...

Page 681: ...25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs Rear Insulator to Bracket Through Bolt 2WD 68 N m 50 ft lbs Rear Insulator to Crossmember Support Bracket Nut 2WD 41 N m 30 ft lbs Rear Insulator Mounting Plate to Rail Assembly Nuts 4WD 41 N m 30 ft lbs Rear Support Bracket to Crossmember Flange Nuts 41 N m 30ft lbs Rear Support Plate to lnsulator Mounting P...

Page 682: ...quid Cooled Forced Circulation Cooling Capacity 14 7L 15 5 Qts Ramcharger 4WD 14 2L 15 0 Qts Cylinder Block Cast Iron Crankshaft Nodular Iron Cylinder Head Cast Iron Combustion Chambers Wedge High Swirl Valve Shrouding Camshaft Nodular Cast Iron Pistons Cast Aluminum Alloy Connecting Rods Forged Steel J9309 99 Fig 1 Engine Description This engine is designed for unleaded fuel Engine lubrication sy...

Page 683: ...lt from frame crossmember sport utility or from the transmission support bracket Fig 5 4 Remove the flange nuts from the crossmember support bracket Fig 5 5 Raise rear of transmission enough to provide insulator to crossmember clearance Remove the in sulator flange nuts and remove the insulator Fig 5 6 If necessary remove the attaching bolts hold ing the transmission support bracket to the transmi...

Page 684: ...Fig 7 Install the bolts and tighten to 41 N m 30 ft lbs torque 2 If removed position the transmission support spacer automatic transmission to the extension as sembly Fig 1 Install the bolts and tighten to 68 N m 50 ft lbs torque 3 Install insulator mounting plate mounting bolts spacers washers and upper lower insulators to the rail assembly Figs 7 and 8 Tighten the mount ing bolt nuts to 204 N m ...

Page 685: ...nnect the power steering hoses if equipped INSULATOR MOUNTING PLATE SPACER UPPER INSULATOR N U T LOWER INSULATOR J9109 245 Fig 8 Rear Engine Support 4WD with Manual Transmission 17 Remove starter motor refer to Group 8B Bat tery Starter Generator Service 18 Remove the generator refer to Group 8B Bat tery Starter Generator Service 19 Raise and support the vehicle on a hoist 20 Disconnect exhaust pi...

Page 686: ...ng a new gasket install MPI throttle body Tighten the throttle body bolts to 23 Nnn 200 in lbs torque 16 Connect the accelerator linkage 17 Connect the starter wires 18 Connect the oil pressure wire 19 Install the distributor cap and wiring 20 Connect the vacuum lines 21 Connect the fuel lines 22 Install the radiator refer to Group 7 Cooling System Connect the radiator hoses and heater hoses 23 In...

Page 687: ...up 7 Cooling System for the proper procedures 3 Remove the heat shields Fig 4 4 Remove the intake manifold to generator bracket support rod Remove the generator 5 Remove closed crankcase ventilation system 6 Disconnect the evaporation control system 7 Remove the air cleaner 8 Disconnect the fuel lines 9 Disconnect accelerator linkage and if so equipped the speed control and transmission kick down ...

Page 688: ... 105 ft lbs torque CAUTION When tightening the rocker arm bolts make sure the piston in that cylinder is NOT at TDC Contact between the valves and piston could occur 5 Install push rods and rocker arm assemblies in their original position Tighten the bolts to 28 N m 21 ft lbs torque 6 Place the 4 plastic locator dowels into the holes in the block Fig 7 Fig 6 Cylinder Head Bolt Tightening Sequence ...

Page 689: ...g strap bolt to 23 N m 200 In lbs torque Refer to Group 7 Cooling Sys tem for adjusting the belt tension 22 Install the intake manifold to generator bracket support rod Tighten the bolts 23 Place the cylinder head cover gaskets in posi tion and install cylinder head covers Tighten the bolts to 11 N m 95 in lbs torque 24 Install closed crankcase ventilation system 25 Connect the evaporation control...

Page 690: ... The intake and exhaust valves have a 43 1 4 to 43 3 4 face angle and a 44 1 4 to 44 3 4 seat angle Fig 13 CONTACT A SEAT WIDTH INTAKE 1 016 1 524 mm 0 040 0 060 in EXHAUST 1 524 2 032 mm 0 060 0 080 in B FACE ANGLE INTAKE EXHAUST 4374 433 4 C SEAT ANGLE INTAKE EXHAUST 447 443 A D CONTACT SURFACE J9309 95 Fig 13 Valve Face and Seat Angles VALVES Inspect the remaining margin after the valves are re...

Page 691: ...fer to specifications to obtain specified height and allowable tensions Discard the springs that do not meet specifications SPECIAL TOOL C 647 9209 37 Fig 16 Testing Waive Spring for Compressed Length with Tool C 647 INSTALLATION 1 Coat valve stems with lubrication oil and insert them in cylinder head 2 If valves or seats are reground check valve stem height If valve is too long replace cylinder h...

Page 692: ...ly more than 1 tappet will be noisy When oil level and leaks have been corrected engine should be operated at fast idle for sufficient time This allows all of the air inside of the tappets to be bled out TAPPET NOISE DIAGNOSIS 1 To determine source of tappet noise operate en gine at idle with cylinder head covers removed 2 Feel each valve spring or rocker arm to detect noisy tappet The noisy tappe...

Page 693: ...ast idle until all hy draulic tappets have filled with oil and have become quiet AL E TIMING 1 Turn crankshaft until the No 6 exhaust valve is closing and No 6 intake valve Is opening 2 Insert a 6 350 mm 1 4 inch spacer between rocker arm pad and stem tip of No l intake valve Allow spring load to bleed tappet down giving in ef fect a solid tappet 3 Install a dial indicator so plunger contacts valv...

Page 694: ...e of cover Fig 3 TIMING CHAIN STRETCH 1 Place a scale next to the timing chain so that any movement of the chain may be measured 2 Place a torque wrench and socket over cam shaft sprocket attaching bolt Apply torque in the di Fig 3 Removal of Front Crankshaft Oil Seal rection of crankshaft rotation to take up slack 41 N m 30 ft lbs torque with cylinder head installed or 20 N m 15 ft lbs torque wit...

Page 695: ...nt of Mopar Silicone Rubber Adhe sive Sealant or equivalent at the joint between tim ing chain cover gasket and the oil pan gasket Finger tighten the timing chain cover bolts at this time 2 Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 Fig 6 Seat the oil seal in the groove of the tool CRANKSHAFT FRONT OIL SEAL INSTALL THIS END INTO SPECIAL TOOL 6635 J9309 44...

Page 696: ...t Fig 7 7 Using the vibration damper bolt tighten the bolt to draw the seal into position on the crankshaft Fig 8 8 Remove the vibration damper bolt and seal in stallation tool 9 Install the vibration damper 10 Connect the negative cable to the battery CAMSHAFT This procedure requires that the engine is removed from the vehicle The camshaft has an integral oil pump and distrib utor drive gear Fig ...

Page 697: ...d chain oil tab Make sure tang enters lower right hole in thrust plate Tighten bolts to 24 N m 210 in lbs torque Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication 5 Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores 6 Place timing chain around bot...

Page 698: ...stems for the proper procedure OIL PAN REMOVAL 1 Disconnect the negative cable from the battery 2 Remove engine oil dipstick 3 Raise vehicle 4 Drain engine oil 5 Remove exhaust pipe 6 Remove left engine to transmission strut 7 Remove oil pan and one piece gasket CLEANING Clean the block and pan gasket surfaces Trim or remove excess sealant film in the rear main cap oil pan gasket groove DO NOT rem...

Page 699: ...oil pan 2 Remove the oil pump from rear main bearing cap DISASSEMBLE 1 Remove the relief valve as follows a Remove cotter pin Drill a 3 175 mm 1 8 inch hole into the relief valve retainer cap and in sert a self threading sheet metal screw b Clamp screw into a vise and while supporting oil pump remove cap by tapping pump body using a soft hammer Discard retainer cap and remove spring and relief val...

Page 700: ...ly Fig 8 Measuring Outer Rotor Clearance in Housing Install inner rotor and shaft into pump body If clearance between inner and outer rotors is 0 203 mm 0 008 inch or more replace shaft and both ro tors Fig 9 OUTER ROTOR INNER ROTOR RH179 Fig 9 Measuring Clearance Between Rotors Place a straightedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm 0 004 inch or more can...

Page 701: ...ore removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation 5 Be sure the connecting rod and connecting rod cap are identified 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 cylinder block When removing piston and connecting rod ass...

Page 702: ...m 0 0080 inch side clearance d Pistons with insufficient or excessive side clearance should be replaced 3 Arrange ring gaps 90 apart as shown in Fig 14 CONNECTING ROD BEARINGS Fit all rods on a bank until completed DO NOT al ternate from one bank to another because connect ing rods and pistons are not interchangeable from one bank to another GROOVE J9209 136 Fig 13 Measuring Piston Ring Side Clear...

Page 703: ...t and bearings are replaced REMOVAL 1 Remove the oil pan 2 Remove the oil pump from the rear main bear ing cap 3 Identify bearing caps before removal Remove bearing caps and bearings one at a time 4 Lift the crankshaft out of the block 5 Remove and discard the crankshaft rear oil seals 6 Remove and discard the front crankshaft oil seal Undersize Journal Identification Stamp 0 025 mm 0 001 inch Rod...

Page 704: ... carry the crankshaft thrust loads They are NOT interchangeable with any other bearing halves in the engine Fig 18 Bearing shells are available in stan 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 below specifications Fig 18 Main Bearing Identifi...

Page 705: ... the oil pan seal groove 12 Install new front crankshaft oil seal 13 Immediately install the oil pan UPPER SEAL REPLACEMENT CRANKSHAFT INSTALLED 1 Remove the oil pan 2 Remove the oil pump from the rear main bear ing cap 3 Remove the rear main bearing cap Remove and discard the old lower oil seal 4 Carefully remove and discard the old upper oil seal 5 Lightly oil the new upper seal lips with engine...

Page 706: ...operation should be closely co ordinated with the fitting of pistons and rings so specified clearances may be maintained Refer to Standard Service Procedures in the begin ning of this Group for the proper honing of cylinder bores OIL LINE PLUG The oil line plug is located in the vertical passage at the rear of the block between the Oil To Filter and Oil From Filter passages Fig 20 Improper install...

Page 707: ...moval 2 Using proper drive plug drive 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 cooling system can be filled and the vehicle placed in service immediately ASSEMBLE 1 Install the piston connecting rod assembly 2 Install the oil pan 3 Install the cylinder head 4 Install the engi...

Page 708: ...al Clearance No 1 0 0127 0 0381 mm 0 0005 0 0015 in Max Allowable No l 0 0381 mm 0 0015 in Nos 2 3 4 and 5 0 0127 0 0508 mm 0 0005 0 0020 in Max Allowable Nos 2 3 4 5 0 0635 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 71 361 71 387 mm 2 8095 2 8105 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Blo...

Page 709: ...7 oz Piston Pins Clearance In Piston 0 006 0 019 mm 0 00023 0 00074 in Diameter 25 007 25 015 mm 0 9845 0 9848 in End Play NONE Length 67 8 68 3 mm 2 67 2 69 in Piston Rings Ring Gap Compression Ring Top 0 30 0 55 mm 0 012 0 022 in Compression Rings 2nd 0 55 0 80 mm 0 022 0 031 in Oil Control Steel Rails 0 381 1 397 mm 0 015 0 055 in Ring Side Clearance Compression Rings 0 040 0 085 mm 0 0016 0 00...

Page 710: ...v e r l a p 26 J9309 33 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION 0 025 mm 0 001 inch U S Crankshaft R o r M M 2 3 etc Indicating No 2 3 main bearing journal and or R l 4 etc Indicating No 1 4 connecting rod journal Milled flat on number three crankshaft counterweight 0 508 mm 0 020 inch O S Cylinder Bores A Following engine serial number ...

Page 711: ...m 25 ft lbs Oil Pump Attaching Bolts 41 N m 30 ft lbs Oil Pump Cover Bolts 11 N m 95 in lbs Rear Insulator to Bracket Through Bolt 2WD 68 N m 50 ft lbs Rear Insulator to Crossmember Support Bracket Nut 2WD 41 N m 30ft lbs Rear Insulator Mounting Plate fo Rail Assembly Nuts 4WD 41 N m 30ft lbs Rear Support Bracket to Crossmember Flange Nuts 41 N m 30ft lbs Rear Support Plate to lnsulator Mounting P...

Page 712: ... order is 1 5 3 6 2 4 Fig 2 J898D 10 Fig 2 Firing Order The engine data plate is located on the driver side of the engine forward of the fuel injection pump ENGINE FRONT MOUNTS INSULATORS BRACKETS REMOVAL 1 Raise hood and position fan to assure clearance for radiator top tank and hose 2 Raise vehicle on a hoist Support the engine 3 Remove the through bolts and nuts from the bracket Fig 3 4 Remove ...

Page 713: ...mber bracket nuts and remove the bracket Fig 4 INSULATOR TRANSMISSION BLOCKER BRACKET TRANSMISSION SUPPORT BRACKET INSULATOR CROSSMEMBER BRACKET CROSSMEMBER J9109 149 Fig 4 Rear Engine Support 2WD INSTALLA TION 2WD 1 Install the insulator crossmember bracket to the crossmember Tighten the nuts to 41 N m 30 ft lbs torque 2 Install the transmission blocker bracket to the crossmember and the insulato...

Page 714: ... the vehicle ENGINE ASSEMBLY REMOVAL 1 Disconnect the electrical connection into the hood Scribe the hood hinge bolt locations and re move the hood Fig 7 2 Disconnect the battery cables and remove the battery 3 Drain the coolant from the cooling system re fer to Group 7 Cooling System for the proper proce Fig 7 Scribe Hood Hinge dures DO NOT waste reusable coolant If the solution is clean drain th...

Page 715: ...ions Fig 13 17 Disconnect the transmission cooler lines 18 AUTOMATIC TRANSMISSION a Remove torque converter bolt access cover Fig 11 Generator Removal Fig 12 Accelerator Speed Control Throttle Valve Linkage b Mark torque converter and drive plate for as sembly alignment Note that bolt holes in crank shaft flange drive plate and torque converter all have one offset hole c Rotate crankshaft in clock...

Page 716: ...ough bolts from the cylinder block mounting bracket CAUTION When removing the engine take care not to damage the wiper motor and voltage regulator mounted on the dash panel Fig 15 28 Lift the engine out of the vehicle Fig 16 29 Install the engine on a suitable stand 30 Remove all accessories and brackets not previ ously removed for use with the replacement engine Fig 15 Wiper Motor Voltage Regulat...

Page 717: ...he clutch electrical wire 19 Install the generator Tighten the upper mounting bolts to 24 N m 18 ft lbs torque Now tighten the lower mounting bolts to 43 N m 32 ft lbs torque Connect all wires 20 Install the radiator fan fan clutch assembly and fan shroud refer to Group 7 Cooling Systems for the proper procedures Connect the radiator hoses 21 Position the intercooler inlet duct to the tur bocharge...

Page 718: ...ocket for signs of scoring or cracks where the ball and the socket are pressed into the tube 6 Check the push rods for roundness and straightness 7 Install the push rods into the sockets of the valve tappets Lubricate the push rod sockets with clean engine oil 8 Make sure the rocker lever adjusting screws are completely backed out INSTALLATION 1 Make sure the dowel rings in the pedestals are insta...

Page 719: ... and inspect the coolant pas sages A large build up of rust and lime will require removal of the cylinder block for cleaning in a hot tank Inspect the cylinder bores for damage or excessive wear Rotate the crankshaft so the piston is at Bot tom Dead Center BDC to inspect the bores Measure the cylinder bores Fig 8 DO NOT pro ceed with in chassis repair if the bores are damaged or worn beyond the li...

Page 720: ...94 00 0 25 mm 3 7008 0 0010 inch SURFACE FINISH 1 5 to 3 2 micrometers 60 to 128 microinches J9109 134 Fig 10 Cylinder Head Stock Removal Wash the cylinder head in hot soapy water solution 88 C or 140 F After rinsing use compressed air to dry the cylin der head Polish the gasket surface with 400 grid paper Use an orbital sander or sanding block to maintain a flat surface INSTALLATION 1 The cylinde...

Page 721: ...th clean lubricating oil re fer to Group 0 Lubrication and Maintenance VALVES AND VALVE SPRINGS REMOWAL 1 Remove the cylinder head 2 Mark the valves to identify their position 3 Compress the valve spring and remove the valve stem collets Fig 1 4 Release valve spring and remove the retainer and spring Fig 1 5 Remove the remaining collets retainers springs and valves Keep the valves in a labeled rac...

Page 722: ...e INSTALLATION THIN WALL SERVICE GUIDES Machine the cylinder head valve guide bores to 11 125 0 013 mm 0 4380 0 0005 inch in diame ter Fig 6 Service valve guides must be centered with valve seats within 0 35 mm 0 01378 inch diameter They must also be square with the combustion face within 0 10 mm 0 004 inch at 50 0 mm 1 9685 inch ra dius Lubricate the valve guides with oil and press the guides flu...

Page 723: ...CTION Cylinder head with integral valve seats can be ground only once Previously ground integral seats must be replaced with service seats One X stamped into the head casting identify seats that have been ground previously Fig 8 Two X s stamped on the head indicate service seats have been installed Fig 8 Service seats can be ground SERVICE SEATS INSTALLED n o REGROUND INTEGRAL VALVE SEAT J9109 138...

Page 724: ...if the depth is over this limit Apply a light coat of valve lapping compound to each valve and lap each valve to its mating seat Remove the valves and clean lapping compound from the valves and seats Measure the valve seat width indicated by the lap ping surface The valve seat width limit is 1 50 2 00 mm 0 060 0 080 inch If required grind the areas with a 60 stone and a 15 stone to center the seat...

Page 725: ...lve and seats Measure the valve seat width indicated by the lapped surface Fig 15 The width limits are 1 5 2 0 mm 0 060 0 080 inch If required grind lower area with 60 stone and upper area with 15 stone Fig 15 Be sure to center the seat on the valve face Maintain the valve seat within limits MIN 0 990 mm 0 039 inch MAX 1 520 mm 0 060 inch J9109 44 Fig 14 Valve Depth with Seat Insert MINIMUM 1 5 mm...

Page 726: ...lve lash adjustment is 0 254 mm 0 010 inch for the intake valve The valve lash adjustment is 0 508 mm 0 020 inch for the exhaust valve Tighten the valve adjusting nuts to 24 N m 18 ft lbs torque Be sure timing pin is disengaged before rotating the crankshaft Mark the pulley and rotate the crankshaft 360 5JL DIESEL ENGINE 9 121 Fig 18 Locating TDC using Timing Pin I INTAKE E EXHAUST E I E I E I J91...

Page 727: ...ue 2 Install the camshaft Make sure the alignment marks on the camshaft and crankshaft gears are aligned Fig 2 3 If a new housing is installed the timing pin as sembly must be accurately located 4 Install the following Fan hub assembly refer to Group 7 Cooling Sys tem Fuel injection pump refer to Group 14 Fuel Sys tem Gear driven accessories 5 Install the gear housing cover refer to Gear Housing C...

Page 728: ...allation tool and a plas tic hammer to install the seal to the correct depth To prevent damage to the seal carrier hit the align ment installation tool alternately at the 12 3 6 and 9 o clock positions 10 Install the oil fill tube and mounting bolts Tighten the bolts to 43 N m 32 ft lbs torque 11 Install the vibration damper DO NOT tighten the bolts to the correct torque valve at this time 12 Inst...

Page 729: ...mper First Mark Fig 10 Mark Vibration Damper Second Mark Fig 11 Location of Top Dead Center TDC mark is the TDC mark Fig 11 12 Completely loosen the No l cylinder exhaust valve adjusting screw 13 Rotate the crankshaft with Cummins Barring Tool 3377371 approximately 180 in the direction of engine rotation until the pointer is aligned with the TDC mark Look through the back side of the gear housing ...

Page 730: ... contacts the plate 5 Mark the vibration damper Fig 11 6 Rotate the engine in the opposite direction un til the piston contacts the plate 7 Mark the vibration damper Fig 11 8 Mark the vibration damper for TDC TDC will be one half the distance between the first two marks Fig 11 9 Remove the plate and rotate the engine in the direction of rotation until the pointer aligns with the TDC mark 10 Look f...

Page 731: ... tappet NORMAL WEAR STEM DIAMETER ABNORMAL WEAR J9109 152 Fig 2 Tappet Inspection INSTALLATION 1 Insert the trough the full length of the cam bore 2 Feed the installation tool down the tappet bore and into the trough Fig 3 J9109 153 Fig 3 Tappet Installation Tool 3 Feed the installation tool cord through the cam bores Carefully pull the trough and installation tool out the front The barrier at the...

Page 732: ...pump 2 Insert the dowels through the push tube holes and into the top of each tappet When properly in stalled the dowels can be used to pull the tappets up Fig 6 3 Pull the tappets up and wrap a rubber band around the top of the dowel rods Fig 6 This will prevent the tappets from dropping down 4 Rotate the crankshaft to align the crankshaft to camshaft timing marks Fig 7 5 Remove the bolts from th...

Page 733: ...10 6 Measure the installed bushing The limit of the inside diameter is 54 133 mm 2 1312 inch CAMSHAFT GEAR REPLACEMENT 1 Press the camshaft out of the gear J9109 54 Fig 10 Oil Hole Alignment 2 Remove all burrs and smooth any rough sur faces caused by removing the gear 3 Install the camshaft key 4 Lubricate the camshaft surface with Lubriplate 105 or equivalent 5 Heat the gear in an oven at 121 C 2...

Page 734: ... 9 129 Fig 1 Combustion Deck Face Measurement Inspect the cylinder bores for damage or excessive wear Measure the cylinder bores Fig 2 If the cylinder bores exceeds the limit refer to Cylinder Bore Re pair MIN 102 0 mm 4 0157 inch MAX 102 1 16 mm 4 0203 inch Out of Round 0 038 mm 0 0015 inch Taper 0 0 76 mm 0 003 inch Oversize pistons and rings are available for bored cylinder blocks J9209 167 Fig...

Page 735: ...azing Drill Speed and Vertical Speed 8 Inspect the bore after 10 strokes 9 Use a strong solution of hot water and laundry detergent to clean the bores Clean the cylinder bores immediately after de glazing 10 Rinse the bores until the detergent is removed and blow the block dry with compressed air 11 Check the bore cleanliness by wiping with a white lint free lightly oiled cloth If grit residue is ...

Page 736: ...of standard 0 50 mm 0 0197 inch or 1 00 mm 0 0393 inch overbore may be used in the same engine If more than 1 00 mm 0 0393 inch overbore is needed a repair sleeve can be installed refer to Method 2 Repair Sleeve Cylinder block bores may be bored twice before use of a repair sleeve is required Fig 10 The first bore is 0 50 mm 0 0197 inch oversize The second bore is 1 00 mm 0 0393 inch oversize Afte...

Page 737: ...the cyl inder bore beyond the oversize limit BORE DIAMETER BLOCK REBORE FOR REPAIR SLEEVE BORE DIA 104 500 0 015 mm 4 1142 0 0006 inch STEP DIM 6 35 mm 0 25 inch J9109 120 Fig 12 Block Bore for Repair Sleeve Dimensions After machining the block for the new repair sleeve thoroughly clean the bore of all metal chips debris and oil residue before installing the sleeve Cool the repair sleeve s to a te...

Page 738: ...fter rinsing blow the block dry with compressed air Wipe the bore with a white lint free lightly oiled cloth Make sure there is no grit residue present Apply a rust preventing compound if the block will not be used immediately A standard diameter piston and a piston ring set must be used with a sleeved cylinder bore CAM BORE REPAIR The front cam bushing bore can be bored to 57 740 Mm 0 018 mm 2 27...

Page 739: ...cting rod through the cylinder bore 9 Store the piston rod assemblies in a rack DISASSEMBLE 1 Remove the retainer rings from the piston Fig 1 2 Remove the piston pin Heating the piston is not required 3 Remove the piston rings Fig 1 RETAINER RING CONNECTING ROD PISTON PISTON RIN RETAINER RING J9109 62 Fig 1 Retainer Rings CLEANING CAUTION DO NOT use bead blast to clean the pis tons DO NOT clean th...

Page 740: ...6 Fig 5 Piston Pin Diameter Measure the connecting rod pin bore Fig 6 The maximum diameter is 40 092 mm 1 5784 inch If out of limits replace the connecting rod CONNECTING Fig 6 Connecting Rod Pin Bore CONNECTING ROD BEARING CRANKSHAFT JOURNAL CLEARANCE Measure the connecting rod bore with the bearings installed and the bolts tightened to 100 N m 73 ft lbs torque Record the smaller diameter Measure...

Page 741: ...at ing to install the pin however the piston does need to be at room temperature or above 4 Determine the piston diameter and obtain the appropriate ring set The piston rings can be identi fied as shown in Fig 9 TOP RING INTERMEDIATE RING OIL CONTROL RING TOP J9109 69 Fig 9 Piston Ring Identification 5 Position each ring in the cylinder and use a piston to square it with the bore at a depth of 89 ...

Page 742: ...r connecting rod bearings INSTALLATION 1 Lubricate the cylinder bore with clean engine oil 2 Generously lubricate the rings and piston skirts with clean engine oil 3 Compress the rings using a piston ring com TOP RING INTERMEDIATE RING OIL CONTROL RING J9109 73 Fig 14 Piston Ring Positioning STANDARD J9109 82 OVERSIZE 0 250 mm 0098 in 0 500 mm 0197 in 0 750 mm 0295 in 1 000 mm 0394 in Fig 15 Conne...

Page 743: ...e the side clearance between the con necting rod and the crankshaft Fig 19 DO NOT measure the clearance between the cap and crank shaft 13 Install the suction tube and oil pan 14 Install the cylinder head onto the block 15 Install the engine assembly into the vehicle SIDE CLEARANCE LIMITS MIN MAX 0 100 mm 0 300 mm 0 004 inch 0 012 inch Fig 19 Side Clearance between Connecting Rod Crankshaft CRANKS...

Page 744: ...exception is the main journal thrust width surface This journal must be ground in incre ments of 0 50 mm 0 0197 inch up to a total of 1 00 mm 0 0394 inch The thrust surface is located on the No 6 main bearing When the thrust surface re quires grinding the main journal must be ground to the same undersize dimension MAIN JOURNAL All main journals are to be ground in the opposite direction of engine ...

Page 745: ...is ground ALTERNATIVE PROCEDURE Smoothly blend a 1 25 0 020 mm 0 0492 0 0008 inch radius to the ground diameters Fig 9 ROD JOURNAL All rod journals are to be ground in the opposite di rection of engine rotation clockwise as viewed from ORIGINAL RADIUS JOURNAL SURFACE SURFACE FINISH 0 8 micrometer 32 0 microinch for a minimum of 45 into the fillet beyond journal surface 1 6 micrometer 64 0 microinc...

Page 746: ...r cover was replaced use the align ment tool from the seal kit to make sure the cover is aligned with the crankshaft SURFACE FINISH 0 8 micrometer 32 0 microinch for a minimum of 45 into the fillet beyond journal surface 1 6 micrometer 64 0 microinch for remainder of fillet 0 4 micrometer 16 0 microinch CD J9109 131 Fig 11 Crankshaft Rod Journal Grind Preferred Method 3 Apply a bead of Loctite 277...

Page 747: ... 3 Align the seal housing to the crankshaft with the alignment tool provided in the seal kit Fig 14 Make sure the seal housing is level with both sides of the block oil pan rail Tighten the bolts to 9 N m 7 ft lbs torque 4 Remove the alignment tool and trim the gasket even with the oil pan mounting surface Fig 14 Fig 14 Crankshaft Rear Seal Housing Alignment Tool 5 The rubber O D rear crankshaft s...

Page 748: ...O D rear crankshaft seals are lubricated with soapy water Seals without rubber O D use Loctite 277 or equivalent sealant 4 Use the alignment tool to install the seal to the correct depth in the housing Use a hammer to drive the seal into the housing until the alignment tool stops against the housing Fig 18 5 Hit the tool at the 12 3 6 and 9 o clock posi tions to drive the seal evenly and prevent b...

Page 749: ...asket Fig 1 Tighten the bolts to 24 N m 18 ft lbs torque 5 Install the drain plug with a new sealing washer and tighten to 80 Nnn 60 ft lbs torque 6 Install the engine assembly into the vehicle 7 Fill the engine with clean lubrication oil refer to Group 0 Lubrication and Maintenance Run the engine and check for leaks 8 Stop the engine and let it set for five minutes Check the oil level and add oil...

Page 750: ...aximum clearance is 0 127 mm 0 005 inch If the oil pump is out of limits replace the pump PORT PLATE GEROTOR J9109 22 Fig 5 Gerotor to Port Plate Clearance Measure the clearance of the gerotor planetary to the body bore Fig 6 Maximum clearance is 0 381 mm 0 015 inch If the oil pump is out of limits re place the pump BODY BORE GEROTOR PLANETARY J9109 23 Fig 6 Gerotor Planetary to Body Bore Clearanc...

Page 751: ...ean the area around the lubricating oil filter head Remove the filter using a 90 95 mm filter wrench 5 Clean the gasket surface of the filter head The filter canister O Ring seal can stick on the filter head Make sure it is removed INSTALLATION 1 Fill the oil 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 ...

Page 752: ...TALLATION 1 Clean and inspect the plunger bore and seat before assembly The plunger must move freely in the valve bore 2 Install the valve spring gasket and plug Tighten the plug to 80 N m 60 ft lbs torque OIL COOLER ELEMENT GASKET The non intercooled turbocharged engine filter head coolers can not be used on intercooled engines REMOVAL 1 Drain the cooling system refer to Group 7 Cooling System fo...

Page 753: ...4 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 sealing gasket Install the oil filter 5 Fill the coolant system and operate the engine to check for leaks Stop the engine and check the coolant and oil level SHIPPING PLUG J9109 18 Fig 14 Oil Cooler ...

Page 754: ... inch CYLINDER H E A D Cylinder Head Flatness Max Overall 0 030 mm 0 012 inch Max Variation within 0 01 mm 0 0004 inch in any 50 8 mm 2 0 inch diameter area GEAR TRAIN Gear Backlash all gears 0 08 0 33 mm 0 003 0 013 inch Camshaft End Clearance 0 152 0 254 mm 0 006 0 010 inch CAMSHAFT Journal Diameter Min 53 962 mm 2 1245 inch Valve Lobes Min Diameter at Peak of Lobe Intake 47 040 mm 1 852 inch Ex...

Page 755: ...2 mm 2 7150 inch Machined 0 25 mm 68 712 mm 2 7052 inch Machined 0 50 mm 68 462 mm 2 6954 inch Machined 0 75 mm 68 212 mm 2 6855 inch Machined 1 00 mm 67 962 mm 2 6757 inch Out of Round Max 0 050 mm 0 002 inch Taper Max 0 013 mm 0 0005 inch Oil Clearance Max 0 089 mm 0 0035 inch CYLINDER B L O C K Top Surface Flatness Max Overall Variation 0 075 mm 0 003 inch Max Variation any 50 mm 2 inch Diamete...

Page 756: ...ount Isolator Mounting to Mount Front Engine Mount Through Bolt Front Engine Mount to Block Front Oil Filler Pipe Access Cover Fuel Banjo Screw In Fuel Pump Fuel Banjo Screw In Head Fuel Banjo Screw In Injector Fuel Filter Fuel Heater Assembly Mounting Fuel Heater Ground Mounting to Intake Manifold Fuel Link Fitting High Pressure Fuel Low Pressure Supply Fuel Pump Drive Gear With Pump Unlocked Fue...

Page 757: ...ut Tappet Cover Fuel Drain Line Supports Thermistor Thermostat Housing Throttle Bracket Mounting to Mounting Bracket Throttle Rod Mounting to Throttle Lever Nut Timing Pin Flange Mounting Torque Converter Access Cover Plate Mounting Transfer Case Linkage Bracket Mounting Trans Transfer Case Mounting to Transmission 24 N m 18 ft lbs 43 N m 32 ft lbs 24 N m 18 ft lbs 13 N m 10 ft lbs 8 N m 6 ft lbs ...

Page 758: ...s Transmission Torque Converter Mounting 47 N m 35 ft lbs Turbine Housing 11 N m 8 ft lbs Turbo Compressor Housing Clamp 8 5 N m 75 in lbs Turbo Mounting Nut 32 N m 24 ft lbs Turbo Oil Drain Tube 24 N m 18 ft lbs Turbo Oil Supply Both Ends 15 N m 11 ft lbs Vacuum Pump Mounting 9 N m 7 ft lbs Vacuum Pump to Gear Housing Mounting 77 N m 57 ft lbs Valve Cover 24 N m 18 ft lbs Vibration Damper Mountin...

Page 759: ......

Page 760: ...e heat will not be the fault of the converter If un burned fuel enters the converter overheating may occur If a converter is heat damaged correct the cause of the damage at the same time the converter is replaced Also inspect all other components of the exhaust system for heat damage Unleaded gasoline must be used to avoid contami nating the catalyst core EXHAUST HEAT SHIELDS GASOLINE ENGINES Exha...

Page 761: ...t At the other end of the shaft is the compressor wheel The compressor wheel draws air in and forces it into the engine cylinders through the intake manifold Supplying Increased air flow to the engine pro vides Improved engine performance Lower exhaust smoke density Improved operating economy Altitude compensation Noise reduction ...

Page 762: ... Tighten clamps at leaking joints 2 Replace 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 restriction if possible Replace muffler or tail pipe as necessary LEAKING EXHAUST GASES 1 Leaks at pipe joints 2 Damaged or improperly installed gaskets 1 Tight...

Page 763: ... nuts 3 Remove clamps isolators and bolts 4 Remove the catalytic converter 5 Clean ends of pipes and muffler to assure mat ing of all parts 6 Discard rusted clamps broken or worn isola tors supports and attaching parts Replace a compo nent with original equipment parts or equivalent This will assure proper alignment with other parts in the system and provide acceptable exhaust noise lev els INSTAL...

Page 764: ... els INSTALLATION 1 Assemble exhaust tailpipe isolators and clamps loosely to permit proper alignment of all parts 2 Position the exhaust tailpipe for proper clear ance with the underbody parts 3 Tighten all clamp nuts bolts and support bracket nuts bolts to the proper torques Refer to Figs 2 4 5 and 7 4 Lower the vehicle 5 Start the engine and check for leaks EXHAUST HEAT SHIELDS Refer to Figs 3 ...

Page 765: ...FOLD HOLE LOCATION FOR SUPPORT 4 WHEEL DRIVE REAR CONVERTER PIPE 115 WHEELBASE1 131 WHEELBASE 5 9L ENGINES HANGER ASSEMBLY CONVERTER PIPE INSULATOR MUFFLER 3 9L AND 5 2L ENGINES J9211 16 Fig 1 Single Exhaust System Light Duty Trucks 1 of 3 ...

Page 766: ...1 7 INSULATOR FRAME SIDE RAIL 3 9L AND 5 2L ENGINES TAIL PIPE TAIL PIPE TAIL PIPE EXTENSION 5 9L ENGINES HANGER ASSEMBLY TAIL PIPE FRAME SIDE RAIL INSULATOR 3 9L AND 5 2L ENGINES J9211 17 Fig 2 Single Exhaust System Light Duty Trucks 2 of 3 ...

Page 767: ...11 8 EXHAUST SYSTEM AND INTAKE MANIFOLD Fig 3 Single Exhaust System Exhaust Heat Shields Light Duty Trucks 3 of 3 ...

Page 768: ...SION CROSSMEMBER BRAKE LINE SHIELD 2 WHEEL DRIVE 12 7 4 8 MM 0 50 0 19 INCH TYPICAL SLIP JOINT MUST BE FULLY ENGAGED TIGHTENING TORQUE 26 N m 19 FT LBS 43 N m 32 FT LBS 23 N m 200 IN LBS 14 N m 125 IN LBS 54 N m 40 FT LBS J9211 19 Fig 4 Dual Exhaust System 5 9L Engines Heavy Duty Trucks 1 of 2 ...

Page 769: ...LER PIPE FRAMERAIL 131 WHEELBASE 135 WHEELBASE FRAMERAIL 135 WHEELBASE 131 WHEELBASE ISOLATORS 159 WHEELBASE MUFFLER PIPE 131 135 WHEELBASE FRAMERAIL BRACKET CONVERTER PIPE FRAMERAIL TIGHTENING TORQUE 23 N m 200 IN LBS 14 N m 125 IN LBS 28 N m 250 IN LBS J9211 20 Fig 5 Dual Exhaust System 5 9L Engines Heavy Duty Trucks 2 of 2 ...

Page 770: ...EXHAUST SYSTEM AND INTAKE MANIFOLD 1 1 1 1 RETAINER CATALYTIC CONVERTER PIPE HEAT SHIELD FRAMERAIL J9211 22 Fig 6 Sport Utility Exhaust System 1 of 3 ...

Page 771: ...11 12 EXHAUST SYSTEM AND INTAKE MANIFOLD Fig 7 Sport Utility Exhaust System 2 of 3 ...

Page 772: ...d if so equipped the speed control and transmission kick down cables 7 Remove the return spring 8 Remove the distributor cap and wires 9 Disconnect the coil wires 10 Disconnect the heat indicator sending unit wire 11 Disconnect the heater hoses and bypass hose 12 Remove the closed crankcase ventilation and evaporation control systems 13 Remove intake manifold bolts 14 Lift the intake manifold and ...

Page 773: ...ensure a leak proof seal However an excessive amount of sealant may reduce the effectiveness of the flange gasket The sealant should be slightly higher than the cross over gaskets approx 5 mm 0 2 in 5 Install the front and rear cross over gaskets onto the dowels Fig 11 FRONT CROSS OVER GASKET REAR CROSS OVER GASKET J9209 99 Fig 11 Cross Over Gaskets and Locator Dowels 6 Install the flange gaskets ...

Page 774: ...ct the coil wires 11 Connect the heat indicator sending unit wire 12 Connect the heater hoses and bypass hose 13 Install distributor cap and wires 14 Hook up the return spring 15 Connect the accelerator linkage and if so equipped the speed control and transmission kick down cables 16 Install the fuel lines 17 Install the generator and drive belt Tighten generator mounting bolt to 41 Nun 30 ft lbs ...

Page 775: ...caution is not taken 1 Position the engine exhaust manifolds on the two studs located on the cylinder head Install coni cal washers and nuts on these studs Fig 15 or 16 2 Install two bolts and conical washers at the in ner ends of the engine exhaust manifold outboard arms Install two bolts WITHOUT washers on the center arm of engine exhaust manifold Fig 15 or 16 Starting at the center arm and work...

Page 776: ...ld Cover Air Intake Heater 19 Muffler and Extension Pipes 17 Turbocharger 21 INSTALLATION 1 Align the front exhaust pipe with the front ex haust extension pipe and the turbocharger exhaust outlet 2 Install the exhaust pipe support strap Tighten the nut to 4 1 Nun 30 ft lbs torque 3 Install the exhaust pipe support clamps and nuts Tighten the nuts to 54 Nun 40 ft lbs torque 4 Lower the vehicle 5 In...

Page 777: ...pport the vehicle 2 Remove the clamp from the pipe Fig 5 3 Remove the bolt from the exhaust tailpipe bracket 4 Separate the exhaust tailpipe from the rear ex tension pipe or from the muffler rear extension pipe 5 If required remove the exhaust tailpipe bracket from the frame rail Fig 5 TAIL PIPE BRACKET J9211 25 Fig 5 Exhaust Tailpipe INSTALLATION 1 If removed install the exhaust tailpipe bracket ...

Page 778: ... N I F O L D GASKET J9111 6 Fig 9 Engine Exhaust Manifold Bolt Tightening Sequence Nun 18 ft lbs torque Tighten the oil supply line fitting nut to 15 Nun 11 ft lbs torque 6 Connect the cab heater supply and return lines Tighten the line nuts to 24 Nun 18 ft lbs torque 7 Operate the engine to check for leaks INTAKE MANIFOLD COVER AIR INTAKE HEATER REMOVAL 1 Remove the charge air cooler intercooler ...

Page 779: ...rature Switch AAANIFOLD INTAKE COVER FUEL HEATER GROUND WIRE J9111 50 Fig 13 Manifold Intake Cover and Fuel Heater Ground Wire 5 Some of the intake manifold bolt holes are drilled through and must be sealed Apply liquid te flon sealant to the bolts Install the intake manifold cover bolts Tighten the bolts to 24 Nun 18 ft lbs torque 6 Install a new gasket between the air intake heater and the intak...

Page 780: ... Band clamps Fig 16 4 Remove the compressor housing and inspect for impeller contact Fig 16 5 Remove the square cut O ring Fig 16 6 Remove the impeller nut Fig 16 Turn the impeller nut to the right to loosen The nut and shaft have left hand threads 7 Remove the impeller and inspect the blades for damage The wheel and shaft assembly is balanced as a unit If the impeller is damaged the complete as s...

Page 781: ...g type seal Fig 21 CAUTION The wheel and shaft assembly is bal anced as a unit If the turbine blades or shaft are damaged the complete assembly must be replaced 21 Remove and discard the outer retainer rings Fig 22 22 Remove and discard the turbocharger shaft bearings Fig 22 23 Remove and discard the inner snap rings Fig 22 CLEANING Use a stiff bristle nylon brush and solvent to clean all parts Do...

Page 782: ...ket in a soft jawed vice and posi tion the shaft in the socket 4 Install the inner retainer rings The beveled face must be towards the bearing Fig 25 5 Lubricate the turbocharger bearing with engine oil and install the bearings in the housing 6 Install the outer retainer ring The beveled face must be towards the bearings Fig 26 7 Assemble the turbine shaft and heat shield to the bearing housing Ro...

Page 783: ...areful not to move the bearing housing 17 Do not allow the impeller to turn when in stalling the nut The impeller nut and the shaft have LEFT hand threads Tighten the nut to 14 N m 129 in lbs torque 18 Install the bearing housing assembly into the turbine housing Fig 30 19 Align the scribe marks Fig 30 20 Apply anti seize compound to the bolt threads 21 Install the clamp plates lock plates and bol...

Page 784: ...oil supply line Tighten the oil sup ply line fitting nut to 15 N m 11 ft lbs torque 7 Position the Charge air cooler intercooler in let duct to the turbocharger With the clamp in posi tion tighten the clamp nut to 8 N m 72 in lbs torque 8 Position the air intake pipe and the exhaust pipe onto the turbocharger Tighten the clamps to 8 N m 72 in lbs torque 9 Connect the negative cable to the battery ...

Page 785: ... Intercooler Ducts 2 Install the inlet and outlet ducts to the charge air cooler intercooler Fig 35 With the clamps in position tighten the clamp nut to 8 N m 72 in lbs torque 3 If the vehicle is equipped with air conditioning install the condenser as follows a Position the condenser and sealing plate as sembly onto the charge air cooler intercooler studs Install the nuts and tighten b Connect the...

Page 786: ... M E N S I O N S Air Intake Restrictions 635 mm Water 25 in Water Max Turbo Radial Clearance 0 300 0 460 mm 0 012 0 018 inch Turbo Rotor Assembly End Play Before S N 840638 0 102 0 152 mm 0 004 0 006 inch S N 840638 AND AFTER 0 026 0 076 mm 0 001 0 003 inch Turbo Shaft Bearing Diameter 10 97 0 432 inch J9111 26 ...

Page 787: ...fer to Procedure in Service Manual Intake Manifold Cover Bolts 24 N m 18 ft lbs Intercooler Attaching Bolts 2 N m 17 in lbs Intercooler Duct Clamp Nuts 8 N m 72 in lbs Muffler to Tail Pipe Clamp Nuts 43 N m 32 ft lbs Plenum Pan Bolts 3 9L 5 2L 1st Step 2 7 N m 24 in lbs 2nd Step 5 4 N m 48 in lbs 3rd Step 9 5 N m 84 in lbs Throttle Body MPI Bolts 23 N m 200 in lbs Throttle Control Bracket Mounting...

Page 788: ...the frame rails 3 Remove support and remove bumper from the vehicle STANDARD BUMPER REMOVAL 1 Support the bumper 2 Remove bumper nuts and bolts from the frame side rails and bumper brackets 3 Remove support and bumper from vehicle 4 Remove nuts and bolts and remove bumper brackets from bumper BOLT FRAME RAIL NUT LOCK NUT BUMPER BRACKET J9123 326 Fig 1 Front Bumper INSTALLATION 1 Position the bumpe...

Page 789: ...g 5 4 Lower the bumper and remove as a unit 5 Remove the bracket and brace bolts to the bumper Remove the brackets and braces from the bumper Fig 5 INSTALLATION 1 Attach brackets and braces to the bumper with the bolts and nuts Tighten the support bracket nuts to 68 N m 50 ft lbs torque Tighten the brace nuts to 41 N m 30 ft lbs torque 2 Position step bumper assembly to the rear of the vehicle 3 A...

Page 790: ...used with power angle plowing Power angling cylinders Enable the operator to move the moldboard either straight ahead or to the side Hinge pins Allows the A Frame to pivot up and down The pins act as attaching points Cutting edge Replaceable blade edge extends the life of the blade Runners Adjustable runners retain the cutting edge at the proper height Sno Flo paint Specially developed high visibi...

Page 791: ...ssary because solenoid valves B and C have some leakage One check valve is located 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 would force fluid through solenoid valve C into the right side cylinder The other check valve is located between valve B and v...

Page 792: ...ITION SWITCH ANGLE TAN LIGHT GREEN ORANGE WITH WHITE TRACER FUSE BATTERY o SOLENOID SWITCH MOTOR ENERGIZED MOTOR AND B COIL PRESSURE RELIEF B SOLENOID JUL C SOLENOID ANGLING CYLINDER CSSE OPERATING PRESSURE EXHAUST INTAKE OR DRAIN METERED FLOW RB525 Fig 2 Raise Blade Voltage Application Hydraulic Fluid Flow ...

Page 793: ...ANGE WITH WHITE TRACER L f FUSE LIGHT GREEN u c SOLENOID SWITCH BATTERY o ENERGIZED A COIL C SOLENOID POWER ANGLING CYLINDER LOWER AND FLOAT FORCE APPLIED AGAINST LIFT RAM OPERATING PRESSURE EXHAUST INTAKE OR DRAIN METERED FLOW RB526 Fig 3 Lower Float Blade Voltage Application Hydraulic Fluid Flow ...

Page 794: ...FRAME AND BUMPERS 13 7 IGNITION SWITCH L BLACK mm OPERATING PRESSURE EXHAUST SS3 INTAKE OR DRAIN METERED FLOW RB527 Fig 4 Angle Blade Right Voltage Application Hydraulic Fluid Flow ...

Page 795: ...13 8 FRAME AND BUMPERS TAN IGNITION SWITCH BLACK WSSm OPERATING PRESSURE mm EXHAUST ESBS3 INTAKE OR DRAIN METERED FLOW J9001 1 Fig 5 Angle Blade Left Voltage Application Hydraulic Fluid Flow ...

Page 796: ...No 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 ring seal at bottom of cylinder a Runner height incorrect b Cutting edge unevenly worn a Not in Lower Float Position b Insufficient slack in lift chain a Sno Flo paint worn off a Add fluid to proper l...

Page 797: ...SH 10 SP4 18WT BR PLOW CONTROL SWITCH UP DOWN L SP4 18WT BR SP4 18WT BR PLOW CONTROL SWITCH LEFT TO RIGHT SP4 18WT BR Dl 18RD YL TRANSMISSION OIL TEMPERATURE LAMP SP4 18WT BR SP4 18WT BR SP4 18WT BR SP1 18WT BK I Dl 18RD YL SP3 18 WT RD SP3 18WT RD SP1 18WT BK SP4 18WT BR I SP4 18WT BR SP4 18WT BR j Dl 18RD YL SP5 18WT LG I SP5 18WT LG T2 18LG RD 8901 3 Fig 6 Snow Plow Control Wiring Diagram ...

Page 798: ...OID FRONT SNOW PLOW FRAME SNOW PLOW RIGHT SOLENOID FRONT SNOW PLOW FRAME TRANSMISSION OIL TEMPERATURE LAMP TRANSMISSION OIL TEMPERATURE SWITCH RIGHT SIDE BELOW RADIATOR 8901 4 Fig 7 Snow Plow Control Wiring Diagram Cont d ...

Page 799: ...14LG TO FRONT END WIRING SEE SH 22 BLACK RIGHT SIDE RADIATOR YOKE PANEL BLACK RIGHT UPPER SNOW PLOW FRAME BLACK LEFT AUXILIARY PARK AND TURN SIGNAL LAMP LEFT AUXILIARY HEADLAMP RIGHT AUXILIARY HEADLAMP RIGHT AUXILIARY PARK AND TURN SIGNAL LAMP 8901 2 Fig 8 Snow Plow Auxiliary Lighting Wiring Diagram ...

Page 800: ... from the valve block Fig 9 Clean the solenoid valve Inspect it for external damage 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 Inspect the solenoid valve for external damage 25 Disassemble the four way valve Fig 12 Dis card the O ring seals Fig 12 26 Test solenoid valve B and C coils for electrical continu...

Page 801: ...14 FRAME AND BUMPERS RB530 Fig 9 Power Unit Exploded View ...

Page 802: ... BASE O RING RETAINER SPRING NSERT VALVE O RING 31 Valve Block 32 Socket Head Cap Screw 33 Filter 34 Plug 35 Strainer 36 Check Valve Retainer 37 Ball 38 Insert Valve 39 Cylinder Tank 40 Cylinder 41 4 Way Solenoid 42 4 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 Valv...

Page 803: ...ove 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 and support from the front of the vehicle frame Fig 15 INSTALLATION 1 Position and support the snow plow frame at the front of the vehicle frame with the bolt holes aligned Fig 15 2 Install the snow plow frame attaching bolts washers and nuts fing...

Page 804: ...ttaching bolts and nuts Fig 15 Tighten the nuts to 68 N m 50 ft lbs torque 4 Tighten the pivot bracket attaching nuts to 68 Nrni 50 ft lbs torque 5 Remove the support from under the pivot bracket SNOW PLOW CONTROL MODULE FRAME FRAME REMO VAUDISASSEMBL Y 1 Remove the screws and module retainers from the instrument panel Fig 17 2 Remove the control module from the instru ment panel Fig 17 3 Remove t...

Page 805: ...8 4 Mate the switch cover with the module hous ing Install the housing attaching screws Fig 18 Tighten the screws until the screw heads are seated against the housing 5 Position the control module on the instrument panel with the slots aligned with the holes Install the retainers and screws Fig 17 Tighten the screws until the module is tightly attached to the in strument panel INSTRUMENT PANEL WIR...

Page 806: ... Current 230 Amperes HYDRAULIC SPECIFICATIONS PUMP m Pressure Output pump relief valve opening pressure 1650 50 psi CROSSOVER RELIEF VALVE SOLENOID VALVES A B AND C SPECIFICATIONS A Coll Applied Voltage 12 Volts DC Current 0 83 Amperes Nominal resistance one ohmmeter probe to coil wire other to metal coil cover 9 0 10 ohms i and C Colls Applied Voltage 12 Volts DC Current 1 24 Amperes Nominal resi...

Page 807: ...d brackets The cargo box is attached to the rear of the frame with screws Ram Chassis Cabs and Ram Trucks with 8 foot cargo boxes are equipped with frames that have adapters attached to the top of the frame rails Fig 2 FRONT BODY TO FRAME ADAPTER REAR BODY TO FRAME ADAPTER BOLT BOLT KAC MODEL 64 CAB AND CHASSIS VEHICLES NUT REAR BODY TO FRAME ADAPTER BOLT FRONT BODY TO x FRAME ADAPTER NUT NUT BOLT...

Page 808: ...MID FRAME CROSSMEMBER EXTRA 159 165 W B ENGINE SUSPENSION FRONT SUPPORT CROSSMEMBER ALL FASTENERS ARE RIVETS EXCEPT AS NOTED PU892C 30 O m 30 OS I Fig 3 AD1 2 3 Frame Structure ...

Page 809: ...Fig 4 AD4 Frame Structure ...

Page 810: ...RIVETS EXCEPT AS NOTED PU893B Fig 5 ADS 6 7 Frame Structure ...

Page 811: ......

Page 812: ...res Adjust as necessary HORIZONTAL DIAGONAL FRAME MEASUREMENTS Determine the frame horizontal according to the following procedure 1 Select several reference points along one frame side rail preferably at the crossmember junctions 2 Transfer these reference points to the surface floor Paper sheets can be attached to the surface be low the reference points 3 Locate the same reference points on the ...

Page 813: ...T O O U T S I D E O F M E T A L I N S I D E O F M E T A L 37 68 CENTERLINE OF FRONT WHEELS 750 DIAMETER GAUGE HOLE 5 55 REAR OVERHANG SEE SPECIFICATIONS Fig 7 Frame Dimensions AD1 2 3 m m ...

Page 814: ... FRAME AND BUMPERS 13 27 ...

Page 815: ......

Page 816: ...nly to a small area A damaged frame member should be examined for hairline cracks Repair frame member cracks accord ing to the following procedure 1 Stop drill a hole at each end of the crack with a 3 mm 1 8 in diameter drill bit 2 V groove the crack to allow good weld penetra tion 3 Weld the crack 4 Grind the weld surface area smooth Install a reinforcement section at the welded area The flanges ...

Page 817: ...kid plate 2 Remove the nuts and bolts that attach the skid plate to the frame rails rear crossmember and the support bracket 3 Remove the skid plate from the fuel tank and the vehicle INSTALLATION 1 Position and support the skid plate under the fuel tank Insert the studs in the support bracket 2 Install the nuts to attach the skid plate to the support bracket Install the bolts at the rear cross me...

Page 818: ... in lbs CAB REMOVAL The cab is attached to the frame with holddowns Figs 4 and 5 The cab can be removed for repair or service Refer to the associated component procedure when necessary 1 Disconnect the battery cables from the termi nals Remove the battery from the tray 2 Disconnect the wire harness connectors from the engine components Disconnect from the frame 3 Disconnect the parking brake cable...

Page 819: ... operational CARGO BOX REMOVAL The cargo box is attached to the rear frame struc ture with holddown bolts Fig 6 The box can be re moved for repair or service access Refer to the associated component procedures when necessary 1 Disconnect the battery cables from the termi nals 2 Disconnect the rear lamp wire harness connec tors 3 Support the exhaust pipe Disconnect the sup port hanger from the carg...

Page 820: ...es lines hoses fuel rail fuel injectors and fuel pressure regulator A Fuel Return System is used on all vehicles all engines except the 5 9L V 8 gas powered engine On this engine a returnless type fuel system is used The fuel return system consists of fuel tubes lines and hoses that route fuel back to the fuel tank The Fuel Tank Assembly consists of the fuel tank filler tube fuel gauge sending uni...

Page 821: ...oline blended with MTBE or ETBE may be used in your vehicle CLEAN AIR GASOLINE Many gasolines are now being blended that con tribute to cleaner air especially in those areas of the country where air pollution levels are high These new blends provide a cleaner burning fuel and some are referred to as Reformulated Gasoline In areas of the country where carbon monoxide lev els are high gasolines are ...

Page 822: ...be used with any 5 9L gas powered engine FUEL PUMP M0DULE 3 9L 5 2L ENGINES The fuel pump module on vehicles equipped with 3 9L 5 2L engines is installed in the top of the fuel tank Fig 1 The fuel pump module contains the fol lowing components Fig 2 Fuel pump Fuel pump reservoir A separate in tank fuel filter Pressure relief rollover valve PRESSURE RELIEF PUMP GAUGE Fig 1 Top View of Fuel Pump Mod...

Page 823: ...P MODULE THE FUEL SYSTEM P R E S S U R E MUST B E R E LEASED CAUTION Whenever the fuel pump module is ser viced the locknut and gasket must be replaced 1 Drain the fuel tank Refer to Draining Fuel Tank in the Fuel Tank section of this group 2 Remove fuel tank Refer to the Fuel Tank sec tion of this group 3 The fuel pump module locknut is threaded onto the fuel tank Remove the fuel pump module lock...

Page 824: ...he fuel tank filler tube cap to release fuel tank pressure 3 Remove protective cap from pressure test port on the fuel rail Figs 6 7 or 8 WARNING DO NOT ALLOW FUEL TO SPILL ONTO THE ENGINE INTAKE OR EXHAUST MANIFOLDS PLACE SHOP TOWELS UNDER AND AROUND THE PRESSURE PORT TO ABSORB FUEL WHEN THE PRESSURE IS RELEASED FROM THE FUEL RAIL WARNING WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRES...

Page 825: ...nspect pressure regulator vacuum line for leaks kinks or blockage If vacuum line checks OK and fuel pressure does not rise approxi mately 8 10 psi after disconnecting vacuum line re place fuel pressure regulator The fuel pressure regulator is not adjustable 4 If fuel pressure exceeds 45 psi check fuel re turn line for kinks or obstructions If the previous tests checked good fuel pump pres sure is ...

Page 826: ...system obtain the DRB II scan tool Refer to the ap propriate Powertrain Diagnostic Procedures service manual for DRB II operation MOMENTARILY pinch the rubber hose portion of adapter tool 6631 Pressure should rise to approxi mately 75 psi within two 2 seconds DO NOT pinch hose for longer than five seconds If fuel pump pressure now rises to approximately 75 psi within two seconds but this pressure ...

Page 827: ...pressurize the system obtain the DRB II scan tool Refer to the ap propriate Powertrain Diagnostic Procedures service manual for DRB II operation 5 3 9L 5 2L Engines A good fuel pump will de liver approximately 1 liter of fuel per minute 5 9L Engines A good fuel pump will deliver approxi mately 2 liters of fuel per minute FUEL PRESSURE LEAK DOWN TEST 3 JL 5 2L ENGINE ENGINE OFF Abnormally long peri...

Page 828: ... for 30 minutes If pressure has dropped more than 138 kPa 20 psi in 30 minutes pressure is bleeding past the in tank mounted fuel pump outlet check valve Replace Fuel Pump Module assembly Refer to Fuel Pump Module removal and installation in this group If pressure drop is within specifications proceed to next step 13 Clamp off the rubber hose portion of adapter tool number 6631 connected to the fu...

Page 829: ...9L 5 2L GAS ENGINE For diesel engines refer to Fuel Water Separator Filter in the Diesel Fuel Injection Service Proce dures section of this group REMOVAL WARNING THE FUEL SYSTEM IS UNDER A CON STANT P R E S S U R E EVEN WITH THE ENGINE OFF BEFORE SERVICING THE FUEL FILTER THE FUEL SYSTEM P R E S S U R E MUST BE RELEASED The fuel filter is located under the vehicle and near the fuel tank It is moun...

Page 830: ...ng Be sure that the plastic fuel tubes are properly routed to prevent pinching and to avoid heat sources CAUTION The tubes hoses used on fuel injected vehicles are of a special construction This is due to the higher fuel pressures and the possibility of contaminated fuel in this system If it is necessary to replace these tubes hoses only tubes hoses marked EFM EFI may be used CAUTION The hose clam...

Page 831: ...until the hooks on the re tainer legs clear the stop on the fuel tube fitting Fig 25 PULL Fig 24 Separating Retainer Legs Fig 25 Manually Disconnecting Fitting 6 Pull the fuel tube out of quick connect fitting Fig 26 7 Inspect the quick connect fitting body and re tainer for damage Replace as necessary FUEL QUICK CONNECT TUBE FITTING STOP J9114 171 Fig 26 Fuel Tube and Fitting 8 Prior to connectin...

Page 832: ...l tab until the hooks on the re tainer legs clear the stop on the fuel tube fitting Fig 29 7 Pull fuel tube out of quick connect fitting 8 Inspect fitting body and retainer for damage Replace as necessary W A R N I N G R E L E A S E FUEL S Y S T E M P R E S S U R E B E F O R E DISCONNECTING A QUICK CONNECT FIT TING R E F E R T O T H E FUEL P R E S S U R E R E L E A S E P R O C E D U R E This type ...

Page 833: ...14 14 FUEL SYSTEM FUEL TUBE REMOVAL QUICK CONNECT FITTING PUSH INSTALLATION PUSH PLASTIC RETAINER J93U 100 Fig 30 Plastic Ring Type Fitting PUSH ...

Page 834: ...s the diaphragm from relaxing The lever will continue to move up and down on the shaft connecting it to the diaphragm However the lever is prevented from op erating the diaphragm until the check valve again opens to expel fuel from the pump chamber This pro cess continues as long as the engine is running Minimum lift pump output pressure is 21 Kpa 3 psi Lift pump output volume is 0 75 liters 0 70 ...

Page 835: ...SENDING UNIT 1 Remove sending unit mounting screws Fig 5 2 Mark the sending unit electrical wires for cor FUEL GAUGE TABS IN TANK FUEL FILTER J9114 146 Fig 5 Fuel Gauge Sending Unit and In Tank Filter Service rect installation when the new unit is installed Carefully disconnect electrical wires from sending unit Remove sending unit 3 Reverse order of removal for installation IN TANK FUEL FILTER CA...

Page 836: ...h a straight blade screwdriver PULL TAB RETAINER TAB RETAINER TAB BENT IN ORIGINAL UPRIGHT DOWN FOR POSITION REMOVAL J9114 168 Fig 8 Retainer Tabs MANUAL DISASSEMBLY CAUTION If retainer tab on removable pull tab is not bent down before disconnecting quick connect fitting connector could be damaged 1 Bend the retainer tab downward Fig 9 PULL Fig 9 Separating Retainer Legs 2 While pushing upward on ...

Page 837: ... pull tab is not bent down before disconnecting the quick connect fitting the connector could be dam aged 1 Bend the retainer tab downward Fig 8 2 Insert screwdriver tip between connector body and retainer pull tab Fig 12 3 Turn screwdriver 90 degrees to lift retainer up Fig 13 4 Raise pull tab until hooks on the retainer legs clear the stop on the fuel tube fitting Fig 14 5 Pull fuel tube out of ...

Page 838: ...uel Tubes At the end of the fuel tube fitting is a raised shoul der When the fuel tube is installed into the quick connect fitting the shoulder is locked in place by tangs inside the fitting Fig 16 After the tube is in stalled into the fitting Verify that connection is se cure by firmly pulling back on fuel tube Fig 17 The tube should be locked in place To disconnect the fitting from the fuel tube...

Page 839: ... fuel injected vehicles have a special rolled edge construction This prevents the edge of the clamp from cutting into the hose Only these rolled edge type clamps may be used on this system Other clamps may cut into the hoses This could cause high pressure fuel leaks NO LEAD FUEL TANK FILLER TUBE All catalyst equipped vehicles have a special fuel tank filler tube The fuel filler opening is smaller ...

Page 840: ...ller neck Drain fuel tank through filler hose REMOVAL MID FRAME MOUNTED TANKS 1 Drain fuel tank Refer to Draining Fuel Tank in this group 2 Disconnect negative battery cable at battery 3 Remove fuel tank filler tube cap 4 Pump all fuel from fuel tank into an approved portable holding tank If this equipment is not avail able disconnect fuel tube line and drain tank dry into a properly identified Ga...

Page 841: ... fuel tubes to be disconnected from fuel pump module The fuel pump module is located at top of fuel tank Disconnect fuel tubes from fuel pump module on top of tank Fig 7 Refer to Quick Connect Fittings in the Fuel Delivery sections of this group Mid Frame Mounted Fuel Tanks Typical 8 Remove fuel tank filler tube hose and fill vent hose from tank Figs 7 and 8 9 Lower the fuel tank INSTALLATION 1 Po...

Page 842: ...CTOR FUEL SUPPLY TUBE FUEL RETURN TUBE J9114 232 J9014 183 NUT 2 ASSEMBLY 200 INCH POUNDS Fig 5 Fuel Pump Module Connections Typical FUEL RESERVOIR The fuel reservoir Fig 9 is part of the lower end of the fuel pump module The purpose of the reser voir is to provide fuel at the pump intake during all driving conditions This is especially those times TIGHTEN NUT TO END OF THREAD ON STUD VIEW A STRAP...

Page 843: ...All vehicles pass a full 360 de gree rollover without fuel leakage The pressure relief rollover valve Fig 5 is mounted at top of fuel pump module REMOVAL 1 Remove fuel tank Refer to Fuel Tanks section in this group 2 Wedge the blade of a straight screwdriver be tween rubber grommet and fuel tank where support rib is located Do not wedge between valve and grommet or damage to valve may result upon ...

Page 844: ...hicle INSTALLATION 1 Position pedal bracket assembly over the two dash panel mounting studs and install retaining nuts 2 Tighten nuts to 7 N m 65 in lbs torque 3 From inside the vehicle hold up the accelerator pedal Install the throttle cable core wire and plastic cable retainer into the upper end of the pedal arm page Throttle Cable Except Diesel 25 Throttle Linkage Adjustment Diesel Engine 26 PI...

Page 845: ...tle body linkage ball snaps on Connect cable to throttle body bracket push down and lock Connect cable to fan shroud clip J 9 3 1 4 1 0 5 Fig 5 Cable Release Tab Except Diesel Typical 2 Install the remaining cable housing end into the dash panel opening snaps into position 3 Install the ball end of the cable wire through the hole in the pedal arm Install the plastic cable re tainer The plastic ret...

Page 846: ...R SPRING J9114 209 Fig 9 Incorrect Breakover Spring Position Diesel THROTTLE ACTUATION ROD L INDICATING LEFT HAND THREAD NUT J9114 210 Fig 10 Throttle Actuation Rod Diesel 8 The throttle actuation rod can be rotated to in crease or decrease adjustment Fig 10 9 Adjust the throttle actuation rod until The throttle lever contacts idle stop screw The spring loaded breakover lever has moved off the sto...

Page 847: ...cking For Breakover Diesel LOW IDLE STOP SPEED DIESEL Transmission Minimum RPM Automatic 700 RPM Manual 750 RPM J9114 212 FULL THROTTLE STOP SPEED DIESEL Minimum RPM M a x i m u m RPM 2825 RPM 2925 RPM J9114 213 ...

Page 848: ...the brake light switch air conditioning select switch and the speed control switches All inputs to the PCM are converted into signals Electrically operated fuel injectors spray fuel in precise metered amounts into the intake port directly above the intake valve The injectors are fired in a specific sequence by the PCM The PCM maintains page Ignition C o i l P C M Output 37 Malfunction Indicator La...

Page 849: ...powertrain control module PCM tests many of its own input and output circuits If a diagnostic trouble code DTC is found in a major system this information is stored in the PCM memory Refer to On Board Diagnostics in the Multi Port Fuel Injec tion General Diagnosis Except Diesel section of this group for DTC information POWERTRAIN CONTROL MODULE PCM The Powertrain Control Module PCM Fig 2 op erates...

Page 850: ...Tachometer on instrument panel if equipped The powertrain control module PCM contains a voltage convertor This converts battery voltage to a regulated 8 0 volts It is used to power the crankshaft position sensor and camshaft position sensor The PCM also provides a five 5 volt supply for the man ifold absolute pressure MAP sensor and throttle po sition sensor TPS AIR CONDITIONING A C CONTROLS PCM I...

Page 851: ... Camshaft Position Sensor in Group 8D Ig nition System for more information Fig 3 Camshaft Position Sensor CHARGE AIR TEMPERATURE SENSOR PCM INPUT The intake manifold charge air temperature sensor is installed in the intake manifold with the sensor el ement extending into the air stream Fig 4 The sensor provides an input voltage to the powertrain control module PCM indicating intake manifold air t...

Page 852: ...ifferent input voltage to the PCM The input volt age level supplies the PCM with information about ambient barometric pressure during engine start up cranking and engine load while the engine is run ning The PCM uses this input along with inputs from other sensors to adjust air fuel mixture The MAP sensor is mounted on the side of the en gine throttle body Fig 7 The sensor is connected to the thro...

Page 853: ...not shift into overdrive or downshift if already in overdrive Refer to Group 21 for more information PARK NEUTRAL SWITCH PCM INPUT The park neutral switch is located on the transmis sion housing and provides an input to the powertrain control module PCM This will indicate that the au tomatic transmission is in Park Neutral or a drive gear selection This input is used to determine idle speed varyin...

Page 854: ...f the transmission 2WD or on the transfer case extension housing 4WD The sensor input is used by the powertrain control module PCM to determine vehicle speed and distance trav eled The speed sensor generates 8 pulses per sensor rev olution These signals in conjunction with a closed throttle signal from the throttle position sensor indi cate a closed throttle deceleration to the PCM When the vehicl...

Page 855: ...he throttle body throttle plate Never attempt to adjust the engine idle speed using this screw All idle speed functions are controlled by the PCM RUBBER FITTING J9314 87 Fig 14 Throttle Body Air Control Passage AUTO SHUT DOWN ASD RELAY PCM OUTPUT The ASD relay is located in the engine compart ment Fig 12 The ASD supplies battery voltage to the fuel pump fuel injector ignition coil generator field ...

Page 856: ...UT The malfunction indicator lamp formerly referred to as the check engine lamp illuminates at the bot tom of the instrument panel each time the ignition key is turned on It will stay on for three seconds as a bulb test If the powertrain control module PCM receives an incorrect signal or no signal from certain sensors or emission related systems the lamp is turned on This is a warning that the PCM...

Page 857: ...control module PCM receives input signals and responds only according to preset PCM programming Input from the oxygen 02 sensor s is not monitored dur ing Open Loop modes During Closed Loop modes the PCM will monitor the oxygen 02 sensor input This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air fuel ratio This ratio is 14 7 parts air to 1 par...

Page 858: ... IAC motor and adjusts ignition tim ing The PCM operates the A C compressor clutch through the clutch relay This is done if A C has been selected by the vehicle operator and requested by the A C thermostat If the vehicle has a manual transmission the up shift light is operated by the PCM When engine has reached operating temperature the PCM will begin monitoring 0 2 sensor s input The system will ...

Page 859: ...s done until the vehicle is no longer under de celeration if the A C system is operating WIDE OPEN THROTTLE MODE This is an Open Loop mode During wide open throttle operation the powertrain control module PCM receives the following inputs Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold charge air temperature sensor Manifold absolute pressure MAP sensor ...

Page 860: ...l rail J9214 32 Fig 20 Fuel Rail Typical Regulator Operation The fuel pressure regulator is a mechanical device that is not controlled by the powertrain control module PCM The fuel pressure regulator used is a vacuum bal anced nonadjustable type The regulator is mounted on the output end of the fuel rail and is connected to intake manifold vacuum Figs 21 or 22 The fuel re turn tube to the fuel tan...

Page 861: ... This is done on the spring side of the dia phragm and results in lower system fuel pressure 5 9L ENGINE On vehicles equipped with a 5 9L engine the fuel filter and fuel pressure regulator are one combined part Fig 23 The fuel filter fuel pressure regulator is located on the top of the fuel pump module Fig 24 It is pressed into a rubber grommet on module Fig 23 Regulator Operation The fuel pressur...

Page 862: ...save unnecessary test and diagnostic time A thorough visual inspection will in clude the following checks 1 Verify that the 60 way connector is fully in serted into the connector of the powertrain control module PCM Fig 1 Verify that the connector mounting screw is tightened to 4 N m 35 in lbs torque PCM MOUNTING BOLTS PCM CONNECTOR CONNECTOR MOUNTING BOLT J9314 165 Fig 1 Powertrain Control Module...

Page 863: ...or output wire generator connector and ground wire are firmly connected to the generator 7 Inspect the system body grounds for loose or dirty connections Refer to Group 8 Wiring for ground locations 8 Verify positive crankcase ventilation PCV valve operation Refer to Group 25 Emission Control System for additional information Verify PCV valve hose is firmly connected to PCV valve and manifold Fig ...

Page 864: ...e 17 Verify that MAP sensor electrical connector is firmly connected to MAP sensor Fig 11 Also verify that rubber L shaped fitting from MAP sensor to the throttle body is firmly connected Fig 12 18 Verify that fuel injector wire harness connec tors are firmly connected to injectors in the correct Fig 10 Air Temperature Sensor 5 2U5 9L V 8 Engines MANIFOLD ABSOLUTE Fig 11 MAP Sensor Typical order E...

Page 865: ...l harness is firmly connected to park neutral switch Refer to Automatic Transmis sion section of Group 21 26 Verify that the harness connector is firmly connected to the vehicle speed sensor Fig 16 Fig 16 Vehicle Speed Sensor Typical 27 Verify that fuel pump gauge sender unit wire connector is firmly connected to harness connector 28 Inspect fuel hoses at fuel pump gauge sender unit for cracks or ...

Page 866: ...AY CONNECTOR Terminal identification and specific circuit applica tions are shown in the PCM connector chart Fig 17 Also refer to Group 8W Wiring Diagrams SYSTEM SCHEMATICS Fuel system schematics for fuel injected engines are shown in figures 18 19 and 20 ...

Page 867: ...ED CONTROL VENT SOLENOID 18 DB GY INJECTOR DRIVER 8 V 8 ONLY 54 OR BK SHIFT INDICATOR LIGHT MANUAL TRANSMISSION ONLY 19 BK GY IGNITION COIL DRIVER 54 OR BK CONVERTOR CLUTCH SOLENOID AUTO TRANSMISSION 20 DG GENERATOR FIELD CONTROL 55 OR WT OVERDRIVE SOLENOID AUTO TRANSMISSION ONLY 21 BK RD CHARGE TEMPERATURE SENSOR 56 GY PK SRI LAMP 5 9L HDC ENGINE 22 OR DB THROTTLE POSITION SENSOR TPS 57 DG OR ASD...

Page 868: ... THROTTLE POSITION SENSOR CO Fig 18 System Schematic 3 9L V 6 Engine CO ...

Page 869: ...C J 1 m r co C O J9314 120 Fig IS System Schematic 5 2U5 9L LDC V 8 Engine ...

Page 870: ... m J9314 172 Fig 20 System Schematic SSL HDC V 8 Engine ...

Page 871: ...ire harness connector terminal 2 and the sensor connec tor terminal Also test continuity of wire harness ter minal 4 to the sensor connector terminal Repair the wire harness if an open circuit is indicated 4 After tests are completed connect electrical connector to sensor The sensor connector is symmet rical not indexed It can be installed to the sensor in either direction SENSOR RESISTANCE OHMS C...

Page 872: ...n terminals A and B Fig 25 With the ignition switch ON and the en gine OFF output voltage should be 4 to 5 volts The voltage should drop to 1 5 to 2 1 volts with a hot neutral idle speed condition 3 Test powertrain control module PCM pin 1 for the same voltage described above to verify the wire harness condition Repair as necessary Fig 24 Rubber L Shaped Fitting MAP Sensor to Throttle Body A Groun...

Page 873: ...nal of the TPS is the output termi nal Fig 28 AAANIFOLD ABSOLUTE Fig 28 Throttle Position Sensor TPS Connector Typical With the ignition key in the ON position check the TPS output voltage at the center terminal wire of the connector Check this at idle throttle plate closed and at wide open throttle WOT At idle TPS output voltage should must be greater than 200 millivolts At wide open throttle TPS...

Page 874: ...ion while operating the en gine Always return the engine idle speed to normal be fore disconnecting the exerciser tool 1 With the ignition OFF disconnect the IAC mo tor wire connector at throttle body Fig 31 2 Plug the exerciser tool 7558 harness connector into the IAC motor Fig 32 MANIFOLD ABSOLUTE Fig 31 IAC Motor Typical Fig 32 IAC Motor Testing Typical 3 Connect the red clip of exerciser tool ...

Page 875: ...nos tics Procedures service manual RELAYS OPERATION TESTING OPERATION The following operations tests apply to these relays only Automatic Shut Down ASD and Fuel Pump For operations tests on all other relays refer to the appropriate section of this service manual These relays are located in the engine compart ment Fig 34 DATA LINK CONTROL CONNECTOR MODULE J9314 164 Fig 34 Relay Location The relay t...

Page 876: ...ce tests did not pass re place relay If tests passed refer to Group 8W Wir ing Diagrams for fuel system relay wiring schematics and for additional circuit information STARTER MOTOR RELAY TEST Refer to Group 8A Battery Starting Charging Sys tem Diagnostics for starter motor relay testing FUEL INJECTOR TEST Disconnect the fuel injector wire harness connector from the injector Fig 36 Place an ohmmete...

Page 877: ...ISUALLY PLUGGED AT INJECTOR FUEL INLET REPLACE FUEL RAIL IF VISUALLY PLUGGED OR RESTRICTED AT INJECTOR DELIVERY COUPLING N O REPLACE INJECTOR N O TEST THE INJECTOR RESISTANCE USING AN OHMMETER ACROSS THE INJECTOR TERMINALS WITH THE INJECTOR CONNECTOR REMOVED PLACE A 12 VOLT TEST LAMP ACROSS THE INJECTOR ELECTRICAL CONNECTOR TERMINALS OBSERVE THE TEST LAMP WHILE CRANKING THE ENGINE CIRCUIT IS OK CH...

Page 878: ...to Open Loop Closed Loop Modes Of Operation in the Component Description System Operation section for an explanation of Closed or Open Loop opera tion NON MONITORED CIRCUITS The PCM does not monitor the following circuits systems or conditions that could have malfunctions that result in driveability problems A diagnostic trouble code DTC may not be displayed for these conditions Fuel Pressure Fuel...

Page 879: ...LINK CONTROL CONNECTOR MODULE J9314 164 Fig 37 Data Link Connector Location Typical EXAMPLES If the lamp flashes 4 times pauses and flashes 1 more time a diagnostic trouble code DTC number 41 is indicated If the lamp flashes 4 times pauses and flashes 6 more times a diagnostic trouble code DTC number 46 is indicated Refer to the Diagnostic Trouble Code DTC charts for DTC identification If the prob...

Page 880: ...emains below normal operating temperatures during vehicle travel thermostat 21 O2 Signal Stays at Center or Oo Signal Shorted to Voltage Neither rich or lean condition is detected from the oxygen sensor input Oxygen sensor input voltage maintained above normal operating range 22 ECT Sensor Voltage Too Low or ECT Sensor Voltage Too High Coolant temperature sensor input below the minimum acceptable ...

Page 881: ...etected during diagnostic test California emissions packages only 33 A C Clutch Relay Circuit An open or shorted condition detected in the A C clutch relay circuit 34 Speed Control Solenoid Circuits An open or shorted condition detected in the speed control vacuum or vent solenoid circuits 37 Torque Converter Clutch Solenoid Circuit CKT An open or shorted condition detected in the torque converter...

Page 882: ...y at Rich Limit 0 2 sensor signal stays lean Additive adaptive memory at rich limit 5 2 0 2 Signal Stays Above Center Rich or Additive Adaptive Memory at Lean Limit 0 2 sensor signal stays rich Additive adaptive memory at lean limit 53 Internal PCM Failure Internal failure in the PCM Powertrain Control Module 54 Sync Pick up Signal No fuel sync signal detected during crankshaft rotation 55 NA Comp...

Page 883: ...procedures AUTOMATIC SHUT DOWN ASD RELAY The ASD relay is located in the engine compart ment Fig 1 page Fuel Rail 69 Fuel System Pressure Release Procedure 71 Fuel Tank Pressure Relief Rollover Valve 71 Fuel Tanks 71 Fuel Tubes Lines Hoses and Clamps 71 Idle Air Control IAC Motor 71 Ignition Coil 71 Intake Manifold 71 Manifold Absolute Pressure MAP Sensor 71 Oxygen 02 Sensor 72 Park Neutral Switch...

Page 884: ...sor 2 Tighten to 11 Nnn 8 ft lbs torque 3 Connect electrical connector to sensor The sensor connector is symmetrical not indexed It can be installed to the sensor in either direction 4 Replace any lost engine coolant Refer to Group 7 Cooling System E AP CANISTER PURGE SOLENOID Refer to Group 25 Emission Control System for re moval installation procedures FUEL FILTER 3 9L 5 21 ENGINE The fuel filte...

Page 885: ...clamp 4 Gently cut the old fuel tube line clamp Fig 8 taking care not to damage the plastic fuel tube Remove and discard the old fuel tube clamp Fig 7 Plastic Tube and Snap Ring Fig 8 Fuel Tube and Clamp 5 Remove the plastic fuel tube from the filter reg ulator by gently pulling downward Remove filter regulator from fuel pump module INSTALLATION 1 Install a new clamp over the plastic fuel tube 2 I...

Page 886: ...f engine oil to each fuel injector O ring This will help in fuel rail installa tion 2 Install injector s and injector clip s to fuel rail 3 Install fuel rail assembly Refer to Fuel Rail in stallation 4 Install air cleaner 5 Start engine and check for leaks FUEL PRESSURE REGULATOR WARNING T H E FUEL S Y S T E M IS UNDER A C O N STANT P R E S S U R E EVEN WITH T H E ENGINE TURNED OFF B E F O R E SER...

Page 887: ...se procedure 2 Remove the air cleaner 3 Remove the vacuum line from the pressure reg ulator 4 Remove the clamp bolt and regulator retaining clamp from fuel rail 5 Remove pressure regulator from fuel rail INSTALLATION 5 2L ENGINE 1 Install new O ring seals to pressure regulator 2 Install pressure regulator to fuel rail 3 Install retaining clamp and clamp bolt 4 Install vacuum line to pressure regul...

Page 888: ...ove throttle body from intake manifold Re fer to Throttle Body removal in this group 5 If equipped with air conditioning remove the A C compressor to intake manifold support bracket three bolts Fig 16 6 Disconnect electrical connectors at all fuel in jectors Fig 17 The factory fuel injection wiring harness is numerically tagged INJ 1 INJ 2 etc for injector position identification 7 If equipped wit...

Page 889: ... fuel rail down until fuel injectors have bottomed on injector shoulder INJECTOR J9214 24 Fig 21 Fuel Injector Clip Typical 6 Install fuel rail mounting bolts 7 Install EVAP canister purge solenoid to intake manifold 8 Connect electrical connector to intake manifold charge air temperature sensor 9 Connect wiring to all fuel injectors The injec tor wiring harness is numerically tagged 10 Install th...

Page 890: ...E Fig 22 idle Air Control Motor Typical REMOVAL 1 Remove air cleaner assembly 2 Disconnect electrical connector from IAC motor 3 Remove two mounting bolts screws Fig 23 J9214 23 Fig 23 Mounting Bolts Screws IAC Motor 4 Remove IAC motor from throttle body INSTALLATION 1 Install IAC motor to throttle body 2 Install and tighten two mounting bolts screws to 7 N m 60 in lbs torque 3 Install electrical ...

Page 891: ...t down pipe Fig 26 On 5 9L HDC engines the dual 0 2 sensors are located on each left and right exhaust down pipe Fig 27 Fig 27 Dual Oxygen Sensors 5 9L HDC Engine REMOVAL W A R N I N G T H E E X H A U S T MANIFOLD B E C O M E S VERY HOT DURING ENGINE OPERATION ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN S E N S O R 1 Raise and support the vehicle 2 Disconnect the wire connector from the 0 2 sen so...

Page 892: ...ring harness connec tor for bent pins or corrosion Repair as necessary 3 Install 60 way connector to PCM Tighten mounting screw to 4 Ne m 35 in lbs torque 4 Install battery cable to battery QUICK CONNECT FITTINGS Refer to the Fuel Delivery System section of this group for removal installation procedures THROTTLE BODY A factory adjusted set screw is used to mechani cally limit the position of the t...

Page 893: ...take tube at throttle body 2 Disconnect TPS electrical connector 3 Remove two TPS mounting screws Fig 32 4 Remove TPS from throttle body INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS Fig 33 The TPS must be installed so that it can be rotated a few degrees If the sensor will not rotate install the sensor with the throttle shaft on the other side of the soc...

Page 894: ...n Typical 1 Raise and support vehicle 2 Disconnect the electrical connector from the sensor 3 Remove unscrew the speedometer cable if equipped from the sensor Fig 35 4 Loosen the sensor mounting nut Fig 35 Fig 35 Sensor and Components Typical 5 Remove the sensor INSTALLATION 1 Install new sensor into speedometer adapter 2 Tighten sensor mounting nut 3 Connect electrical connector to sensor 4 Conne...

Page 895: ...ry Refer to On Board Diagnostics in the Diesel Fuel Injection General Diagnosis section of page Mechanical Lift Pump 86 Overdrive Indicator Lamp PCM Output 82 Overdrive Solenoid PCM Output 82 Overdrive Override Switch PCM Input 79 Park Neutral Switch PCM Input 79 Power G r o u n d P C M Input 79 Powertrain Control Module PCM 76 SCI Receive PCM Input 80 SCI Transmit PCM Output 82 Sensor Return PCM ...

Page 896: ... ground Speed control switch Throttle position sensor Auto trans only Transmission thermo switch Auto trans only Vehicle speed sensor Water in fuel sensor Based on these inputs the PCM regulates various engine and vehicle operations through different sys tem components These are called PCM outputs PCM outputs are to the A C compressor clutch relay Air intake heater relays Generator field control A...

Page 897: ...ous key on BRAKE SWITCH PCM INPUT If the PCM receives a brake switch input while the speed control system is on it will disable speed con trol CHARGE AIR TEMPERATURE SENSOR PCM INPUT The charge air temperature sensor is located on top of the intake manifold Fig 4 It provides an input to the PCM that indicates air temperature in the manifold Based on the charge air temperature input the PCM determi...

Page 898: ...When the thermo switch opens the trans mission will not shift into overdrive The transmis sion downshifts if it is in overdrive when the thermo switch opens Once the thermo switch opens it will not close until transmission fluid temperature drops to 116 C 240 F The switch is located in the trans mission to radiator cooling line Fig 7 PARK NEUTRAL SWITCH PCM INPUT The park neutral switch Fig 8 is l...

Page 899: ...o the sensor TPS output to the PCM varies from approximately 1 0 volt at idle to 3 5 volts at wide open throttle WOT T J9114 237 Fig 9 Throttle Position Sensor VEHICLE SPEED SENSOR PCM INPUT The vehicle speed sensor Fig 10 is located in the extension housing of the transmission 2WD or on the transfer case extension housing 4WD A signal is sent from this sensor along with signals from both the TPS ...

Page 900: ...hen they are energized they make a clicking noise CAUTION Do not energize the air intake heater re lays more than once per 15 minutes If the relays are cycled and the key is turned off and then turned back on the engine could be damaged Wait 15 minutes before turning the key back to the ON po sition AIR INTAKE HEATER When energized the air intake heaters warm in coming air as it enters the intake ...

Page 901: ...and any codes stored in the PCM memory will be displayed This is done in a series of flashes representing digits Refer to On Board Diagnostics in the General Diagnosis section of this group for more information OVERDRIVE INDICATOR LAMP PCM OUTPUT Indicates the state of the overdrive defeat switch on the instrument panel OVERDRIVE S0LEN0ID PCM OUTPUT The overdrive solenoid is used on vehicles that ...

Page 902: ...53 F FUEL INJECTION PUiVSP The injection pump is a Bosch VE Distributor type Fig 17 The injection pump is driven by the engine camshaft A gear on the end of the pump shaft meshes with the camshaft gear The pump is timed to the engine Fuel injection occurs near the end of the compression stroke for each cylinder Refer to In jection Pump Removal and Installation in the Diesel Service Procedures sect...

Page 903: ...losed by the needle valve spring and fuel flow into the combustion chamber is stopped Exhaust gases are prevented from entering the injector nozzle by the needle valve HIGH PRESSURE FUEL FROM INJECTION PUMP J91 14 82 Fig 20 Fuel Injector Operation FUEL SOLENOID The fuel solenoid Fig 21 is mounted on the injec tor pump When energized the solenoid allows fuel to reach the high pressure chamber of th...

Page 904: ...d internal pump pressure reaches 8 bars 116 psi When the so lenoid is not energized internal pump pressure should be approximately 4 bars 58 psi The KSB solenoid circuit contains an air tempera ture switch Battery voltage is supplied to the sole noid through the ignition switch The air temperature switch is mounted on the in take manifold next to the charge air temperature sensor Fig 23 The air te...

Page 905: ... be replaced as a complete assembly CAUTION D o not operate the engine if the fuel sup ply line has a restriction of more than 95 M M Hg 3 75 in Hg The lift pump has a manual lever Fig 26 The le ver is located on the lower right side of the pump housing The purpose of the lever is to prime the fuel system and bleed air from the system if the vehicle has run out of fuel Raise and lower the lever un...

Page 906: ...tch opens The switch opens when intake manifold air temperature is above 32 C 90 F If the transmission thermo switch is open the transmission will not be allowed to enter into over drive automatic transmission If the switch opens when the vehicle is in overdrive the transmission will be downshifted The transmission thermo switch opens at 134 C 273 F The thermo switch will close once the transmissi...

Page 907: ... visual inspection of the fuel injec tion system includes the following checks 1 Be sure that the battery connections are tight and not corroded Fig 1 POSITIVE v 3t TERMINAL J91 14 QUICK DISCONNECT PCM MOUNTING BOLTS PCM CONNECTOR CONNECTOR MOUNTING BOLT J9314 165 Fig 2 Powertrain Control Module PCM HEATER RELAYS Fig 1 Battery Connections 2 Be sure that the 60 way connector is fully en gaged with ...

Page 908: ...ain Dispose of mixture in drain pan according to applicable regulations 9 Verify that the electrical connector is connected to the fuel solenoid on the injection pump Fig 7 In spect the connector for corrosion or damage 10 Verify that the electrical connector is con nected to the KSB solenoid on the injection pump Fig 7 Inspect the connector for corrosion or dam age Fig 8 Air Intake Heater 12 Insp...

Page 909: ...efective seals Air can also enter the fuel system between the fuel tank and the lift pump Inspect the fuel tank and fuel lines for damage that might allow air into the system AIR INTAKE HEATER PREHEAT POST HEAT CYCLE The PCM provides a ground path for the air intake heater relays The ground path is provided if intake manifold temperature is below 16 C 60 F when the ignition key is in the ON positi...

Page 910: ...gine Fig 12 To perform a complete test of the engine speed sen sor and its circuitry refer to the DRB II scan tool Also refer to the appropriate Powertrain Diagnostics Procedures manual FUEL HEATER A malfunctioning fuel heater can cause a wax build up in the fuel water separator Fig 13 Wax build up in the fuel water separator can cause engine starting problems and prevent the engine from rev ving ...

Page 911: ...S HIGH P R E S S U R E FUEL OF APPROXIMATELY 59 000 KPA 8 000 PSI TO E A C H INDIVIDUAL INJECTOR THROUGH THE HIGH P R E S S U R E LINES FUEL UN DER THIS AMOUNT O F P R E S S U R E C A N P E N E TRATE THE S K I N A N D C A U S E P E R S O N A L INJURY W E A R S A F E T Y G O G G L E S A N D A D E Q U A T E P R O TECTIVE CLOTHING AVOID CONTACT WITH FUEL S P R A Y W H E N BLEEDING HIGH P R E S S U R ...

Page 912: ...SOLENOID The KSB solenoid will click when it is energized and de energized If the solenoid does not click when 12 volts is sup plied to it replace the solenoid MECHANICAL LIFT PUMP An improperly operating lift pump can cause low engine power Inspect the fuel supply line to the pump for restrictions kinks or leaks Fuel leaking from the weep hole Fig 15 in the pump casing in dicates a leaking pump d...

Page 913: ...ble code DTC to be entered into PCM memory The criteria may be a specific range of engine rpm en gine temperature and or input voltage to the PCM It is possible that a DTC for a monitored circuit may not be entered into memory even though a mal function has occurred This may happen because one of the DTC criteria for the circuit has not been met ACCESSING DIAGNOSTIC TROUBLE CODES A stored diagnost...

Page 914: ...ng pages a list of diagnostic trouble codes is provided for the diesel engine A DTC indi cates that the powertrain control module PCM has recognized an abnormal signal in a circuit or the sys tem A DTC may indicate the result of a failure but never identify the failed component directly SYSTEM SCHEMATICS 5 9L DIESEL ENGINE Refer to the following system schematic for the 5 9L diesel engine ...

Page 915: ...Engine Speed Sensor No speed sensor signal detected during road load conditions Coolant temperature sensor input below the minimum acceptable voltage Coolant temperature sensor input above the maximum acceptable voltage Charge Air Temperature Sensor input above below acceptable minimum Throttle position sensor TPS input above the maximum acceptable voltage Throttle position sensor TPS input below ...

Page 916: ...harging System Voltage Too Low 53 Internal PCM Failure 62 PCM Failure SRI Miles Not Stored 63 PCM Failure EEprom Write Denied An open or shorted condition detected in overdrive solenoid circuit Charging system voltage too high Charging system voltage too low Internal failure in the PCM PCM failure SRI miles not stored PCM failure EEprom write denied Automatic Transmission Only J9314 183 ...

Page 917: ...OVERDRIVE OVER RIDE SWITCH AUTO ONLY CO oo c 3 L S T A R J E R J _ j J9314 184 5 9 1 DIESEL SYSTEM SCHEMATIC ...

Page 918: ...D CHARGE INTAKE AIR TEMPERATURE SENSOR 57 DG OR ASD SENSE 22 OR DB THROTTLE POSITION SENSOR 58 23 59 24 GY BK REFERENCE PICKUP 60 25 PK DATA LINK TRANSMIT WIRE COLOR CODES LB LIGHT BLUE VT VIOLET 26 BK BLACK LG LIGHT GREEN WT WHITE 27 BR A C CLUTCH REQUEST BR BROWN OR ORANGE YL YELLOW 28 LG RD THERMO SWITCH DB DARK BLUE PK PINK WITH TRACER 29 WT PK BRAKE SWITCH DG DARK GREEN RD RED 30 BR YL PARK N...

Page 919: ...tighten connections as necessary Bleed fuel system Wax buildup in fuel filter cold weather only Replace fuel filter use recommended diesel fuel Incorrect injection pump to engine timing Adjust injection pump timing Malfunctioning air heating system Repair air heating system Injection sequence does not correspond with firing order Install fuel injection lines in correct order Malfunctioning KSB val...

Page 920: ...ring order Install injection lines in correct order Low or uneven engine compression Repair as necessary Fuel injection pump malfunctioning or not adjustable Replace fuel injection pump Engine mines under lead Improper fuel Drain fuel tank flush system fill with proper fuel Empty fuel tank or fuel tank vent blocked Fill tank bleed system check tank vent Air in fuel system Bleed fuel system Clogged...

Page 921: ...flow fitting switched with inlet fitting Install fittings in proper positions Leaking injection lines damaged lines or loose connections Replace damaged lines or tighten connections as necessary Bleed fuel system Incorrect injection pump to engine timing Adjust injection pump timing Restricted or damaged injector nozzle Repair or replace as necessary Clogged or restricted air filter Remove restric...

Page 922: ... fuel injection pump Unabie to shut engine off Voltage to fuel solenoid interrupted or fuel solenoid inoperative Correct voltage supply problem or replace solenoid Either poor performance black m o k e or low power Improper fuel Drain fuel tank flush system fill with proper fuel for conditions Refer to owner s manual Air in fuel system Bleed fuel system Intercooler internally blocked or leaking Ch...

Page 923: ...striction or replace lines Restricted or blocked fuel supply lines Remove restriction or replace lines Wax buildup in fuel filter cold weather only Replace fuel filter use recommended i diesel fuel Inspect fuel heater electrical connector for damage Incorrect injection pump to engine timing Adjust injection pump timing Injection pump overflow fitting switched with inlet fitting Install fittings in...

Page 924: ...el filter Restricted or blocked fuel supply lines Remove restrictions or replace lines Wax buildup in fuel filter cold weather only Inspect fuel heater electrical connector for damage Replace fuel filter use recommended diesel fuel Incorrect injection pump timing Adjust injection pump timing Injection pump overflow fitting switched with inlet fitting Install fittings in proper sequence Low or unev...

Page 925: ... manual lever feels as if it is not pumping ro tate crank the engine approximately 90 degrees Continue pumping until air is removed 3 Tighten low pressure bleed screw to 8 N m 6 ft lbs torque CAUTION The manual lever must be returned to the lock position up after priming INJECTION PUMP W A R N I N G T H E ENGINE M A Y S T A R T W H E N C R A N K I N G T O B L E E D A I R F R O M T H E INJECTION pa...

Page 926: ...g 3 Fig 3 Air Fuel Control Tube Removal Installation 2 Disconnect tube from intake manifold 3 Remove tube Discard seals INSTALLATION 1 Connect tube to intake manifold Tighten fit ting to 8 Nnn 6 ft lbs torque 2 Connect tube to injection pump using new seals Tighten fitting screw to 12 Nnn 9 ft lbs torque AIR INTAKE HEATER 1 Disconnect negative cable from battery 2 Disconnect the throttle rod from ...

Page 927: ...MOUNTING BOLT J9314 165 Fig 8 PCM Mounting 5 Remove the three PCM to mounting bracket bolts Fig 8 Do not remove the PCM mounting bracket from the fender 6 Remove PCM from vehicle INSTALLATION 1 Check pins in 60 way PCM connector for dam age Repair as necessary 2 Position PCM and install mounting bolts Tighten bolts to 4 N m 35 in lbs torque 3 Connect 60 way electrical connector to the PCM Tighten ...

Page 928: ...lts 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 notches Fig 9 on the vibra tion damper If sensor is adjusted at or near these notches it will be damaged when engine is started 6 Tighten sensor mounting nuts to 24 N m 18 ft lbs torque 7 Remove feeler gauge 8...

Page 929: ...EMOVAL 1 Disconnect negative cable from battery 2 Disconnect throttle linkage 3 Remove throttle bracket Fig 15 Fig 15 Throttle Bracket 4 Remove injection pump supply line Refer to Fuel Injection Pump Supply Line 5 Remove high pressure fuel lines Refer to High Pressure Lines 6 Disconnect electrical connector from fuel sole noid 7 Disconnect electrical connector from KSB Sole noid INSTALLATION 1 Usi...

Page 930: ...nd Bracket 13 Place a shop towel below the retainer nut in the gear housing cover opening to prevent the nut or washer from falling into the gear housing Remove the gear retaining nut and washer The engine can be rotated with a barring tool such as Snap On No SP371 MTE No 3377462 Cummins Tool Division or an equivalent 14 Insert the barring tool into the flywheel hous ing opening The opening is loc...

Page 931: ...w the injection pump mounting nut Remove washer from injection pump Fig 23 Attach washer to injection pump with wire tag for use dur ing installation 19 Tighten lockscrew J9114 58 Fig 22 Injection Pump Timing Marks Fig 23 Injection Pump Shaft LockScrew and Washer 20 Use a T bar puller to separate the gear from the pump shaft Use M8 X 1 24 MM metric screws to attach T bar to shaft Pull the injectio...

Page 932: ...iginal injection pump rotate pump to align timing marks If installing a new or rebuilt pump without a timing mark take up gear lash by rotating pump counterclockwise towards cyl inder head 9 Tighten injection pump mounting nuts to 24 Nnn 18 ft lbs torque If installing a new or rebuilt pump permanently mark the injection pump flange in line with the mark on the gear housing Fig 25 FUEL SYSTEM 14 11...

Page 933: ...erator Pedal and Throttle Cable section of Group 14 Fuel Systems FUEL INJECTION PUMP SUPPLY LINE REMOVAL 1 Disconnect negative cable from battery 2 Disconnect supply line at fuel water separator filter Fig 27 Fig 27 Supply Line to Separator Filter Connection 3 Do not allow the injection pump inlet fit ting to move when loosening supply line Use two wrenches when removing line Disconnect supply lin...

Page 934: ... in this section 8 Install throttle linkage 9 Connect negative cable to battery Fig 32 Injector Installation 10 Bleed air from the high pressure lines Refer to High Pressure Lines in the Air Bleeding section FUEL WATER SEPARATOR FILTER REMOVAL 1 Disconnect electrical connector from water in fuel WIF sensor at the bottom of the separator filter Fig 33 Fig 33 Fuel Water Separator Filter CAUTION When...

Page 935: ...ion CAUTION The high pressure fuel lines must be clamped securely in place in the holders The lines cannot contact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged Only use the recom mended lines when replacement of high pressure fuel line is necessary REMOVAL 1 Disconnect negative cable from battery 2 Remove throttle linkage 3 Remo...

Page 936: ...e barring tool while lightly pushing in on the timing pin Stop when the timing pin engages the in dex hole in the camshaft gear 2 Once TDC has been located pull the timing pin out of the camshaft gear to the normal run position 3 Remove plug and copper washer from the rear of the injection pump Fig 39 PLUG J9114 63 Fig 39 Timing Indicator Plug Dial gauges and dial gauge holders used to check injec...

Page 937: ...nes 1 3 Install plug tod washer into injection pump Tighten plug to 1 0 Nnn 7 ft lbs torque 1 4 If high pressure fuel lines were removed bleed air from the fuel system Refer to High Pres sure Fuel Lines in the Air Bleeding section INJECTION PVMP TO ENGINE TIMING 1 With the gear housing cover off be sure that the crankshaft gear and camshaft gear are correctly timed Correct as necessary Refer to Gr...

Page 938: ... Clean mating surfaces on lift pump and engine block FUEL SYSTEM 14 119 Fig 44 Lift Pump Removal Installation INSTALLATION 1 Install lift pump with new gasket Tighten mounting screws to 24 N m 18 ft lbs torque 2 Install low pressure fuel lines 3 Manually bleed the system of air Refer to Manual Bleeding in this section 4 Connect battery cable to battery THROTTLE POSITION SENSOR TPS The TPS is used ...

Page 939: ... Fig 48 Positioning Nylon Adapter 2 Position the TPS to nylon adapter Refer to the previous CAUTION 3 The TPS is spring loaded After positioning the TPS on the adapter be certain to rotate the TPS in a clockwise direction to allow installation of its two mounting screws 4 Install and tighten both TPS mounting screws If the TPS bracket mounting screws were removed tighten them to 7 N m 60 in lbs to...

Page 940: ...ld in wide open position check TPS output voltage It should be 2 25 to 2 75 volts higher than the output voltage is at closed throttle position If not gently rotate nylon adapter to obtain correct voltage Fig 51 Adjusting Throttle Position Sensor Fig 52 Correct Breakover Spring Position WATER IN FUEL SENSOR REMOVAL 1 Remove fuel water separator filter Refer to Fu el Water Separator Filter Removal ...

Page 941: ...ed personnel LOW IDLE SPEED Use an optical tachometer such as Snap on No MT139 or MTE Cummins tool division No 3377462 to read engine rpm 1 If necessary adjust low idle speed at the low idle speed screw Fig 54 If the vehicle has an auto matic transmission with the air conditioning on set low idle speed to 700 rpm If the vehicle has a man ual transmission with the air conditioning on set low idle s...

Page 942: ...ing tolerances and refill procedures FUEL SOLENOID 5 9L DIESEL J9014 182 Current Draw 2 Amps Minimum Voltage 10 Volts Operating Voltage 12 Volts Resistance 6 9 7 9 Ohms J9114 214 ENGINE SPEED 5 9L DIESEL Full Throttle Stop Speed No Load 2925 RPM Max Full Throttle Stop Speed No Load 2824 RPM Min Low Idle Stop Speed A C On Auto Trans 700 RPM Low Idle Stop Speed A C On Man Trans 750 RPM J9114 215 FUE...

Page 943: ... Filter Mounting Bolts 8 N m 75 in lbs Fuel Hose Tube Clamps 1 N m 10 in lbs IAC Motor To Throttle Body 7 N m 60 in lbs Intake Manifold Charge 60 in lbs Air Temperature Sensor 28 N m 20 ft lbs MAP Sensor Mounting Screws 3 N m 25 in lbs Oxygen Sensor 30 N m 22 ft lbs PCM 60 Way Connector Mounting Screw 4 N m 35 in lbs Throttle Body Mounting Bolts 23 N m 200 in lbs Throttle Position Sensor Mounting ...

Page 944: ...jection Pump Lockscrew Unlocked Position 13 Nm 10ft lbs Injection Pump Gear Retaining Nut 65 Nm 48 ft lbs Injection Pump Support Bracket 24 Nm 18 ft lbs Injection Pump Timing Plug 10Nm 7 5 ft lbs Injector Drain Screw 8 N m 6 ft lbs Injector Retainer Nut 60 Nm 44 ft lbs Low Pressure Bleed Screw on Filter Head 8 Nm 6 ft lbs Mechanical Lift Pump Mounting Screws 24 Nm 18ft lbs Throttle Linkage Rod Loc...

Page 945: ......

Page 946: ...e transmitting torque The axle rides sus pended by springs in a floating motion This means the propeller shaft must contract expand and change operating angles This is accomplished through uni versal joints The U joints permit the propeller shaft to operate at different angles The slip joints or yokes permit contraction or expansion Tubular propeller shafts are balanced by the man ufacturer with w...

Page 947: ... joint Fig 3 LUBRICATION The slip yoke on the front shaft is equipped with a zerk type lubrication fitting Use a multi purpose NLGI Grade 2 EP lubricant Refer to Group 0 Lubri cation and Maintenance for additional information The factory installed U joints are lubricated for the life of the vehicle and do not need re lubrication All RETAINER J9216 20 Fig 2 Single Cardan Universal Joint Typical U j...

Page 948: ...llowing procedure Removing and re indexing the propeller shaft 180 may eliminate some vibrations 1 Raise and support the vehicle 2 Clean all foreign material from propeller shaft and U joints 3 Inspect propeller shaft for missing balance weights broken welds and bent areas If the pro peller shaft is bent it must be replaced 4 Ensure the U joints are not worn and are prop erly installed 5 Check the...

Page 949: ...ews Separated 16 If the amount of vibration remains unaccept able apply procedures at the front end of propeller shaft RUNOUT 1 Remove dirt rust paint and undercoating from the propeller shaft surface Areas where the dial indicator will contact the shaft must be clean 2 The dial indicator must be installed perpendic ular to the shaft surface 3 Measure runout at the center and ends 4 Refer to Runou...

Page 950: ... when the vibration occurred Prop shaft angles will change according to the amount of load in the vehicle Always check an gles in loaded and unloaded conditions Check the condition of all suspension components and verify all fasteners are torqued to specifications Check the condition of the engine and transmis sion mounts and verify all fasteners are torqued to specifications MEASUREMENT To accura...

Page 951: ...G ANGLE Refer to rules given below and the example in Fig 8 for additional information Good cancellation of u joint operating angles with in 1 Operating angles less than 3 At least 1 2 of one degree continuous operating propeller shaft angle 7663 J 23498A J9216 12 Fig 7 Rear input Angle Measurement B Horizontal Level A Output Yoke 3 0 4 9 B Axle Input Yoke 3 2 Q r 4 9 C Prop Shaft 4 9 r 3 0 C Prop...

Page 952: ...ay shudder is the vibration that occurs at first acceleration from a stop Shudder vibration usu ally peaks at the engines highest torque output Shudder is a symptom associated on vehicles using a two piece prop shaft Shudder can be decreased by lowering the center bearing in 1 4 inch increments with shim stock or fabricated plates Fig 10 Plate stock must be used to maintain compression of the rubb...

Page 953: ... 13 Frames 2 Scribe alignment marks on the yokes at the transfer case Place marks at the pinion shaft and at each end of the propeller shaft These marks will be used for installation reference Fig 2 3 Remove the U joint strap bolts at the pinion shaft yoke 4 Remove bolts from transfer case yoke and re move the propeller shaft TRANSFER Fig 2 Front Propeller Shaft INSTALLATION 1 Position the propell...

Page 954: ... Remove the universal joint strap bolts at the pinion shaft yoke 4 Scribe alignment marks at the frame cross member for reference Remove the bolts that attach the center bearing to the support bracket Fig 4 Fig 4 Center Bearing Support 5 Slide the slip yoke off of the transmission transfer case output shaft and remove the propeller shaft INSTALLATION 1 Slide the slip yoke on the transmission trans...

Page 955: ...e upper bearing assembly and press it through to re lease the lower bearing assembly Fig 3 J9316 19 Fig 2 Remove Snap Ring J9316 2V Fig 3 Press Out Bearing 6 If the bearing assembly will not pull out by hand after pressing tap the base of the lug near it to dis lodge 7 To remove the opposite bearing turn the yoke over and straighten the cross in the open hole Then carefully press the end of the cr...

Page 956: ...with a soft hammer to seat tjie needle bearings In stall a snap ring 6 Add grease to lube fitting if equipped PROPELLER SHAFTS 16 11 7 Install the propeller shaft Refer to Propeller Shaft Replacement in this group DOUBLE CARDAN CV REMOVAL DISASSEMBL Y Single cardan universal joints are not serviceable If worn or leaking they must be replaced as a unit 1 Remove the propeller shaft Refer to Propelle...

Page 957: ...and 5 for re moving the opposite side bearing This will then al low removal of the cross centering kit assembly and spring Fig 10 J9316 8 Fig 10 Remove Centering Kit 7 Press the remaining bearing assemblies out the other cross as described above to complete the disas sembly CLEANING AND INSPECTION 1 Clean all the U joint yoke bores with cleaning solvent and a wire brush 2 Inspect the yokes for dis...

Page 958: ...ere with removal Fig 12 Install Bearing Assembly 3 Press the bearing assembly in place and install a snap ring Fig 13 Fig 13 Press in Bearing Assembly 4 Flip the tube yoke and bearing assembly instal lation on the opposite trunnion Install a snap ring Fig 14 J 9 3 1 6 1 2 Fig 14 Press In Bearing Assembly 5 Fit the center yoke on the remaining two trun nions and press bearing assemblies in place bo...

Page 959: ...the remaining cross opposite sides Fit the open trunnions into the center yoke holes and the bearing assemblies into the centering kit Fig 17 Align the lube fitting on the cross with the other two lube fittings J9316 15 Fig 17 Install Remaining Cross 8 Press the remaining two bearing assemblies into place and install snap rings Fig 18 I 1 J9316 16 Fig 18 Press In Bearing Assembly 9 Tap the snap ri...

Page 960: ...peller shaft Refer to Propeller Shaft Replacement in this group J9316 18 Fig 20 Check Assembly TORQUE SPECIFICATIONS PROPELLER SHAFTS A N D U JOINTS DESCRIPTION TORQUE Center Bearing to Support Bracket Two Piece Shaft 68 N m 50 ft lbs Double Cardan to Transfer Case Yoke Bolts 88 N m 65 ft lbs Prop Shaft to Axle Yoke Screws Gas Engine 19 N m 14 ft lbs Prop Shaft to Axle Yoke Screws Diesel Engine 29...

Page 961: ......

Page 962: ...er end When the worm shaft is turned the rack piston moves The rack piston teeth mesh with the pitman sector shaft Turning the worm shaft turns the pit man shaft which turns the steering linkage The steering gears can be adjusted and internally serviced An identification code on the upper adjustment cover designates the ratio Code XS designates 13 16 1 ratio used in Dodge Ram Truck vehicles POWER ...

Page 963: ...eck fluid level add fluid as necessary Fig 2 Saginaw P Series Pump Both types of steering columns have anti theft pro visions They are energy absorbing collapse from im pact in the event of a front end collision S Y S T E M D I A G N O S I S 7 Gauge should read below 862 kPa 125 psi if above inspect the hoses for restrictions and repair as necessary The initial pressure should be in the range of 3...

Page 964: ... STEERING 19 3 PUMP LEAKAGE DIAGNOSIS 9119 1 ...

Page 965: ... and dash seal Ensure steering column lower coupling has no metal to metal contact within the coupling by performing an electrical continuity check Remove coupling for check If hiss is still extremely objectionable 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 Pressure hose touching other par...

Page 966: ...em SUCKING AIR SOUND 1 Loose return line clamp 2 Missing O ring on hose connection 3 Low fluid level 4 Air leak between reservoir and pump 1 Tighten or replace clamp 2 Inspect connection and replace o ring as required 3 Fill to proper level and perform leakage diagnosis 4 Inspect and replace reservoir as required SQUEAK OR RUB SOUND 1 Sound from steering column 2 Sound internal to steering gear 1 ...

Page 967: ...rect condition See Steering Column Service Procedure 8 Realign as necessary 9 Replace gear SHAKE SHUDDER V I B R A T I O N C O N D I T I O N POSSIBLE CAUSE CORRECTION VIBRATION OF THE STEERING WHEEL A N D OR DASH DURING DRY PARK OR LOW SPEED STEERING MANEUVERS 1 Air in the power steering system 2 Tires not properly inflated 3 Excessive engine vibration 4 Faulty accessory drive belt tensioner Poly ...

Page 968: ...f steering gear is at fault replace steering gear POOR RETURN TO CENTER CONDITION POSSIBLE CAUSE CORRECTION STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Tires not properly inflated 2 Improper front wheel alignment 3 Lack of lubrication in ball joint 1 Inflate tires to proper pressure 2 Check and adjust as necessary 3 Replace as required or lubricate 4 Steering column U joints misali...

Page 969: ...n 4 Check and replace as required 5 Check and replace as required 6 Tighten hub nut or replace with new parts as necessary 7 Check and replace as required 8 Replace gear 9 Replace gear VEHICLE L E A D S TO THE SIDE C O N D I T I O N POSSIBLE CAUSE CORRECTION WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION 1 Radial tire lead 2 Front end misaligned 3 Wheel braking 4 Unbalanced steering gear valve I...

Page 970: ... 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 F O A M Y O R MILKY FLUID CONDITION POSSIBLE CAUSE CORRECTION AERATION AND OVERFLOW OF FLUID 1 Air leaks 2 Low fluid level 3 Cracked pump housing 4 Water contamination 1 Check for air leak as described under sucking air and correct 2 Extremely c...

Page 971: ...E C O V E R S E A L IF T H E L E A K A G E PERSISTS 2 A D J U S T E R P L U G S E A L R E P L A C E T H E A D J U S T E R P L U G S E A L S 3 PRESSURE LINE FITTING TOR QUE THE HOSE FITTING NUT TO 2 7 N m 20 FT LBS IF LEAKAGE PERSISTS REPLACE THE SEAL 4 PITMAN SHAFT SEALS REPLACE THE SEALS 5 T O P C O V E R S E A L R E P L A C E T H E S E A L J 9 2 1 9 2 9 ...

Page 972: ...NNECTED HOSES DO NOT A L L O W THE H O S E S T O TOUCH A HOT EXHAUST MANIFOLD OR T H E CATALYTIC CONVERTER REMOWAL 1 Remove fasteners from hose retaining brackets at all locations 2 Disconnect pressure and return hose from the steering gear Drain the fluid from pump and reser voir Fig 1 2 3 If applicable remove cooler bracket fasteners from block 4 Disconnect pressure and return hose from the pump...

Page 973: ...ve the nut from the steering pump attaching bracket Fig 4 6 Remove upper bolt from the pump assembly Fig 5 Remove the assembly from the engine Fig 6 7 Remove the gasket from the mounting surfaces on engine block and pump assembly 8 Drain the fluid from the steering pump 9 Remove the steering pump to vacuum pump bracket attaching nuts Fig 7 10 Slide the steering pump from the bracket Use care not t...

Page 974: ...ign and install the pump assembly on the en gine Ensure the steering pump stud is inserted into PUMP BRACKET SPACERS J9119 69 Fig 8 Steering Pump Removal Installation Fig 9 Steering Vacuum Pump Assembly the block bracket Tighten the pump to engine block attaching bolts to 77 N m 57 ft lbs torque 6 Install the steering pump to attaching bracket nut and tighten to 24 N m 18 ft lbs torque 7 Remove pl...

Page 975: ...bracket Loosen upper bracket bolt Remove the lower bracket to engine block bolts Pivot the pump assembly past the coolant tube Remove the upper stud Remove upper bolt from cylinder head The steering pump and mounting bracket will be re moved from engine as an assembly 4 Remove the pump pulley refer to the procedure below This will allow access to the pump attaching screws 5 Remove the bracket to p...

Page 976: ...housing and reser voir Fig 14 4 Remove flow control valve and spring from housing INSTALLATION Clean all parts before installation Lubricate new O ring seals with MOPAR Power Steering Fluid or an equivalent product 1 Install flow control valve and spring Fig 15 2 Install new O ring seals in housing Fig 15 Tighten mounting studs to 48 N m 35 ft lbs torque 3 Install fitting in flow control valve bor...

Page 977: ...ng the wheel stops 6 Add power steering fluid if necessary 7 Lower the vehicle and turn the steering wheel slowly from lock to lock 8 Stop the engine Check the fluid level and refill as required 9 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure Fig 14 Pump and Reservoir the steering VALVE AND SPRING J8919 101 Fig 15 Flow Control Valve Sprin...

Page 978: ...2 Remove the tie rod end ball studs from steering knuckle arms Fig 1 and 2 Use care to avoid damaging the seals 2 Remove inner tie rod ends Fig 1 and 2 from center link 3 Remove idler arm ball stud from center link Fig 2 Remove idler arm bolts from frame side rail Fig 2 4 Remove pitman arm ball stud from center link 5 Mark the pitman arm and shaft positions for reference Remove pitman arm with Pul...

Page 979: ... t y 34 N m 25 ft lbs torque STEERING LINKAGE 4WD VEHICLES Use Puller C 4150 to remove a drag link or pit man arm Failure to use this tool could cause damage to the seals Fig 4 TOOL C 4150 R H 4 0 4 Fig 4 Drag Link Removal REMOVAL 1 Remove drag link tie rod end ball studs from steering arm and pitman arm Fig 4 and 5 Use care to avoid damaging the seals 2 Remove the steering arm nuts and washers Fi...

Page 980: ...t tie rod ends into steering knuckle arm Fig 2 Tighten the nuts to 61 N m 45 ft lbs torque Install new cotter pins 6 Remove the supports and lower the vehicle to the surface Adjust the wheel toe position refer to the Alignment Specifications chart within Group 2 Front Suspension Position the clamp on the sleeve so retaining bolt is located on the bottom side of the sleeve 7 After adjustment tighte...

Page 981: ...SHER DOUBLE UP SEAL BACKUP WASHER SINGLE LIP SEAL NEEDLE BEARING J8919 39 Fig 1 Pitman Shaft Seals CAUTION Use care 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 the seals and washers Stop the engine 5 Remove backup washer and single lip seal wit...

Page 982: ......

Page 983: ...1 2 the total number of turns This is the center of the gear travel Fig 8 J8919 58 Fig 5 Alignment Marking On Housing Fig 6 Remarking The Housing 3 Turn the pitman shaft adjuster screw back COUNTERCLOCKWISE until extended then turn back in CLOCKWISE one full turn 4 Place the torque wrench in the vertical position on the stub shaft Rotate the wrench 45 degrees each side of the center and record the...

Page 984: ... clean at all times Thor oughly clean the exterior of the gear with cleaning solvent before disassembly Drain as much of the fluid as possible Use protective vise jaws at all times when clamping components During assem bly lubricate all components with power steering fluid except when instructed otherwise Fig 10 STEERING 19 23 Fig 8 Steering Gear Centered Fig 9 Checking Over center Rotation Torque...

Page 985: ...DUST 23 RING RETAINING 24 NUT ADJUSTER PLUG LOCK 25 BEARING ASSY NEEDLE PITMAN SHAFT 26 SEAL PITMAN SHAFT SINGLE LIP 27 WASHER SEAL BACK UP PITMAN SHAFT 28 SEAL PITAAAN SHAFT DOUBLE LIP 29 WASHER SEAL BACK UP PITMAN SHAFT 30 RING RETAINING PITMAN SHAFT SEAL 31 WASHER PITMAN SHAFT LOCK 32 NUT PITMAN SHAFT 33 NUT RACK PISTON 34 BALL 35 GUIDE BALL RETURN 2 36 CLAMP BALL RETURN GUIDE 37 SCREW ASSY LOC...

Page 986: ...ut 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 assembly and side cover to housing 5 Install side cover bolts and tighten to 60 N m 44 ft lbs 6 Adjust pitman shaft refer to Over Center Ad justment INSTALL 1 Install steering gear Refer to Power Steering Gear Replacement in this section 2 Install pitm...

Page 987: ... mm 1 inch from access hole Fig 14 Fig 14 Installing The Retaining Ring 2 Install pitman arm onto steering gear Refer to Steering Linkage in this group ADJUSTER PLUG ASSEMBLY REPLACEMENT REMOWE 1 Remove steering gear from vehicle Refer to Power Steering Gear Replacement in this section DISASSEMBLE 1 Remove adjuster plug lock nut from housing 2 Remove adjuster plug from housing with Span ner Wrench...

Page 988: ...adjuster plug 5 Install large bearing race thrust bearing small bearing race and bearing spacer to adjuster plug 6 Install thrust washer bearing retainer to ad juster plug Fig 19 NEEDLE BEARING PUNCH SEAL RETAINER ADJUSTER PLUG J9219 10 Fig 19 Install Retainer CAUTION When installing adjuster plug should be taken NOT to cut the seals care 7 Install adjuster plug into housing with Spanner Wrench C ...

Page 989: ...l O ring seal Remove valve body teflon rings and O ring seals Fig 24 J9319 36 Fig 22 Remove and Install Stub Shaft Fig 23 Remove and Install Spool ASSEMBLE 1 Install valve spool O ring seal to valve spool 2 Lubricate valve spool and O ring seal with power steering fluid 3 Install valve spool to valve body by pushing and rotating Hole in valve spool for stub pin must be accessible from opposite end...

Page 990: ...aft COUNTERCLOCKWISE until the rack piston begins to come out of the housing 4 Remove rack piston plug Fig 26 EXTENSION END PLUG RACK PISTON J9219 9 Fig 26 Remove and Install Rack Piston End Plug 5 Insert Arbor C 4175 into bore of rack piston Fig 27 Hold tool tightly against worm shaft while turning the stub shaft COUNTERCLOCKWISE The rack piston will be forced onto the tool and hold the rack pist...

Page 991: ...Mack a n d 12 are silver Chrome The black w INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING W O R M COUNTERCLOCKWISE J9319 39 Fig 29 Installing Balls in Rack Piston rack piston balls are smaller than the silver balls THE BLACK AND SILVEE BALLS MUST BE INSTALLED ALT1ENATELY INTO THE RACK PISTON AND BALL GUIDE This proce dure will maintain worm shaft preload 3 Lubricate and install rack piston ball...

Page 992: ...r Adjustments 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 Remove pitman arm from gear Refer to Pit man Arm Removal in Steering Linkage 2 Clean exposed end of pitman shaft and housing Use a wire brush to clean the shaft splines 3 Remove retaining ring with snap ring plier...

Page 993: ...ection DISASSEMBLE CAUTION Use care not to damage the threads of the housing when prying out check valve 1 Remove valve by prying from housing with a small screwdriver ASSEMBLE 1 Install the valve into the housing with a 3 8 inch diameter piece of tubing 100 mm 4 inches long INSTALL 1 Install steering gear Refer to Power Steering Gear Replacement in this section STEERING GEAR REPLACEMENT REMOVAL 1...

Page 994: ...rame rail Install and tighten the attaching bolts SCREW REINFORCEMENT Fig 38 Steering Gear Removal Installation 2WD Fig 39 Steering Gear Removal Installation 4WD finger tight Fig 38 Center the steering gear and align the steering column shaft and the stub shaft 4WD vehicles install the steering gear to the frame reinforcement bracket Fig 39 Tighten the screws to 176 N m 130 ft lbs torque Install t...

Page 995: ...eering Gear Lubricants Lubricate pitman shaft seals bearings 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 Nm 4 to 10 in lbs Pitman Shaft Overcenter Drag Torque New Gear less than 400 miles 640 km 0 45 0 90 Nm 4 to 8 in lbs in addition to wormshaft bearing prelo...

Page 996: ...able from the battery before servicing any component on the column CAUTION Do not attempt to remove the pins to dis semble the tilting mechanism Damage will occur Safety goggles should be worn at all times when involved with steering column service STEERING WHEEL REMOWAL 1 Make sure the front wheels are in the straight ahead position 2 Disconnect the negative ground cable from the battery 3 Remove...

Page 997: ... gain access to the clockspring wiring 5 Release wire connector at clockspring 6 Pull clockspring assembly from column by lift ing locking fingers as necessary The clockspring cannot be repaired and must be replaced if faulty INSTALLATION 1 Snap clockspring assembly onto column If clockspring is not properly positioned follow the cen tering procedures before installing steering wheel 2 Connect the...

Page 998: ...crews Fig 6 6 Remove the dash panel column and fuse block cover Fig 7 7 For column shift vehicles make sure shift lever is in Park position and remove PRNDL driver cable 8 Remove tilt lever if equipped from column 9 Remove the upper and lower lock housing shroud Fig 1 Remove the lower fixed shroud 10 Remove the turn signal multi function switch with a 7mm socket Fig 8 11 Loosen the upper Support B...

Page 999: ...capsules are fully seated in the slots in the column support bracket Tighten the two upper bracket nuts to 12 N m 105 in lbs torque 10 Tighten the toe plate to floor pan attaching nuts to 22 5 N m 200 in lbs torque 11 Install the wiring connections to the column Fig 10 Install the lower fixed shroud 12 Column shift vehicles install the PRNDL driver cable 13 Install the lock housing shrouds Install...

Page 1000: ... STEERING 1 9 3 9 Fig 14 Do Not Remove Retainer ...

Page 1001: ...ll Stud Nuts 4WD AII Idler Arm to Frame Bolts Pitman Shaft Nut Steering Arm to Knuckle Nuts 4WD Model 44 Tie Rod Clamp Nut Standard Duty 2WD Tie Rod Clamp Nut Heavy Duty 2WD Tie Rod Clamp Nut 4WD tie Rod End to Center Link Nut Tie Rod End Nut to Steering Knuckle Arm 2WD Tie Rod End Nut to Steering Knuckle Arm 4WD 88 N m 65 ft lbs 81 N m 60 ft lbs 88 N m 65ft lbs 251 NTn 185ft lbs 122 N m 90ft lbs ...

Page 1002: ...e shift cover Tapered roller bearings support the drive gear mainshaft and countershaft in the gear case Pilot roller bearings in the drive gear hub support the for ward end of the mainshaft The mainshaft gears are all supported on caged type roller bearings Drive gear thrust reaction is controlled by a needle type thrust bearing The bearing is located at the forward end of the mainshaft TRANSMISS...

Page 1003: ...lash synchronizer clutch and stop rings or mainshaft gear teeth may be worn or damaged Hard shifting may also be caused by a loose or misaligned shift cover or alignment dowels Worn or damaged shift cover components will also cause hard shifting Any of the foregoing faults will cause com ponent bind and high shift efforts Misassembled synchro components will also cause shift problems Incorrectly i...

Page 1004: ...calibration can lead to an underfill condition CLUTCH PROBLEMS Worn damaged or misaligned clutch components can cause difficult shifting gear clash and noise A damaged pilot bearing will cause noise If bear ing damage is severe drive gear misalignment and hard shifting can also occur A worn or damaged clutch disc pressure plate or release bearing can cause hard shifting and gear clash Damaged or w...

Page 1005: ... Install rear crossmember 13 Remove transmission jack and engine support fixture 14 Align and connect propeller shaft 15 Fill transmission with required lubricant if necessary 16 Lower vehicle 17 Install shift lever on transmission stub lever 18 Install shift boot and bezel 19 Connect battery negative cable TRANSMISSION REMOVAL 4 WHEEL DRIVE 1 Disconnect battery negative cable 2 Shift transmission...

Page 1006: ... to remain unsupported after drive gear has entered clutch disc 7 Install and tighten transmission to clutch hous ing bolts to 108 N m 80 ft lbs torque 8 Connect speed sensor and backup light switch wires 9 Position transmission harness wires in clips on shift cover 10 Tighten slave cylinder attaching nuts and in stall slave cylinder shield if equipped 11 Install transmission mount on transmission...

Page 1007: ...N ADAPTER HOUSING REMOVAL 1 Remove bolts attaching extension adapter hous ing to gear case Fig 4 Use 10 mm 12 point socket to remove housing bolts Loosen bolts 4 5 threads with socket and ratchet first An air wrench can then be used to complete removal but only after bolts are loose CAUTION Spline head bolts are used to attach the extension or adapter housing to the gear case The bolt splines are ...

Page 1008: ...eal 2 Wheel Drive Models 4 WHEEL DRIVE ADAPTER HOUSING J9221 88 Fig 8 Adapter Housing 4 Wheel Drive Models MAINSHAFT AND COUNTERSHAFT FIFTH GEAR REMOWAL The fifth gear components can be removed in dividually or as an assembly If the fifth gear components are only being removed for access to another component remove them as an as sembly However if any of the fifth gear compo nents require service r...

Page 1009: ... 2 wheel drive models install Socket Wrench 6441 on mainshaft splines On 4 wheel drive models install Socket Wrench 6442 on main shaft splines Then install breaker bar in socket wrench Fig 13 Wedge breaker bar handle J9221 90 GEAR Fig 11 Removing Countershaft Fifth Gear Synchro Components against workbench Purpose of socket wrench and breaker bar is to prevent mainshaft from turning while nut is l...

Page 1010: ...l with plastic mallet Leave sleeve engaged in fork or note position of sleeve for assembly refer ence 7 Remove countershaft fifth gear and hub assem bly Fig 16 8 Remove countershaft fifth gear needle bearing assemblies Fig 17 9 Remove cone shaped rear bearing thrust washer from end of countershaft Fig 18 Note posi tion of washer for assembly reference Also note that PLASTIC FIFTH Fig 15 Fifth Gear...

Page 1011: ...1 99 Fig 19 Installing First Puller Jaw On Mainshaft Fifth Gear b Assemble Puller Flange 6444 1 and Puller Rods 6444 3 Fig 20 c Slide assembled puller flange and rods onto output shaft Then seat flange in notch of puller jaw Fig 20 d Position second Puller Jaw 6459 on gear and in notch of puller flange Fig 21 e Slide Retaining Collar 6444 8 over puller jaws to hold them in place Fig 21 f Install P...

Page 1012: ... 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 4 Remove bearing cup from front retainer as fol lows a Assemble Puller Flange 6444 1 and Puller Rods 6444 6 Fig 26 b Insert Puller Jaws 6453 1 in puller flange Fig 26 Narrow lip of puller jaws will go under bearing cup c Install assembl...

Page 1013: ...bearing from drive gear as follows J9221 105 DRIVE GEAR MAINSHAFT PILOT BEARING J9221 106 Fig 30 Pilot Bearing Removal Installation 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 Flange 6444 1 and Puller Rods 6444 4 Then position first Puller Jaw 6447 on gear Fig 31 c Slide assembled puller flange and rod tools...

Page 1014: ...everse Idler Shaft Fig 35 Drive Gear Thrust Bearing Removal Fig 36 Fourth Speed Clutch Gear Stop Ring Removal 7 Roll gear case onto left side Fig 37 8 Reach into gear case and push reverse idler gear away from mainshaft gears 9 Remove mainshaft assembly as follows Fig 37 a Lift front end of mainshaft slightly b Grasp mainshaft rear splines Then turn spline end of mainshaft in counterclockwise dire...

Page 1015: ... washers from gear case Install washers on idler shaft to keep them to gether for cleaning and inspection 5 Remove countershaft rear bearing Shaft can not be removed from case until rear bearing has been removed Bearing removal procedure is as follows a Assemble Puller Flange 6444 1 and Puller Rods 6444 6 Fig 41 J922M14 Fig 39 Reverse Idler Gear Removal REVERSE BEARINGS IDLER Fig 40 Reverse Idler ...

Page 1016: ...ridge to bolts with re taining nuts Fig 43 J922M 59X 6444 4 Fig 43 Removing Countershaft Front Bearing g Tighten puller bolt to remove bearing from shaft Fig 43 If bearing is exceptionally tight tap end of puller bolt with mallet to help loosen bear ing 9 Remove bearing puller tools 10 Set countershaft and idler gear aside for cleaning and inspection GEAR CASE DISASSEMBL 1 Remove countershaft fron...

Page 1017: ... 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 Store parts in a paper cup to avoid losing them Fig 50 3 4 Synchro Strut And Spring Removal 3 Remove 3 4 sleeve from 3 4 synchro hub Fig 51 4 Remove 3 4 synchro hub from mainshaft splines with suitable size bearing splitter o...

Page 1018: ...g Spacer And Snap Ring Location SECOND GEAR J 9 2 2 M 2 0 Fig 52 Third Gear Stop Ring And 3 4 Hub Removal 5 Remove 3 4 synchro hub third gear stop ring and third gear Fig 52 6 Remove third gear bearing assemblies from mainshaft Fig 53 7 Remove third gear bearing spacer Fig 54 8 Remove snap ring that retains second gear thrust washer on mainshaft Fig 54 9 Remove second gear thrust washer Fig 55 Not...

Page 1019: ...ar synchro clutch ring and synchro stop 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 side of sleeve also goes toward front 17 Remove 1 2 synchro sleeve hub struts and springs as an assembly Fig 62 It is not necessary to disassemble synchro comp...

Page 1020: ...EED CLUTCH GEAR J9221 133 Fig 65 First Speed Clutch Gear Removal 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 puller jaw Fig 66 d Install second Puller Jaw 6445 on bearing cone and on puller flange Fig 66 e Slide Retaining Collar 6444 8 over puller jaws to hold them in place Fig 6...

Page 1021: ...22M35 Fig 68 Reverse Gear Thrust Washer Removal 26 Remove reverse gear and synchro components as assembly Fig 70 It is not necessary to re move or disassemble synchro components unless they are damaged and need to be replaced If synchro sleeve or struts require service mark position of sleeve on hub before removal Cor rect sleeve position is important as sleeve can be installed backwards causing s...

Page 1022: ... 72 32 Remove first gear from bearing and mainshaft Fig 73 33 Remove first gear bearing from mainshaft Fig 74 TRANSMISSION CLEANING AND INSPECTION Clean the gears bearings shafts extension adapter housing and gear case with solvent Dry all parts ex cept the bearings with compressed air Allow the bearings to either air dry or wipe them dry with clean shop towels Fig 71 Reverse Gear Bearing Spacer A...

Page 1023: ...lly Minor corrosion nicks or pitting can be smoothed with 400 grit emery and pol ished out with crocus cloth Wet the abrasive paper and crocus cloth with oil when smoothing polishing Replace the retainer if worn or damaged in any way Inspect the countershaft and bearings Fig 78 Re place the bearings if worn rough flat spotted or heat checked Check the countershaft gear teeth carefully Small nicks ...

Page 1024: ...ce worn distorted synchro parts to avoid shift problems after as sembly and installation The shift fork should be inspected for evidence of wear and distortion Check fit of the sleeve in the fork to be sure the two parts fit and work smoothly Replace the fork if the roll pin holes are worn over EXTENSION HOUSING 2 WHEEL DRIVE ADAPTER HOUSING 4 WHEEL DRIVE J9221 186 Fig 80 Gear Case And Extension A...

Page 1025: ... 24 NV4500 TRANSMISSION OVERHAUL Fig 82 1 2 Synchro Components ...

Page 1026: ......

Page 1027: ...EAR 37 THRUST WASHER AND LOCATING PIN 38 THRUST WASHER SNAP RING 39 THIRD GEAR BEARING SPACER 40 THIRD GEAR 41 THIRD GEAR BEARING ASSEMBLIES 2 42 THIRD GEAR SYNCHRO STOP RING 43 3 4 SYNCHRO SLEEVE 44 SYNCHRO STRUTS AND SPRINGS 3 EACH 45 3 4 SYNCHRO HUB 46 FOURTH GEAR SYNCHRO STOP RING 47 FOURTH SPEED CLUTCH GEAR 48 DRIVE GEAR THRUST BEARING TRANSMISSION ASSEMBLY AND ADJUSTMENT Assembly Information...

Page 1028: ...n Case 7 Install reverse idler gear in case Fig 90 8 Install idler gear rear thrust washer between idler gear and case boss Fig 90 REAR THRUST Fig 90 Idler Gear And Thrust Washer Installation 9 Align idler gear bearings and thrust washers with drift 10 Install reverse idler shaft Fig 91 Be sure notched end of shaft is facing countershaft as shown Use shift cover bolt to hold and insert shaft in ca...

Page 1029: ...t 4 5 times to seat bearings 3 Mount dial indicator on case Then position in dicator plunger on end of countershaft and zero indi cator dial needle Fig 97 COUNTERSHAFT SPECIAL TOOL 6446 REAR BEARING _ J9221 166 Fig 93 Installing Countershaft Rear Bearing FRONT BEARING CAP SEAT WITH WOOD BLOCK J9221 172 Fig 94 Countershaft Front Bearing Cap Installation COUNTERSHAFT REAR BEARING CUP J9221 167 Fig 9...

Page 1030: ...ROLL PINS LUG RAIL SHIFT LUG J922M71 Fig 99 Shift Lug And Rail Installation MAINSHAFT AND GEARTRAIN ASSEMBLY CAUTION The reverse 1 2 and 3 4 synchro compo nents can be assembled and installed incorrectly if care is not exercised Some components can be in stalled backwards resulting in shift problems Refer to the assembly procedures for component identifi cation and location 1 Lubricate mainshaft b...

Page 1031: ...ings as follows WOOD BLOCKS REVERSE GEAR STOP RING XLUTCH GEAR FIRST GEAR x J9221 191 i Fig 102 Clutch Gear Stop Ring Installation REVERSE GEAR BEARING BEARING SPACER FIRST GEAR J9221 192 Fig 103 Reverse Gear Bearing And Spacer Installation CAUTION The reverse sleeve will fit either way on the hub This means the sleeve can be installed backwards if care is not exercised Be sure the ta pered side o...

Page 1032: ...inner race should be flush with shaft 16 Turn mainshaft over and place it in horizontal position on workbench 17 Install first speed clutch gear on mainshaft 1 2 synchro hub Fig 109 Recessed side of gear faces front Be sure gear is seated against snap ring previously installed on hub 18 Install snap ring on mainshaft 1 2 synchro NV4I00 TRANSMISSION OVERHAUL 21 31 Fig 106 Thrust Washer Pin Installa...

Page 1033: ...st Speed Clutch And Stop Ring Installation MAINSHAFT GEAR CASE J9221 222 Fig 113 Mainshaft Positioned For Gear And Synchro Installation 22 If 1 2 synchro hub and sleeve were disassem bled for service reassemble hub sleeve struts and springs as follows a Install weights in hub Fig 114 Use petro leum jelly to hold weights in place if desired b Install weight retainer springs Flat spring goes at fron...

Page 1034: ...y to hold them in place Then compress struts with your fingers and move sleeve upward until struts are started in sleeve Verify that struts are engaged in sleeve before pro ceeding g Turn synchro assembly upright Then move sleeve into neutral position on hub and work struts into sleeve at same time Be sure struts are seated and springs are not displaced during assembly Fig 116 installing 1 2 Synch...

Page 1035: ...lat weight spring from front side of 1 2 synchro hub Removing spring makes installation of 1 2 hub snap ring easier 27 Install snap ring that secures 1 2 synchro on mainshaft hub Fig 121 Be sure snap ring is fully seated in ring groove in mainshaft hub If snap ring will not seat in groove round weight spring at rear of 1 2 synchro hub is probably not seated in recess at front of first speed clutch...

Page 1036: ...l not fit in groove clutch gear is slightly misaligned Or flat weight spring at front of 1 2 synchro hub is probably not seated in recess in front of second speed clutch gear Fig 125 Installing Second Speed Clutch Gear Snap Ring 32 Install second gear bearing on mainshaft Fig 126 33 Install second gear on mainshaft and bearing Rotate gear until tabs of second speed clutch ring are fully seated in ...

Page 1037: ...onents as follows a Align and install synchro sleeve on hub Fig 134 Front side of hub has a narrow groove machined in it Fig 131 Third Gear Bearing Installation Fig 132 Third Gear Installation SYNCHRO THIRD Fig 133 Third Gear Stop Ring Installation b Insert all three synchro struts in slots ma chined in sleeve and hub Fig 134 c Install and seat synchro springs Fig 134 Use flat blade or phillips sc...

Page 1038: ...shaft through bearing bore at rear of case Fig 137 Fourth Speed Clutch Gear Installation 3 Continue holding front of shaft but switch grip at rear to shaft output splines Lift mainshaft assem bly slightly align gears and seat assembly in case Be sure fourth speed clutch gear and stop ring were not displaced during installation Fig 138 MAINSHAFT Fig 138 Mainshaft And Geartrain Installed In Case 4 I...

Page 1039: ... shown Lubricate seal lip with petroleum jelly after installation 6 Clean contact surfaces of gear case and front bearing retainer with a wax and grease remover 7 Apply Mopar Gasket Maker to flange surface of front bearing retainer Fig 143 8 Install front bearing retainer over drive gear and start it into case WOOD BLOCK SPECIAL TOOL 6052 RETAINER J9221 202 Fig 142 Installing Bearing Retainer Oil ...

Page 1040: ...IAL INDICATOR AND BASE REAR BEARING j POSITION J INDICATOR J PLUNGER L L O N BEARING INNER RACE J9221 232 Fig 145 Checking Mainshaft End Play 9 If end play adjustment is required remove bearing plate and install necessary shim 10 Reinstall rear bearing plate Fig 146 Tighten rear bearing plate bolts to 23 N m 200 in lbs torque Be sure oil hole in bearing plate is at top as shown MAINSHAFT FIFTH GEA...

Page 1041: ...0 Installing Fifth Gear Thrust Washer Pin 2 Install thrust washer on countershaft Turn washer until pin engages in washer notch Fig 151 Flat side of washer faces rear and cone side to front as shown J9221 235 Fig 151 installing Fifth Gear Thrust Washer 3 Lubricate and install fifth gear bearings on countershaft Fig 152 4 Install bearing spacer on countershaft and seat it against bearings Fig 152 C...

Page 1042: ...ig 157 Make sure both parts are seated in fifth gear hub 11 Install clutch gear snap ring Fig 158 EXTENSION ADAPTER HOUSING INSTALLATION 1 If extension housing seal needs replacement remove it collapsing with a punch and chisel Then pry seal out of housing with crowfoot pry bar 2 If extension housing bushing must be replaced collapse old bushing with tapered drift Fig 159 Po sition drift in slot p...

Page 1043: ...m socket a ratchet wrench and necessary extensions to in stall bolts Do not use any other type of socket and do not use an impact wrench Splines on bolt heads can be damaged if impact wrench or wrong type of socket is used for tightening pur poses J9221 201 EXTENSION HOUSING Fig 161 Installing Extension Housing Seal EXTENSION HOUSING GEAR CASE J9221 85 Fig 162 Installing Extension Adapter Housing ...

Page 1044: ...wear distortion cracks or be ing loose on the shift rails Also check fit of the shift rails in the cover Replace the cover assembly if the rails are loose in the cover bores Inspect and replace the pads on the fifth reverse shift fork if worn The reverse inhibitor should also be replaced if worn or faulty The expansion plugs at the rear of the cover can be replaced if loose or leak ing A gasket is...

Page 1045: ...Drill 6 mm 1 4 in diameter hole in each plug to be removed 2 Pry plug out of cover with tapered punch 3 Clean all chips from shift cover and plug bores Then clean plug bores with solvent and dry with clean shop towel 4 Apply small bead of sealer to outer edge of each new plug Use Mopar silicone adhesive sealer or equivalent 5 Position each new plug in bore and tap into place with hammer and suitab...

Page 1046: ...ormation NV4500 TRANSMISSION OVERHAUL 21 45 SHIFT COVER SLOT Fig 172 Loosening Shift Cover SHIFT Fig 173 Shift Cover Removal Installation 7 Clean mating surfaces of shift cover and gear case with wax and grease remover 8 Apply Mopar Gasket Maker or Loctite 518 to sealing surface of shift cover or gear case Do not overapply sealer material Excess can be squeezed into gear case and could block lubri...

Page 1047: ...ates the shift rails and forks directly RECOMMENDED LUBRICANT Recommended lubricant for the Getrag G360 trans mission is SAE 5W 30 engine oil The oil should meet A P I service classifications SG or SG CD page Transmission Installation 4 Wheel Drive 52 Transmission Removal 2 Wheel Drive 47 Transmission Removal 4 Wheel Drive 51 Transmission Serviceability 47 Lubricant capacity is 3 3 liters 3 5 qts ...

Page 1048: ...ents become damaged to the point of re placement the transmission must be replaced as an assembly TRANSMISSION REMOVAL 2 WHEEL DRIVE 1 Disconnect battery negative cable 2 Shift transmission into Neutral and remove screws attaching shift lever upper boot to metal plate PLATE SCREW 4 LOWER BOOT AND PLATE J9121 255 Fig 4 Removing Installing Lower Boot And Plate Attaching Screws 4 Remove shift lever e...

Page 1049: ...h plastic mallet to loosen it Note align Fig 8 Removing Shift Lever Snap Ring ment slots in lever color and pivot ball Fig 9 These slots align with shoulder bolts in shift tower Fig 9 Removing Installing Shift Lever 9 Raise and support vehicle 10 Mark propeller shaft U joints and axle yokes for assembly alignment reference Fig 10 11 Remove propeller shaft Remove clamp strap bolts at front of shaft...

Page 1050: ... to re move screws attaching fuel line clamps to driver side frame rail Fig 13 Three clamps must be removed so fuel lines can be moved for access to crossmember bolts on this side of frame rail 16 Remove left and right crossmember to frame braces Fig 14 and remove crossmember G360 MANUAL TRANSMISSION 21 49 Fig 12 Transmission Supported On Jack Fig 13 Removing installing Fuel Line Clamps SAFETY ...

Page 1051: ...0 Fig 16 Loosening Slave Cylinder Nuts 19 Remove bolts attaching transmission to clutch housing and remove transmission Rock transmission slightly to help free input shaft from clutch disc and release bearing 20 Support engine with wood block and adjust able jack stand Fig 17 J9106 22 Fig 17 Typical Method Of Supporting Engine TRANSMISSION INSTALLATION 2 WHEEL DRIVE 1 Mount transmission on jack st...

Page 1052: ...ver and collar downward and in stall shift lever snap ring 17 Tighten shift lever alignment bolts com pletely 18 Install boot over shift lever and onto shift tower and tighten boot clamp securely 19 Install lower boot and plate assembly over shift lever and onto floorpan Position plate so large G360 MANUAL TRANSMISSION 21 51 S K I D PLATE J9121 525 Fig 19 Transfer Case Skid Plate Mounting notch is...

Page 1053: ...pilot bushing release bearing bore release fork release fork ball stud propeller shaft slip yoke 3 Align transmission and clutch housing Move transmission forward and start input shaft into re lease bearing and hub of clutch disc 4 Rotate output shaft with socket or yoke to align input shaft and clutch disc splines If input shaft will not rotate enough in neutral to align splines it will be necess...

Page 1054: ...pection REARING RETAINER AND SHAFT BEARING RACE REMOVAL 1 Remove front bearing retainer bolts and re move retainer Fig 3 Tap retainer with rubber mal let to loosen it if necessary 2 On 2 wheel drive models remove rear bearing retainer as follows Fig 4 a Remove nut attaching yoke to output Torque on nut is quite high Best way to re move nut is with 350 400 ft lb rated high ca pacity impact wrench b...

Page 1055: ...ainer Fig 6 On SHAFT 2 wheel drive transmissions remove shims from re SHIM tainer and slide output shaft rear bearing shims off shaft REAR BEARING RETAINER J9321 270 Fig 6 Shim Locations In Rear Bearing Retainer 5 Remove output shaft and countershaft bearing races Fig 7 Tap front and rear faces of gear case with large plastic mallet to loosen and remove races Do not strike bearing races Tap on cas...

Page 1056: ...Removal COUNTER GEAR AND SHAFT REMOWAL 1 Remove countershaft front bearing cap from case Fig 10 Strike cap with punch to unseat it Ex ercise care as bearing could be damaged if punch penetrates cap and contacts bearing 2 Remove large snap ring retaining counter gear shaft front bearing race in gear case Fig 10 3 Remove counter gear shaft front bearing race from gear case Fig 10 If race proves diff...

Page 1057: ...LER GEAR REMOVAL Two styles of transmission case were used for the G360 transmission Early style cases had a partial radius machined in the reverse idler area while later style cases had a full radius The different machining required different methods for removing the reverse idler gear and shaft On early style gear cases the idler gear must be removed before the counter gear can be removed On new...

Page 1058: ...r to help rotate idler gear out of case OUTPUT SHAFT DISASSEMBLY Do not disassemble the 1 2 3 4 and fifth re verse synchros during overhaul The component parts in each synchro are not available sepa rately The synchros are serviced as assemblies only CAUTION The output shaft and geartrain are quite heavy Have a helper support and hold the output shaft and gear assembly during all press opera tions...

Page 1059: ...r Fig 22 Use shop press and two press plates to press gear off shaft Have helper hold output shaft while removing gear 8 Remove first gear bearing from gear or output shaft 9 Mark position of 1 2 synchro assembly for in stallation reference Then remove synchro assembly from output shaft Fig 23 10 Remove pilot bearing 3 4 synchro assembly and third gear as a unit Use suitable size bearing splitter ...

Page 1060: ...al Fig 27 Procedure is as follows G360 TRANSMISSION OVERHAUL 21 59 Fig 26 Second Gear And Thrust Washer Removal 1 On first gear tap pins through blocker ring and remove ring from gear 2 On second gear remove blocker ring as follows a Position gear on workbench so first roll pin to be removed extends over edge of bench Fig 27 b Tap each roll pin about three quarters of way through blocker ring c Pr...

Page 1061: ...spect the shaft and gears for wear or damage Fig 30 Check for broken or chipped gear teeth SECOND GEAR Fig 29 Removing Roll Pins From Gear damaged synchro blocker rings or worn galled bear ings Discoloration or shiny spots on gear teeth are a normal condition and do not indicate a need for re placement 1 I ...

Page 1062: ......

Page 1063: ...or scratches on the shaft can be reduced and smoothed off with 320 400 grit emery cloth The counter gear and shaft are not serviceable components If either part is damaged it will be nec essary to replace the complete transmission assem bly Reverse Idler Components The reverse idler components consist of the gear shaft thrust washers pins bearings and the shaft bolt Fig 32 Clean and inspect the id...

Page 1064: ...on and sealing Lubricate the transmission components with Mopar 5W 30 engine oil or equivalent during assembly Pe troleum jelly can be used to hold parts in place and prelubricate bearings and seal lips Do not use chassis grease or similar products on any component during assembly Heavy lu bricating grease will plug the transmission oil passages resulting in failure Preload adjustments are require...

Page 1065: ...Use suitable size pipe style tool to tap or press syn chro assembly into place SELECT FIT SNAP RING SECOND GEAR THRUST WASHER J9321 300 Fig 38 Second Gear Snap Ring Installation BLOCKER RING THIRD GEAR J9321 301 Fig 39 Third Gear And Blocker Ring Installation CAUTION Be sure the third gear blocker ring is aligned with the synchro hub before seating the synchro assembly Failure to align the ring co...

Page 1066: ...tall first gear thrust washer Fig 45 Washer is tight fit on shaft Either heat washer in oven to ease installation or use pipe tool or brass drift to press washer onto shaft and against gear FIRST GEAR Fig 45 First Gear Thrust Washer Installation 15 Install first gear snap ring Fig 46 Do not overspread snap ring to install it Also be sure snap ring is fully seated in shaft groove Tap ring into plac...

Page 1067: ...e synchro into reverse position for snap ring se lection if necessary Fig 49 Fifth Reverse Synchro Snap Ring Installation 21 Install fifth gear bearing halves on output shaft Fig 50 Use petroleum jelly to hold bearing halves in place 22 Install blocker ring in fifth reverse synchro sleeve Fig 50 23 Install fifth gear Fig 50 SYNCHRO SLEEVE J9321 316 Fig 50 Fifth Gear Bearings And Blocker Ring Insta...

Page 1068: ...Install reverse idler shaft part way into case Fig 52 Fig 52 Idler Shaft Installed Part Way In Case fin Installation Sequence 3 Position thrust washer at each end of idler gear and install gear assembly in case Fig 53 Be sure slots in thrust washers face outward as idler gear roll pins fit in these slots 4 Align idler shaft pin holes and push idler shaft into place in gear and washers IDLER GEAR F...

Page 1069: ... and thrust washers 4 Install rear pin in idler gear and shaft Then install front pin 5 Check idler gear thrust washer clearance Fig 54 as follows a Check clearance between each thrust washer and idler gear with feeler gauge b Clearance should be 0 05 0 25 mm 0 002 0 010 in 6 If clearance is not within specified limits re move idler gear and replace thrust washers Use new pins when gear and washer...

Page 1070: ...nec essary Use shop press to install bearing USE SOCKET AS INSTALLER TOOL SEAL SEATED IN RETAINER RETAINER J9321 327 Fig 61 Input Shaft Seal Installation 3 Install input shaft Rotate shaft so flats on clutch teeth are facing downward Then install shaft in case 4 Install output shaft and geartrain assembly in case Fig 62 Fig 62 Output Shaft And Geartrain Assembly Installation 5 Install front bearin...

Page 1071: ... Use wood blocks to support transmission on either side of front bearing retainer 2 Tap output shaft and countershaft rear bearing races into place Be sure races are seated on bear ings 3 Measure distance from top each of rear bearing race to case surface with depth gauge Figs 65 and 66 Measurements reflect amount of bearing race that extends above rear surface of case Record these measurements as...

Page 1072: ...AFT BEARING SHIMS REAR RETAINER J9321 325 Fig 69 Preload Shim Location 2 On 2 wheel drive transmissions install new output shaft seal in retainer Then install speedome ter gear and spacers on output shaft Fig 70 3 Install rear retainer on gear case Do not dis place preload shims when installing retainer 4 Apply Mopar or Loctite thread locker to rear retainer bolts Then install and tighten bolts to...

Page 1073: ...er to shift cover bolts Then install and tighten bolts to 22 30 N m 16 22 ft lbs torque 10 Place transmission in level position and in stall drain plug Tighten plug to 47 N m 35 ft lbs 11 Fill transmission to bottom edge of fill plug hole with Mopar 5W 30 engine oil 12 Install and tighten fill plug to 47 N m 35 ft lbs torque 13 Install backup light switch in shift cover if re moved 14 Mount transm...

Page 1074: ...OVERHAUL 46RH 278 G E N E R A L I N F O R M A T I O N 3 2 R H 3 6 R H 3 7 R H INDEX page Components Unique to 37RH Diesel Transmission 76 Description 73 Recommended Fluid 76 page Torque Converter 76 Transmission Hydraulic Control System 76 Transmission Identification 76 DESCRIPTION Chrysler 32RH 36RH 37RH transmissions are three speed fully automatic units with a planetary gear system Figs 1 and 2...

Page 1075: ... 4 FRONT PLANETARY GEAR SET FLEXIBLE DRIVE PLATE Fig 1 Automatic Transmission 32RH PR225 ...

Page 1076: ......

Page 1077: ...etary gear car riers in the 37RH are heavy duty components The transmission planetary carriers have four pinion gears The carrier in the overdrive compounder has five pinion gears Clutch Packs Front and rear clutch packs used in the 37RH con tain 4 discs and 5 steel plates Governor Weight Assembly The governor weight assembly is made of alloyed brass The diesel weight assembly is easily identified...

Page 1078: ...verter clutch valve applies the converter modulated clutch when supplied with line pressure through the converter clutch solenoid The solenoid is controlled by and connected to the powertrain control module through a connector in the transmission case Electronic control of converter clutch engagement includes disengagement at closed throttle during warmup and during part throttle acceleration Non ...

Page 1079: ...ovided by the clutches bands overrunning clutch and plan etary gear set in the transmission Fourth gear range is provided by the overdrive unit Overdrive ratio is 0 69 1 The overdrive unit contains an overdrive clutch di rect clutch planetary gear set and overrunning clutch The overdrive clutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear The governo...

Page 1080: ......

Page 1081: ...TORQUE CONVERTER VALVE BODY Fig 2 46RH Transmission And Overdrive Unit ...

Page 1082: ...diesel 46RH is made of alloyed brass The diesel weight assembly is easily identified by the distinctive gold color of the alloyed material The heavier weight assembly pro vides the shift points needed to offset lower operating speeds of a diesel engine The alloyed weight assembly is unique to the diesel 46RH It is not interchangeable with the weight as semblies used in gas engine versions Diesel T...

Page 1083: ...clutch sliding hub and drum are splined to the annulus gear for direct drive For coasting or reverse gear power flows only through the direct clutch A timing valve disengages the torque converter clutch prior to a 4 3 downshift The clutch solenoid engagement valve and timing valve are actuated in fourth gear range 3 4 Shift Sequence The overdrive clutch is applied in fourth gear only The direct cl...

Page 1084: ...w control clutch band application and lubrication 42RH 46RH system operation is similar to that de scribed in the 32RH 36RH 37RH General Informa tion section The main difference being fourth gear operation which is covered here Pressure Regulation The pressure regulator valve maintains line pres sure The amount of pressure developed is controlled by throttle pressure which is dependent on the de g...

Page 1085: ...is and test section During converter clutch engagement in fourth gear the valve supplies full line pressure directly to the clutch The increased pressure available at the clutch provides smooth shifting and positive engage ment The 3 4 upshift causes the boost valve to increase line pressure to the overdrive clutch Pressure also increases with throttle opening This ensures positive clutch engageme...

Page 1086: ...at dash switch and transmission case Turn control switch to ON position before proceeding 4 Road test and note transmission operating characteristics page Gearshift Linkage 87 General Information 85 Hydraulic Pressure Test 88 Overdrive Fourth Gear Electrical Controls 86 Preliminary Diagnosis 85 Road Test 87 Throttle Valve Cable 86 a If acceleration is sluggish or if abnormal throttle opening is ne...

Page 1087: ...level engine coolant entering the fluid internal failure that generates debris overheat that generates sludge fluid breakdown failure to reverse flush cooler and lines after re pair failure to replace contaminated converter after re pair The use of non recommended fluids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid...

Page 1088: ...ly The overdrive clutch is applied only in fourth gear and the overdrive direct clutch and overrunning clutch are applied in all ranges except fourth gear For example If slippage occurs in first gear in D and 2 range but not in 1 range the transmission overrunning clutch is slipping Similarly if slippage occurs in third and fourth gear the rear clutch is slipping However if slippage only occurs in...

Page 1089: ...r of the case Fig 3 The governor pressure port is at the left side of the extension housing Fig 4 On 42RH 46RH transmissions the governor and overdrive clutch pressure ports are at the rear of the case Fig 5 Hydraulic test pressures range from a low of one psi 6 895 kPa governor pressure to 300 psi 2068 kPa at the rear servo pressure port in reverse Two gauges are needed for the pressure test Use ...

Page 1090: ...essure and front servo ports Fig 3 Either pressure test gauge can be used at either port 2 Start and run engine at 1600 rpm for this test 3 Move selector lever two detents rearward from full forward position This is D range 4 Read pressures on both gauges as transmission throttle lever is moved from full forward to full rear ward position 5 Line pressure should be 54 60 psi 372 414 kPa with thrott...

Page 1091: ...LOW ANYONE TO STAND IN FRONT OF THE VEHICLE DURING A STALL TEST ALWAYS BLOCK THE FRONT WHEELS AND APPLY THE SERVICE AND PARKING BRAKES DURING THE TEST STALL TEST PROCEDURE 1 Connect tachometer to engine 2 Check and adjust transmission fluid level 1EST CONDITION INDICATION Line pressure O K during any one test Pump and regulator valve O K Line Pressure O K in R but low in D 2 1 Leakage in rear dutc...

Page 1092: ...or low speed acceleration Stall Speed Normal If stall speeds are normal but abnormal throttle opening is required to maintain highway speeds the converter overrunning clutch is seized and the torque converter must be replaced Converter Noise During Test A whining noise caused by fluid flow is normal during a stall test However loud metallic noises in dicate a damaged converter To confirm that nois...

Page 1093: ...e posited on the housing and not on the converter j PUMP PUMP PUMP Fig 9 Typical Converter Homing Leak Paths LEAK DIAGNOSIS PROCEDURE 1 Raise rear of vehicle and allow accumulated fluid to drain out of converter housing 2 Check and adjust transmission fluid level 3 Raise vehicle Remove converter housing dust cover and wipe as much fluid as possible from con verter housing 4 Fabricate test probe fr...

Page 1094: ...D OR BRAZE BREAK EDGE 1 16 MIN MATERIAL 1 7 8 INCH O D THIN WALLED STEEL TUBING AND 1 8 INCH STEEL DISC OUTSIDE OF OPEN END FOR THIS DISTANCE ON TUBE RN779 The strap attaching hole positions are approximate only Measure hole position on the converter housing before drilling The pump vent tool is made from 6 35 mm 1 4 in rod and 4 75 mm 3 16 in plate Figs 16 17 The fabricated tools can all be made ...

Page 1095: ...d 3 Remove oil pump and seal Inspect pump hous ing drainback and vent holes for obstructions Clear holes with solvent and wire COOLER LINE FITTING RY254 Fig 19 Pressurizing Transmission 4 Inspect pump bushing and converter hub If bushing is scored replace it If converter hub is scored either polish it with crocus cloth or replace converter if scoring is severe 5 Install new pump seal O ring gasket...

Page 1096: ...arts provide general information on a variety of transmission overdrive unit and con verter clutch fault conditions The Transmission Unit diagnosis charts apply to all transmission models The Overdrive Unit charts apply to the four speed transmissions only The hydraulic flow diagrams outline transmission fluid flow and hydraulic circuitry The flow diagrams also provide basic working pressures for ...

Page 1097: ...ssures 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 converter and flush cooler and lines before installing new converter 11 Remove disassemble and repair transmission as necessary DELAYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Engine idle speed too low 2 Low fluid level 3 Gearshift link...

Page 1098: ...erhaul may be necessary 6 Drain fluid to correct level if overfilled Iffluidis 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 operation disassemble and repair transmission as needed 8 Adjust band NO REVERSE D RANGES OK 1 Gearshift linkage is either out of adjustment or damaged...

Page 1099: ...E VEHICLE WILL NOT MOVE 1 Low fluid level 2 Gearshift linkage loose damaged or misassembled 3 Failure of driveline component such as U joint axle shaft transfer case component etc 4 Low fluid pressure due to worn or damaged oil pump 5 Transmission internal component damaged 6 Valve body malfunction seized valve damaged manual lever valve body screws loose or overtightened causing distortion and bi...

Page 1100: ...roken or seal worn 6 Clutch or servo malfunction leaking seals or worn plates 7 Overrunning clutch worn not holding slips in 1 only 1 Add fluid and check for leaks 2 Check for bad pump gasket or seals dirt between pump halves and loose pump bolts or defective O ring at filler tube 3 Adjust linkage 4 Perform hydraulic and air pressure tests to determine cause 5 Inspect and repair as necessary 6 Air...

Page 1101: ...ut of adjustment 2 Front band out of adjustment 3 Governor valve stuck closed loose output shaft support or governor housing bolts worn pump leaking seal rings or valve body problem i e stuck 1 2 shift valve or governor plug 4 Clutch or servo malfunction 1 Adjust linkage or cable Repair linkage of worn or damaged Relace damaged cable 2 Adjust band 3 Check line and governor pressures to determine c...

Page 1102: ...nspect clutch repair as required GROWLING GRATING OR SCRAPING NOISES 1 Planetary gear set broken or seized 2 Overrunning clutch worn seized or broken 3 Oil pump components scored binding or broken 4 Output shaft bearing or bushing damaged 5 Faulty clutch operation 6 Governor support park gear binding or seal rings broken 7 Front and rear bands out of adjustment 1 Check for debris in oil pan and re...

Page 1103: ...ittings 5 Valve body manual lever shaft seal 6 Pressure port plug loose 7 Rear bearing access plate 8 Gasket damaged or bolts are loose 9 Adapter extension gasket damaged 10 Neutral switch 11 Converter housing area 12 Cooler line fittings and hoses 13 Pump seal 14 Torque converter 1 Replace both adapter seals 2 Tighten pan screws to 150 inch pounds if leaks persist replace gasket do not overtighte...

Page 1104: ...e ratio etc If vehicle is not so equipped it should not be used for severe service operation 2 Drain fluid change filter and install auxiliary cooler 3 Cut down on idling time shift into neutral every so often and run engine at 1000 rpm to help circulate fluid through cooler 4 Be sure vehicle is properly equipped to handle load do not tow Class Ill type loads with a vehicle that is only rated for ...

Page 1105: ... is mandatory after a failure of the converter lockup clutch 2 Incorrect fluid used in transmission 3 Main cooler in radiator is cracked allowing engine coolant to enter transmission 4 Severe overload results in overheat fluid break down and accelerated wear especially in high ambient temperatures Most frequent causes are Vehicle is not properly equipped for heavy duty service Tow vehicle and boat...

Page 1106: ... S 11 Transmission fluid temperature sensor fault if equipped 12 Overdrive piston seal failure 13 Wrong overdrive piston spacer 11 Replace sensor 12 Replace both seals 13 Remove unit check end play and install correct spacer 14 Low hydraulic pressure 14 Pressure test transmission to determine cause 15 Set reset module faulty 15 Replace module if equipped S U P S IN OVERDRIVE FOURTH GEAR 1 2 Low fl...

Page 1107: ...r 4 Remove unit and rebuild clutch pack 5 Replace T P S 6 Disassemble transmission and replace orifice 3 4 UPSHIFT O C C U R S BEFORE C O M P L E T I O N O F 2 3 UPSHIFT 1 Overdrive solenoid connector or wiring problem 2 Overdrive solenoid malfunction 3 Coolant temperature or T P S malfunction 4 Valve body malfunction 5 Powertrain control module malfunction 1 Test connector and wiring for loose co...

Page 1108: ...ace solenoid if seized or shorted 4 Remove valve body remove and disassemble lower housing and 3 4 accumulator housing replace seals and clean valves as necessary be sure all valves slide freely in bores 5 Check operation with DRB II scan tool replace controller only if faulty 6 Replace T P S 7 Check coolant and transmission temperature sensors speed sensor and overdrive control switch N O 4 3 D O...

Page 1109: ...ing and connectors as necessary NOISY OPERATION IN FOURTH GEAR ONLY 1 Overdrive clutch discs plates or snap rings damaged 2 Overdrive piston or planetary thrust bearing brinnelled installed wrong or damaged 3 Output shaft bearings brinnelled scored damaged 4 Planetary gears worn chipped damaged 5 Overdrive unit overrunning clutch rollers rough scored or output bushings are worn 1 Remove unit and r...

Page 1110: ... bearing failure 1 Remove and disassemble unit check clutch pack and replace spring 2 Disassemble unit and rebuild clutch pack 3 Adjust band 4 Air pressure test clutch operation remove and rebuild if necessary 5 Disassemble geartrain and replace bearings NO 1 2 OR 2 3 UPSHIFT HAS LOW AND REVERSE ONLY 1 Governor component loose worn or damaged 1 Remove and disassemble unit replace worn or damaged g...

Page 1111: ...OUT OF BALANCE X FAILED CONVERTER CLUTCH X X X LEAKING TURBINE HUB SEAL X X ALIGN EXHAUST SYSTEM X X TUNE ENGINE X X X FAULTY INPUT SHAFT OR SEAL RING X X THROTTLE CABLE MISADJUSTED X X Z 0 o z o CONVERTER CLUTCH WILL NOT ENGAGE CLUTCH WILL NOT DISENGAGE STAYS ENGAGED AT TOO LOW A SPEED IN 4th GEAR LOCKS UP OR DRAGS IN LOW OR SECOND STALLS OR IS SLUGGISH IN REVERSE CHATTER DURING CLUTCH ENGAGEMENT...

Page 1112: ......

Page 1113: ...HYDRAULIC FLOW IN D FIRST GEAR 32RH 36RH 37RH GOVERNOR VALVE r REAR SERVO FRONT SERVO ACCUMULATOR LOCK UP ONLY FRONT CLUTCH UBRICATION SELECTOR LEVER IN DRIVE BREAKAWAY HALF THROTTLE U 9 0 2 M 6 1 ...

Page 1114: ...ONT CLUTCH ACCUMULATOR 3 OIL FILTER LINE 75 PSI PUMP SUCTION y THROTTLE 40 PSI WMM GOVERNOR 6 75 PSI CONVERTER 5 75 PSI LUBRICATION 5 30 PSI WMM j 1 2 SHIFT CONTROL M 25 35 PSI i SELECTOR LEVER IN TORQUE CONVERTER DRIVE SECOND HALF THROTTLE TO LUBRICATION FRONT CLUTCH LUBRICATION J9021 162 ...

Page 1115: ...GOVERNOR VALVE HYDRAULIC FLOW IN D THIRD GEAR 32RH 36RH 37RH REAR CLUTCH J T X I L FRONT CLUTCH FRONT U J SERVO ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH LUBRICATION J9021 163 ...

Page 1116: ...W IN D THIRD GEAR AFTER CONVERTER CLUTCH ENGAGEMENT 32RH 36RH 37RH GOVERNOR VALVE REAR SERVO ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH IMBRICATION SELECTOR LEVER IN TORQUE CONVERTER DRIVE LOCK UP J902M64 ...

Page 1117: ...DURING PART THROTTLE 3 2 KICKDOWN 32RH 36RH 37RH fs9 ACCUMULATOR LOCK UP ONLY 1 2 SHIFT CONTROL 55 70 PSlk 3 GOVERNOR 6 40 PSI SELECTORLEVER IN DRIVE TORQUE CONVERTER PART THROTTLE KICKDOWN BELOW 40 M P H 33 GO 33 30 4 m 30 J9021 165 ...

Page 1118: ...URING FULL THROTTLE 3 2 KICKDOWN 32RH 36RH 37RHJ REAR SERVO I T FRONT SERVO ACCUMULATOR LOCK UP ONLY 1 2 SHIFT CONTROL P 5 r r i 55 70 ir A GOVERNOR 30 73 PSI f SELECTOR LEVER IN DRIVE TORQUE CONVERTER FULL THROTTLE KICKDOWN J902M66 ...

Page 1119: ...6RH 37RH ro REAR CLUTCH REAR SERVO FRONT CLUTCH FRONT SERVO ACCUMULATOR l M l v X X v I OIL FILTER FRONT CLUTCH UBRICATION SELECTOR LEVER IN TORQUE CONVERTER TWO MANUAL SECOND I B U w S S S i CLOSED THROTTLE J9021 167 O O ao oo 00 m r O 30 c 3 o 30 30 3 r o 30 30 r ...

Page 1120: ...VALVE HYDRAULIC FLOW IN 1 POSITION MANUAL LOW 32RH 36RH 37RHf REAR SERVO r r t m FRONT SERVO REAR CLUTCH FRONT CLUTCH ACCUMULATOR FRONT 2CLUTCH LUBRICATION SELECTOR LEVER IN ONE MANUAL LOW CLOSED THROTTLE 21 168 ...

Page 1121: ...GOVERNOR VALVE HYDRAULIC FLOW IN REVERSE 32RH 36RH 37RH REAR CLUTCH R E A R SERVO FRONT CLUTCH FRONT SERVO ACCUMULATOR FRONT iCLUTCH UBRICATION SELECTOR LEVER IN REVERSE ...

Page 1122: ...HYDRAULIC FLOW IN NEUTRAL 42RH 46RH GOVERNOR ...

Page 1123: ......

Page 1124: ...HYDRAULIC FLOW IN REVERSE 42RH 46RHJ ACCUMULATOR J9321 197 IN3 ...

Page 1125: ... ACCUMULATOR LENE PRESSURE 55 62 psi 1 2 SHIFT CONTROL 25 35 pslj GOVERNOR PRESSURE C 30 psi CONVERTER LUSE PRESSURE 5 57 psi PUMP SUCTION SELECTOR LEVER IN MANUAL I FIRST GEAR CLOSED THROTTLE J o 30 Z CO CO f CO i as ac 3 cn C c3 ro as ac as J9321 198 ...

Page 1126: ...HYDRAULIC FLOW IN MANUAL SECOND 42RH 46RHJ j LINE PRESSURE j 55 62 psi 1 2 SHIFT CONTROL 25 35 psi GOVERNOR PRESSURE 6 57 psi CONVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION ...

Page 1127: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR 42RH 46RH J9321 200 ...

Page 1128: ...ND GEAR 42RH 46RH SELECTOR LEVER IN DRIVE D SECOND GEAR PART THROTTLE LINE PRESSURE 57 94 psi GOVERNOR PRESSURE 0 57 psi 1 2 SHIFT CONTROL 25 70 psi THROTTLE PRESSURE 0 94 psi COVERTER LUBE PRESSURE 5 57 psi PUMP SUCTION J9321 201 ...

Page 1129: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR 42RH 46RH ...

Page 1130: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR OVERDRIVE 42RH 46RH G O V E R N O R VALVE J9321 203 r3 ...

Page 1131: ...TF Plus type 7176 Use Mopar Dexron II only when ATF Plus is not readily available page Park Lock Service 32RH 36RH 37RH 138 Park Neutral Position Switch 134 Rear Band Adjustment 133 Speedometer Service 134 Transmission Cooler Service 140 Transmission Throttle Cable Adjustment Cummins Diesel Engine 132 Transmission Throttle Cable Adjustment Gas Engines 131 Valve Body Control Pressure Adjustments 14...

Page 1132: ...ing swivel lock screw Be sure swivel turns freely on rod 5 Verify that valve body shift control lever is in Park detent Move lever fully rearward to check 6 Adjust swivel position on the shift rod to a ob tain free pin fit in torque shaft lever Fig 1 Then tighten swivel lock screw to 10 N m 90 in lbs torque 7 Check adjustment by starting engine in Park and Neutral Engine should start in these posi...

Page 1133: ...ocking pawl on the cable sheath Fig 5 The rear of the cable is connected to the transmis sion throttle valve lever The forward end of the ca ble is attached to a pin on the engine throttle cam RETURN SPRING BRACKET CABLE BRACKET THROTTLE VALVE LEVER ROTATE LEVER IN DIRECTION OF ARROW FOR ADJUSTMENT THROTTLE VALVE CABLE J9221 64 Fig 4 Throttle Cable Attachment At Transmission Gas Engine Fig 6 Rotat...

Page 1134: ...rew locknut Then back locknut off 4 5 turns Also be sure adjusting screw turns freely in case Lubricate screw threads if necessary 3 Tighten band adjusting screw to 8 Nrm 72 in J9121 535 Fig 7 Transmission Throttle Cable Locking Pawl Position Diesel Engine lbs torque If Adapter Extension C 3705 must be used to reach adjuster screw tighten screw to only 5 N m 47 50 in lbs torque 4 Back off adjustin...

Page 1135: ... into adapter with Installer Tool C 4004 until tool bottoms Fig 10 ADAPTER AND PINION INSTALLATION AND ADJUSTMENT CAUTION Before installing the pinion and adapter assembly make sure the adapter flange and flange seat in the housing are perfectly clean Dirt or for eign material on these surfaces will cause misalign ment resulting in pinion gear damage 1 Thoroughly clean adapter flange and flange se...

Page 1136: ...e Tighten switch to 34 Nnn 25 ft lbs torque 6 Test continuity of new switch with 12 volt test lamp 7 Connect switch wires and lower vehicle 8 Top off transmission fluid level EXTENSION HOUSING YOKE SEAL REPLACEMENT 1 Raise vehicle 2 Mark propeller and axle yokes for alignment reference Then disconnect and remove shaft 3 Remove old seal with Remover Tool C 3985 Fig 14 SWITCH RH266 Fig 13 Park Neutr...

Page 1137: ...missions do not have this second snap ring 3 Install new bearing on shaft Be sure locating ring groove in outer circumference of bearing is to ward front Fig 17 4 Install rear bearing retaining snap ring Fig 16 However do not install the locating ring on the bearing The locating ring goes in the extension housing The ring is not seated in the rear bearing until the housing is installed EXTENSION H...

Page 1138: ...vernor body 4 Remove large snap ring from weight end of gover nor body and remove governor weight assembly 5 Remove snap ring from governor weight and remove inner weight and spring from outer weight Fig 21 6 Remove snap ring retaining governor body and park gear on output shaft Fig 22 7 Slide governor body and park gear assembly off output shaft 8 Remove bolts attaching governor body to gear and ...

Page 1139: ...move valve body Refer to Valve Body Service procedures in this section COMPONENT INSPECTION Inspect the sprag shaft for scores and free move ment in the housing and sprag Inspect the sprag and control rod springs for distortion and loss of tension Inspect the square lug on the sprag for broken edges Check the lugs on the park gear for damage Inspect the ball on the end of the control rod for nicks...

Page 1140: ...H Fig 26 Valve Body Assembly 3 Speed Transmission move past sprag when valve body is installed Rotate output shaft to verify sprag engagement 5 Position accumulator spring between accumula tor piston and valve body 6 Position valve body on transmission and work park rod past sprag Be sure accumulator piston and spring remain in position 7 Hold valve body in position and install valve body attachin...

Page 1141: ...ases pressure RH258 Fig 27 Line Pressure Adjustment THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between the throttle le ver cam and kickdown valve Fig 28 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang...

Page 1142: ...s to flow at all cooler is plugged or damaged and should be replaced MAIN COOLER REPLACEMENT The main transmission cooler is located in the ra diator lower tank The cooler is not a serviceable component If the cooler is damaged in any way the radiator will have to be replaced AUXILIARY COOLER REPLACEMENT 1 Remove grille Also remove A C condenser for access if necessary 2 Remove brackets securing c...

Page 1143: ...t Fig 1 Note that bolt holes in crankshaft flange drive plate and torque converter all have one offset hole 10 Rotate crankshaft in clockwise direction until converter bolts are accessible Then remove bolts one at a time Rotate crankshaft with socket wrench on damper pulley bolt 11 Mark propeller shaft and axle yokes for as sembly alignment Then disconnect and remove pro peller shaft Fig 2 12 Disc...

Page 1144: ...ropeller shaft and axle yokes for assembly alignment 12 Disconnect and remove both propeller shafts Fig 2 13 Disconnect wires from park neutral position switch and transmission solenoids 14 Disconnect transmission gearshift rods and torque shaft assembly from brackets on transmission and frame rail 15 Disconnect throttle valve cable from transmis sion throttle lever 16 Remove transfer case skid pl...

Page 1145: ... torque converter and oil pump are used in 1993 42RH transmissions The new converter has a different style drive hub The hub was changed to accept the new design drive flats on the oil pump inner gear The drive flats replace the square lugs used previously If converter re placement should become necessary be sure to use the new style converter The new converter and oil pump are not interchangeable...

Page 1146: ...tempera ture at 200 250 F 93 C Allow ring gear to re main in oven for 15 to 20 minutes b BOILING WATER Place ring gear in shal low container Add water and heat for approxi mately eight minutes after water has come to a boil c STEAM Place ring gear on a flat surface and direct steam flow around gear for approximately 2 minutes 2 After ring gear is expanded by heating imme diately place gear in posi...

Page 1147: ... install the new seal Fig 9 On 36RH 37RH 46RH pumps use Installer Tool C 3860 A Fig 9 To use the tool place the seal in the pump opening with the seal lip facing inward Then tap the seal into place with the installer tool Fig 9 Tool Han dle C 4171 may be used with the installer tool if de sired J 9 3 2 M 8 0 Fig 9 Pump Seal Installation TRANSMISSION AND TORQUE CONVERTER INSTALLATION 2 WHEEL DRIVE ...

Page 1148: ...hat was disconnected Old 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 into lever and to snap rod into grommet 19 Connect gearshift linkage and transmission throttle cable to levers on manual valve shaft 20 Connect wires to park neutral position switch transmission solenoid s and oxygen sensor Be sure transmission har...

Page 1149: ...e moved or moved for service access 28 Align and install propeller shaft Tighten shaft U joint clamp bolts to 19 Nnn 170 in lbs torque 29 Lower vehicle 30 Fill transmission with Mopar ATF Plus Type 7176 or Mopar Dexron II if ATF Plus is not readily available 31 Check and adjust gearshift and throttle valve linkage if necessary TRANSMISSION AND TORQUE CONVERTER INSTALLATION 4 WHEEL DRIVE CAUTION Th...

Page 1150: ...h surface in the converter If new bolts are required use the bolts specified in this procedure and in the parts book only 21 Verify converter bolt length Bolt measure ment is from bottom underside of bolt head to end of bolt threads On 9 5 in 3 lug converter bolts should be 11 7 mm 0 46 in long On 9 5 in 4 lug converter bolts should be 13 2 mm 0 52 in long On 10 0 in 4 lug converter bolts should b...

Page 1151: ...equires service refer to Overdrive unit Overhaul section Fig 15 Removing Installing Overdrive Attaching Bolts 13 Remove and retain overdrive piston thrust bearing Bearing may remain on piston or in clutch hub during removal 14 Position drain pan on workbench 15 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 16 Examine fluid for clutch material or metal fragments If...

Page 1152: ... realign the splines with Tool 6227 2 12 Align slip fit governor tubes in piston retainer and work compounder unit forward on intermediate shaft and seat unit against transmission case 13 Install bolts attaching overdrive unit to trans mission Tighten bolts in diagonal pattern to 34 N m 25 ft lbs 14 Install crossmember 15 On 4WD models install transfer case and con nect shift linkage and distance ...

Page 1153: ...t ing ring access cover from housing Fig 2 5 Spread rear bearing locating ring with parallel jaw snap ring pliers Fig 2 Then work extension housing off rear bearing and output shaft Remove housing gasket after removing housing 6 Remove rear bearing and snap ring from out put shaft Fig 3 page Support Overhaul 158 Planetary Gear Train Output Shaft Overhaul 171 Rear Clutch Overhaul 168 Rear Servo and...

Page 1154: ...etainer This prevents front rear clutches from coming out with pump and possibly damaging clutch or pump components TRANSMISSION OVERHAUL 32RH 2 1 1 1 3 Fig 7 Removing Installing Valve Body 32RH Fig 8 Removing Installing Accumulator Piston And Spring 32RH Fig 9 Removing Installing Front Band Reaction Pin Access Plug 32RH 15 Remove oil pump bolts 16 Thread bolts of Slide Hammer Tools C 3752 into th...

Page 1155: ...ever Fig 13 Fig 13 Removing Installing Front Band Lever 32RH 22 Slide front band rearward and onto driving shell Band will not be removed until after front rear clutch removal 23 Remove front and rear clutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 14 J9121 124 Fig 14 Removing Front Rear Clutch Assemblies 32RH 24 Lift front clutch off rear clutc...

Page 1156: ...t and remove valve and shaft from governor body Fig 19 Reinstall E clip on shaft to avoid losing it 30 Loosen bolts attaching governor body to park gear 31 Mark position of governor body on park gear with center punch or scriber 32 Remove governor body and park gear as as sembly Fig 20 Work park gear out of rear support and slide assembly off output shaft DRIVING SHELL J9121 127 Fig 17 Front Band ...

Page 1157: ...ip pin Then twist and pull pins to remove them as shown 37 Remove rear band lever and strut 38 Mark position of rear support for assembly reference Fig 24 Use scriber or center punch to mark case and support 39 Remove rear support bolts and remove support from low reverse drum and case Fig 25 Keep rear Fig 23 Removing Rear Band Reaction Pins 32RH support bolts together for assembly reference 40 Re...

Page 1158: ... not excercised 45 Remove compressor tools and remove front servo rod guide spring and servo piston Fig 27 Compressing Front Servo Rod Guide 32RH 46 Compress rear servo spring retainer about 1 16 in with C clamp and Tool C 4470 or SP 5560 Fig 28 Valve Spring Compressor C 3422 A can also be used to compress spring retainer 47 Remove rear servo spring retainer snap ring Then remove compressor tools ...

Page 1159: ...ges with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear Do not use shop towels or rags to dry the case or any other transmission component unless they are m a d e from lint free materials Lint will readily adhere to case surfaces and transmission components and will circulate throughout the transmission after assembly A sufficient quan tity of lin...

Page 1160: ...cam bolts d Install rear support and support attaching bolts e Check low reverse drum rotation Drum should rotate freely in clockwise direction and lock when turned in counterclockwise direc tion as viewed from front of case LOW REVERSE DRUM CLUTCH RACE ON HUB OF DRUM OVERRUNNING CLUTCH J9121 135 Fig 32 Temporary Assemby Of Clutch And Drum To Check Operation 32RH 4 Note component position for asse...

Page 1161: ...ercompressed Replace the clip if it becomes bent or distorted Do not straighten and reuse the clip if this occurs Be sure a replacement sprag is installed so the sprag locking lug will face the park gear Fig 37 Also be sure the spring is correctly positioned as shown Fig 37 The sprag may not retract if the spring is improperly installed GOVERNOR AND PARK GEAR OVERHAUL GOVERNOR PARK GEAR DISASSEMBL...

Page 1162: ...hich has been spotfaced for governor valve end clear ance The new aluminum valve must only be used with an output shaft that has a spotface In addition the governor body and spotfaced side of the valve shaft hole in the output shaft must be indexed Check condition of the park gear seal rings ring grooves and gear teeth Fig 39 Replace the gear as an assembly if the teeth or ring grooves are worn or...

Page 1163: ...Fig 43 Pump Gear Removal 32RH OIL PUMP AND REACTION SHAFT SUPPORT CLEANING AND INSPECTION Clean pump and reaction shaft support components with solvent and dry them with compressed air Inspect the pump housing and support components Replace the housing or support if the seal ring grooves or machined surfaces are worn scored pit ted or damaged Replace the pump gears if pitted worn chipped or damage...

Page 1164: ...ump Gear End Clearance 32RH FEELER GAUGE INNER GEAR J9321 216 Fig 46 Measuring Pump Housing To Inner Gear Clearances OUTER GEAR If Fig 47 Measuring Pump Gear Tooth Clearance REPLACING OIL PUMP BUSHING 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 Fig 48 2 Install new pump bushing with Tool Handle C 4171 and Bushing Installer SP 5117 Fig 48 Bushing should be flush with p...

Page 1165: ...and SP 5325 Fig 50 6 Slide new bushing onto Installer Tool SP 5325 7 Position reaction shaft support upright on a clean smooth surface 8 Align bushing in bore Then tap bushing into place until Bushing Installer SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing SPECIAL TOOL SP 1191 SPECIAL TOOL C 4171 SPECIAL _ U T Q Q L SP 5325 BUSHING INSTALLATION J9221 243 Fig 50...

Page 1166: ... bolts to required torque as follows a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible lrJ9321 221 Fig 54 Assembling Reaction Shaft Support And Pump Housing 32RH b Secure pump assembly in case with 2 or 3 bolts or with pilot studs c Tighten support to pump bolts to 20 N m 15 ft lbs d Remove pump assembly from transmission case 12 ...

Page 1167: ...r check ball Fig 58 Be the check ball moves freely in its seat RETAINER CHECK BALL SPRING RETAINER RETAINER SNAP RING J912M47 Fig 57 Compressing Front Clutch Piston Spring 32RH FRONT CLUTCH INSPECTION Clean the front clutch components in solvent and dry them with compressed air only Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to the component ...

Page 1168: ...ip of piston and retainer seals with liberal quantity of Door Eze or petroleum jelly Then lubricate retainer hub bore and piston with trans mission fluid 4 Install clutch piston in retainer Fig 60 Use twisting motion to seat piston in bottom of retainer Do not attempt to push the piston straight in This could fold the seals over causing leakage and clutch slip 5 Position spring on clutch piston Th...

Page 1169: ... press and suitable size press tool Fig 64 8 Remove input shaft front rear seal rings REAR CLUTCH INSPECTION Clean the clutch components with solvent and dry them with compressed air Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to component surfaces and could restrict or block fluid passages after assembly Replace the clutch discs if warped wor...

Page 1170: ...s and steel plates in transmis sion fluid 2 Install new seal rings on clutch retainer hub and input shaft Fig 65 a Be sure clutch hub seal ring is fully seated in groove and is not twisted b Note that input shaft front seal ring is teflon and rear seal ring is metal Fig 66 Be sure cham fered ends of teflon ring are properly joined and that ends of rear ring are securely hooked together Lubricate b...

Page 1171: ...owed by a clutch disc until entire clutch pack is in stalled Total of 4 discs and 3 plates are required Fig 62 12 Install top pressure plate Fig 62 13 Install selective snap ring Fig 62 Be sure snap ring is fully seated in retainer groove 14 Measure clutch pack clearance Fig 69 Clearance should be 0 64 1 14 mm 0 025 0 045 in If clearance is incorrect steel plates discs snap ring and pressure plate...

Page 1172: ...ear sets if gears pinion pins or carrier are damaged in any way Replace the annu lus gears and supports if either component is worn or damaged Inspect the geartrain spacers thrust plates snap rings and thrust washers Replace any of these parts that are worn distorted or damaged Do not attempt to reuse these parts Inspect the output shaft carefully Pay particular attention to the machined bushing b...

Page 1173: ... gear on output shaft Fig 73 Verify that assembly is fully seated on shaft Fig 73 installing Assembled Rear Annulus And Planetary Gear On Output Shaft 32RH 6 Install front thrust washer on rear planetary gear Fig 74 Use enough petroleum jelly to hold washer on gear 7 Install spacer on sun gear Fig 75 8 Install thrust plate on sun gear Fig 76 Note that driving shell thrust plates are interchangeabl...

Page 1174: ...g shell and install sun gear lock ring Be sure ring is fully seated in sun gear ring groove Fig 79 12 Install assembled driving shell and sun gear on output shaft Fig 80 13 Install rear thrust washer on front planetary gear Fig 81 Use enough petroleum jelly to hold washer on gear and be sure washer tabs are all prop erly seated 14 Install front planetary gear on output shaft and in driving shell F...

Page 1175: ...tioning Thrust Plate On Annulus Support 32RH 19 Install front annulus thrust washer Fig 84 Align flat on washer with flat on planetary hub Also be sure washer tab is facing forward 20 Install front annulus snap ring Fig 85 Use snap ring pliers to avoid distorting ring during in stallation Also be sure ring is fully seated 21 Install planetary selective snap ring with snap ring pliers Fig 86 Be sur...

Page 1176: ...part is worn or damaged Replace any servo component if doubt exists about its condition Do not reuse suspect parts SERVO PISTON SNAP GUIDE RING S E A L J912M72 Fig 88 Front Servo Components 32RH ASSEMBLING FRONT SERVO PISTON 1 Lubricate seal rings and O rings with petro leum jelly Lubricate other servo parts with trans mission fluid 2 Install new O ring on servo piston rod 3 Install new seal on pi...

Page 1177: ...m jelly Lu bricate other servo parts with transmission fluid BE SURE SEAL LIP IS TOWARD SERVO BORE REAR SERVO PISTON J9121 175 Fig 91 Installing Rear Servo Piston Seal 32RH VALVE BODY SERVICE AND ADJUSTMENT VALVE BODY DISASSEMBLY CAUTION Do not clamp any part of the valve body assembly Fig 92 in a vise This practice will dis tort the valve body and transfer plate resulting in valve bind Slide valv...

Page 1178: ...emove screws attaching converter clutch mod ule to valve body and remove module and connecting tube Fig 97 10 Turn valve body over so transfer plate is fac ing upward Fig 98 With valve body in this posi tion valve body check balls will remain in place and not fall out when transfer plate is removed 11 Remove screws attaching transfer plate to valve body Fig 98 SHUTTLE VALVE PARK END PLATE ROD Fig ...

Page 1179: ...move shuttle valve E clip and remove sec ondary spring and spring guides from end of valve Fig 102 19 Remove governor valve end plate Fig 103 20 Remove switch valve and pressure regulator valve from valve body Fig 103 Fig 100 Removing Converter Clutch Solenoid 32RH SEPARATOR J9121 Fig 101 Transfer And Separator Plates 32RH 21 Remove throttle valve and spring kickdown valve and detent and manual va...

Page 1180: ...y assembly Clean the valve body components in a parts clean ing solution only Do not use gasoline kerosene or any type of caustic solution Dry the parts with com pressed air Make sure all passages are clean and free from obstructions Do not use rags or shop towels to wipe off valve body components Lint from these materi als will adhere to the valve body components Lint will interfere with valve op...

Page 1181: ... practice will remove the special coating and cause the valves and plugs to stick and bind Inspect the valves and plugs for scratches burrs nicks or scores Also inspect the coating on the alu minum valves and plugs Fig 105 If the coating is damaged or worn through the valve or valve body should be replaced Aluminum valves and plugs must not be sanded or polished under any circumstances However min...

Page 1182: ...NECTING TUBE SHUTTLE VALVE COVER REGULATOR VALVE THROTTLE PRESSURE PLUG LINE PRESSURE ADJUSTING SCREW ADJUSTING SCREW BRACKET THROTTLE PRESSURE ADJUSTING SCREW SWITCH VALVE A N D SPRING PRESSURE REGULATOR VALVE A N D SPRING 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE PLUG ALUM GOVERNOR VALVE END PLATE MANUAL LEVER DETENT BALL A N D SPRING J9121 369 Fig 105 Valve Body Components 32RH Alum Indicates...

Page 1183: ...ly in a diagnonal pattern to 4 N m 35 in lbs torque 8 Assemble converter clutch module and valves Then install assembly on valve body Fig 108 9 Assemble regulator valve line pressure plug sleeve throttle plug and spring Fig 104 Insert as sembly in valve body and install end plate Tighten end plate screws to 4 N m 35 in lbs torqe 1 4 C H E C K B A L L S 6 11 32 C H E C K B A L L 1 J912M83 Fig 107 C...

Page 1184: ... over throttle lever and start man ual lever into valve body 26 Align manual lever detent with detent ball and align lever arm with manual valve Hold throt tle lever upward Then press down on manual lever until lever is fully seated 27 Install manual lever seal washer and retain ing E clip 28 Lubricate shaft of manual lever with light coat of petroleum jelly This will help protect seal lip when ma...

Page 1185: ...ricants can eventually block or restrict fluid passages and valve operation Use petroleum jelly only Do not force parts into place Most of the transmis sion components are easily installed by hand when properly aligned If a part seems extremely difficult to install it is either misaligned or incorrectly as sembled Also verify that thrust washers thrust plates and seal rings are correctly positione...

Page 1186: ...t into each hole Adjust cam position if necessary before proceeding 8 Install clutch cam bolts Note that cam bolts are shorter than rear support bolts Tighten cam bolts to 17 N m 150 in lbs torque 9 Lubricate overrunning clutch rollers with transmission fluid 10 Install rear band reaction pin Fig 105 Be sure pin is fully seated in case Fig 114 Overrunning Clutch And Rear Band Pin Installation 32RH...

Page 1187: ...m 20 Lubricate governor components and park gear seal rings with transmission fluid Fig 118 Installing Output Shaft Planetary Geartrain 32RH Fig 119 Aligning Seating Rear Planetary In Low Reverse Drum 32RH 21 Install governor filter in park gear and install governor body on gear Fig 120 Align governor body on gear using marks made at disassembly 22 Install new seal rings on hub of park gear Fig 12...

Page 1188: ...and in output shaft If valve shaft binds governor park gear is misaligned E CLIP 2 REQ D GOVERNOR VALVE SHAFT Fig 122 Installing Governor Valve And Shaft 32RH 26 Rotate output shaft until opposite end of gov ernor valve shaft is facing upward Then install re mainig E clip on governor valve shaft Fig 123 Be very sure both E clips are firmly seated on shaft GOVERNOR VALVE SHAFT J9121 188 Fig 123 Sec...

Page 1189: ... sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Fig 128 Installing Output Shaft Thrust Washer 32RH 33 Align drive teeth on rear clutch discs with small screwdriver Fig 129 This will make installa tion on front planetary easier 34 Raise front end of transmission upward as far as possible and support case with wood blocks...

Page 1190: ...nt band reaction pin part way into case Fig 131 39 Install front band lever strut lever pin and adjusting screw Fig 132 40 Tighten front band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still seated before continuing Fig 131 Installing Front Band And Reaction Pin 32RH BAND BAND Fig 132 Front Band Linkage Installation 32RH 41 Coat band lever pin access ...

Page 1191: ...ud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft lbs Fig 136 Installing Oil Pump And Reaction Shaft Support 32RH 48 Measure input shaft end play Fig 137 At tach dial indicator to converter housing Position in dicator plunger against input shaft and zero indicator Move input shaft in and out and record reading End play should be 0 56 2 31 m...

Page 1192: ...usting screws to 8 N m 72 in lbs c Back off front band adjusting screw 2 1 2 turns and rear band adjusting screw 4 turns d Hold each adjusting screw in position and tighten locknuts to 34 N m 25 ft lbs 61 Install new pan gasket on transmission and install oil pan Tighten pan bolts to 17 N m 13 ft lbs 62 Turn transmission over 63 Install new manual lever shaft seal in case Use 15 16 deep well socke...

Page 1193: ...case Then remove rear bearing snap ring access cover from housing Fig 2 4 Spread rear bearing locating ring with parallel jaw snap ring pliers Fig 2 Then work extension housing off bearing and output shaft Remove hous ing gasket after removing housing 5 Remove rear bearing and snap rings from out put shaft Fig 3 Note that two snap rings are used to retain bearing on 36RH 6 Remove throttle and manu...

Page 1194: ... gas ket is in good condition retain gasket and keep it with switch Fig 7 Neutral Switch Removal Installation 9 Remove three fluid filter attaching screws and remove filter Fig 8 Fig 8 Fluid Filter Removal installation 36RH 37RH 10 Remove hex head valve body attaching bolts Fig 9 Fig 9 Valve Body Attaching Bolt Locations 36RH 37RH 11 Lift valve body upward guide park rod out of case opening and re...

Page 1195: ...H 14 Remove oil pump and reaction shaft support assembly as follows a Tighten front band adjusting screw until band is tight around front clutch retainer Fig 13 This will prevent retainer from coming out with pump and possibly damaging clutch or pump com ponents b Remove oil pump bolts c Thread Slide Hammer Tools C 3752 into threaded holes in flange of oil pump housing Fig 14 Fig 13 Tightening Fro...

Page 1196: ...Fig 17 Front Band Linkage 36RH 37RH Fig 18 Removing Front Band 36RH 37RH 19 Remove front and rear clutch assemblies as a unit Fig 19 Set assemblies aside for disassembly and inspection after removal Fig 19 Removing Front And Rear Clutch Assemblies 36RH 37RH 20 Remove front band reaction pin and lever Start pin through lever and out of case bore Use pencil magnet to complete pin removal Fig 20 21 R...

Page 1197: ...vic ing the shaft and geartrain can be removed as a unit Fig 23 In this case simply remove the governor valve shaft governor and park gear and remove the complete assembly Fig 23 Removing Output Shaft And Planetary Geartrain 36RH 37RH 24 Remove planetary gear retaining snap ring from output shaft Fig 24 Retain snap ring if in good condition it is reusable Fig 24 Removing Planetary Snap Ring 36RH 3...

Page 1198: ...isassembling Front Planetary And Annulus Gears 36RH 37RH 27 Remove tabbed thrust washer from driving shell Fig 27 Note washer position for assembly ref erence Fig 27 Removing Driving Shell Thrust Washer 36RH 37RH 28 Remove sun gear and driving shell Fig 28 FRONT Fig 28 Removing Sun Gear And Driving Shell 36RH 37RH ...

Page 1199: ...r for annulus gear Fig 31 assembly reference Fig 29 Removing Rear Planetary Thrust Washer 36RH 37RH 30 Remove rear planetary gear from annulus gear Fig 30 J9121 30 Fig 30 Removing Rear Planetary Gear 36RH 37RH Fig 31 Removing Rear Planetary Plate 36RH 37RH 32 Remove rear annulus gear from Fig 32 J9121 31N Thrust output shaft J9121 32 Fig 32 Removing Rear Annulus Gear 36RH 37RH ...

Page 1200: ...rew 35 Remove snap ring securing low reverse drum to rear support Fig 34 J9221 7 Fig 35 Removing Low Reverse Drum 36RH 37RH 37 Note that overrunning clutch race will remain on splines of low reverse drum after removal Fig 36 The race is a permanent press fit on the hub splines Do not attempt to remove the race REAR BAND LOW REVERSE DRUM REAR SUPPORT OVERRUNNING CLUTCH RACE LOW REVERSE DRUM DRUM RE...

Page 1201: ...ig 39 41 Remove strut from rear band Keep strut with levers and pin for cleaning inspection and assembly reference RtAR BAND REACTION PIN Fig 39 Removing Rear Band Levers And Reaction Pin 36RH 37RH SELECT FIT PLANETARY SNAP RING FRONT ANNULUS SNAP RING SUPPORT SNAP RING ANNULUS GEAR SUPPORT FRONT ANNULUS GEAR FRONT ANNULUS THRUST WASHER DRIVING SHELL REAR THRUST PLATE FRONT PLANETARY THRUST WASHER...

Page 1202: ...p and Tool C 4470 or Valve Spring Compressor C 3422 B Fig 42 Compress servo spring retainer only enough to permit snap ring removal 47 Remove servo piston snap ring Fig 42 Start one end of ring out of bore Then carefully work re moval tool around back of snap ring until free of ring groove Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 48 Re...

Page 1203: ...luid passages thoroughly with solvent Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear Do not use shop towels or rags to dry the ease or any other transmission component unless they are made from lint free materials Lint will readily adhere to case surfaces and transmission components and will circulate throu...

Page 1204: ...e and weights operate freely in the bores and do not bind Also be sure the valve slides freely on the shaft Minor scratches or burrs can be reduced with crocus cloth soaked in transmis sion fluid However do not attempt to salvage com ponents that are severely worn or scored There are three governor component changes on current 36RH 37RH transmissions that affect service procedures The first change...

Page 1205: ...or weight assembly is designed for exclusive use in 37RH diesel trans missions Do not interchange this weight assem bly 1 Coat governor body bores governor components with transmission fluid 2 Assemble and install governor weights and spring in governor body but do not install shaft and valve at this time These parts will not be installed until after governor and park gear are installed on output ...

Page 1206: ... clutch cam bore and case Be sure to re move all chips shavings generated during cam re moval 4 Install rear support in case Align support with reference marks made at disassembly 5 Align and start new clutch cam in case Be sure serrations on cam and in case are aligned Then tap cam into case just enough to hold it in place 6 Verify that cam is correctly positioned be fore proceeding any further N...

Page 1207: ...rollers and springs came out of retainer reinstall them as follows In stall and seat spring in retainer first Then insert roller between spring and retainer stop as shown Fig 57 Verify that each roller and spring are fully seated before proceeding TIGHTEN PULLER NUT TO D R A W CAM INTO CASE J9121 60 Fig 56 Installing Overrunning Clutch Cam 36RH 37RH J 9 2 2 M 0 Fig 57 Overrunning Clutch Roller Spr...

Page 1208: ...move seal ring from rod guide 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discard servo component O ring and seal rings 4 Lubricate new O ring and seal rings with pe troleum jelly and install them on piston guide and rod 5 Install rod in piston Install spring and washer on rod Compress spring and install snap ring 6 Set servo co...

Page 1209: ...em with compressed air INSPECTING PUMP AND SUPPORT Inspect the pump and support components Replace the pump or support if the seal ring grooves or ma chined surfaces are worn scored pitted or damaged Replace the pump gears if pitted worn chipped or damaged Inspect the fiber thrust washer Replace the washer if worn or damaged Inspect the pump and reaction shaft bushings Re place the bushings only i...

Page 1210: ...p Tool SP 3633 Nut SP 1191 and Bushing Remover SP 5301 Fig 66 2 Hold cup tool firmly against reaction shaft Thread remover tool into bushing as far as possible by hand 3 Using wrench thread remover tool an addi tional 3 4 turns into bushing to firmly engage tool 4 Tighten tool hex nut against cup tool to pull bushing from shaft Clean all chips from shaft and support after bushing removal 5 Place r...

Page 1211: ...g 67 4 Remove piston springs Note number and po sition of piston springs for assembly reference 5 Remove compressor tool and remove clutch pis ton 6 Remove and discard clutch piston seals Also discard spring retainer snap ring FRONT CLUTCH CLEANING AND INSPECTION Clean and inspect the front clutch components Re place the clutch discs if warped worn scored burned or charred the lugs are damaged or ...

Page 1212: ... SP 3629 Fig 69 2 Insert remover tool in bushing and drive bush ing straight out of piston retainer 3 Mount Bushing Installer SP 5511 on tool han dle Fig 69 4 Slide new bushing onto installer head and start bushing in retainer SPECIAL TOOL C 4171 FRONT CLUTCH RETAINER It BUSHING REMOVAL SPECIAL TOOL SP 3629 SPECIAL TOOL C 4171 SPECIAL TOOL SP 5511 J9221 247 Fig 69 Front Clutch Retainer Bushing Rep...

Page 1213: ... Fig 71 Measuring Front Clutch Pack Clearance Typical 2 Remove outer pressure plate and steel plates and discs 3 Remove inner pressure plate wave spring spacer ring and piston spring 4 Remove clutch piston and piston retainer from clutch retainer Bump clutch retainer on a wood block to dislodge piston and retainer 5 Remove input shaft thrust washer 6 Remove input shaft snap ring and press shaft ou...

Page 1214: ...r damaged 4 Install new seals on clutch piston Lubricate piston seals with Ru Glyde or Door Ease Be sure seal lips face input shaft 5 Install clutch piston in retainer Use twisting motion to seat piston in retainer Do not push pis ton straight in This could distort seals causing leakage and clutch slip 6 Install thrust washer on retainer Fig 72 Use petroleum jelly to hold thrust washer in place 7 ...

Page 1215: ...on car rier is damaged the entire planetary gear set must be replaced as an assembly Replace the annulus gears if the teeth are chipped broken or worn or the gear is cracked Replace the planetary thrust plates and the tabbed thrust wash ers if cracked scored or worn Inspect the machined surfaces of the output shaft Be sure the oil passages are open and clear Replace the shaft if scored pitted or d...

Page 1216: ...EAR WASHER J9121 71 Fig 79 Installing Rear Planetary Thrust Washer 36RH 37RH 7 Lubricate sun gear bushings with petroleum jelly or transmission fluid 8 Install sun gear and driving shell on output shaft Fig 80 Seat shell against rear planetary gear Verify that thrust washer on planetary gear was not displaced during installation OUTPUT SHAFT DRIVING SHELL REAR PLANETARY GEAR SUN GEAR OUTPUT SHAFT ...

Page 1217: ...e seated on sun gear and that planetary carrier is seated on out put shaft Fig 83 Assembling Front Planetary And Annulus Gears 36RH 37RH Fig 84 Installing Front Planetary And Annulus Gear Assembly 36RH 37RH 13 Place geartrain in upright position Rotate gears to be sure all components are seated and prop erly assembled Snap ring groove at forward end of output shaft will be completely visible when ...

Page 1218: ...me The valves and valve body will be dam aged if force is used Also tag or mark the valve body springs for reference as they are removed Do not allow them to become intermixed 1 Remove screws attaching adjusting screw bracket to valve body and transfer plate Hold bracket firmly against spring force while removing last screw 2 Remove adjusting screw bracket line pressure adjusting screw pressure re...

Page 1219: ...nd 3 2 down shift housing Fig 91 Keep housing screws with housing for installation reference 16 Remove throttle plug from downshift housing Then remove spring retainer and remove limit valve and spring from downshift housing Fig 92 17 Remove 1 2 shift control valve and spring 2 3 shift valve and spring and 1 2 shift valve and spring Fig 92 18 Remove regulator valve end plate Fig 91 19 Remove regul...

Page 1220: ...ATOR VALVE END PLATE SHUTTLE VALVE COVER REGULATOR VALVE PRESSURE PLUG REGULATOR VALVE THROTTLE PRESSURE PLUG 2 3 SHIFT VALVE GOVERNOR PLUG SHUTTLE VALVE PLUG ALUM LINE PRESSURE ADJUSTING SCREW GOVERNOR VALVE END PLATE MANUAL LEVER DETENT BALL A N D SPRING ADJUSTING SCREW BRACKET J9121 52 Fig 92 Valve Body Components 36RH 37RH ALUM indicates aluminum part ...

Page 1221: ...actice will remove the special coat ing and cause the valves and plugs to stick and bind Inspect the valves and plugs for scratches burrs nicks or scores Also inspect the coating on the alu minum valves and plugs If the coating is damaged or worn through the valve or valve body should be replaced Aluminum valves and plugs must not be sanded or polished under any circumstances However minor burrs o...

Page 1222: ...ug sleeve throttle plug and spring Fig 98 Insert as sembly in valve body and install end plate Tighten end plate screws to 4 Nnn 35 in lbs torque 9 Install 1 2 and 2 3 shift valves and springs Fig 98 11 32 DIAMETER CHECK BALL J9121 84 Fig 96 Correct Position Of Valve Body Check Balis 36RH 37RH TRANSFER PLATE SEPARATOR PLATE ASSEMBLY VALVE BODY J9121 85 Fig 97 Installing Transfer Plate On Valve Bod...

Page 1223: ...SURE REGULATOR VALVE 1 2 SHIFT VALVE AND SPRING 1 2 SHIFT CONTROL VALVE AND SPRING Fig 98 Shift Valve And Spring installation 36RH 37RH LINE PRESSURE PLUG J9121 86 SHUTTLE VALVE END PLATE SECONDARY SPRING GUIDES SHUTTLE VALVE PRIMARY SPRING SHUTTLE VALVE THROTTLE PLUG GOVERNOR PLUG END PLATE J9121 50 Fig 99 Control Valve Locations 36RH 37RH ...

Page 1224: ...l washer and retain ing E clip 29 Lubricate shaft of manual lever with light coat of petroleum jelly This will help protect seal lip when manual shaft seal is installed 30 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 100 31 If line pressure and or throttle pressure ad justment screw settings were not disturbed contin...

Page 1225: ...roleum jelly on seals and O rings to ease installation Petroleum jelly can also be used to hold thrust washers and plates in position during assembly operations How ever do not use chassis grease bearing grease white grease or similar lubricants on any part These types of lubricants can eventually block or re strict fluid passages and valve operation Do not force parts into place Most of the trans...

Page 1226: ... band Fig 106 Installing Rear Band And Link 36RH 37RH 7 Install low reverse drum Fig 107 Slide drum through rear band onto rear support hub and into engagement with overrunning clutch race Fig 107 Installing Low Reverse Drum 36RH 37RH 8 Install snap ring that secures low reverse drum to rear support hub Fig 108 Fig 108 Installing Low Reverse Drum Snap Ring 36RH 37RH 9 Install new O rings on band r...

Page 1227: ...ilar size tool on guide to serve as press tool for C clamp b Position C clamp on press tool and case Fig 112 USE SUITABLE TOOL TO HELP SEAT PISTON RING FRONT SERVO PISTON J9121 98 Fig 111 Installing Front Servo Piston 36RH 37RH c Slowly compress rod guide while simulta neously easing seal ring into bore with suitable tool tighten clamp screw with one hand and run tool around guide ring with other ...

Page 1228: ...n valve bore in governor body over spotface on output shaft Then align valve shaft holes in governor body and output shaft c Align splines in output shaft and park gear hub J9221 52 TRANSMISSION OVERHAUL 36RH 37RH 21 227 Fig 115 Installing Governor And Park Gear Assembly 36RH 37RH d Carefully push assembly into place in rear support Fig 115 e Verify that governor valve shaft holes in out put shaft...

Page 1229: ...ds of front seal rings are firmly seated against each other as shown Lubricate seal rings with petroleum jelly after checking them 24 Assemble front and rear clutches Fig 120 Align lugs on front clutch discs Mount front clutch Fig 119 Input Shaft Seal Ring And Thrust Washer instaliation 36RH 37RH on rear clutch Turn front clutch retainer back and forth until front clutch discs are fully seated on ...

Page 1230: ...ssembly 29 Align discs in rear clutch Then install and engage assembly in front planetary and driving shell Fig 122 Turn clutch retainers back and forth until both clutches are seated 30 Slide front band over front clutch retainer and install front band strut and anchor Fig 123 31 Tighten front band adjusting screw until band is tight on clutch retainer Verify that front rear clutch assembly is st...

Page 1231: ...p bolts Tighten pump bolts alternately and evenly to fully seat pump in case Then final tighten pump bolts to 20 Nnn 15 ft lbs torque SEAT OIL PUMP IN CASE BY HAND REMOVE PILOT STUDS WHEN PUMP IS SEATED J9121 105 Fig 126 Oil Pump Installation 36RH 37RH 38 Verify correct assembly Rotate input and out put shafts and check for bind If bind exists compo nents are either misassembled or not seated Disa...

Page 1232: ...ter on valve body Fig 130 Tighten filter screws to 4 Nnn 35 in lbs Fig 130 Installing Valve Body Filter 36RH 37RH 47 Install seal on park neutral position switch Fig 131 Then install and tighten switch to 34 Nnn 25 ft lbs Fig 131 Park Neutral Position Switch Seal Position 36RH 37RH 48 Adjust front and rear band as follows a Loosen locknut on each band adjusting screw 4 5 turns b Tighten both band ...

Page 1233: ...nd shift levers on manual and throttle levers 59 Cap or cover transmission openings cooler line fittings filler tube bore etc to prevent dirt en try 60 Install torque converter Use C clamp or metal strap to hold converter in place for installation 61 Mount transmission on jack preparatory to in stallation in vehicle CAUTION The transmission cooler and lines must Fig 132 Installing Manual Lever Sha...

Page 1234: ...ission exterior with steam gun or with solvent Wear eye protection during cleaning operations 3 Remove 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 pry tool to start overdrive unit off intermediate shaft and transmis sion case Position pry tool betw...

Page 1235: ...into seal before using puller bolt to withdraw seal Fig 6 Oil Pump Seal Removal 42RH I 10 Remove park neutral position switch Fig 7 Fig 7 Park Neutral Position Switch Removal Installation 11 Remove oil pan bolts and remove oil pan and gasket Note location of oil pan magnet for assembly reference Fig 8 J9121 115 Fig 8 Oil Pan Magnet Position 42RH 12 Remove filter from valve body Fig 9 Keep filter a...

Page 1236: ...rive extension to remove plug as shown TRANSMISSION 0VERHAUL 42RH 21 235 ACCUMULATOR OUTER Fig 12 Accumulator Piston And Springs 42RH Fig 13 Removing Installing Front Band Reaction Pin Access Plug 42RH 17 Loosen front band adjusting screw locknut 4 5 turns Then tighten band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out with pump ...

Page 1237: ...Front Band Reaction Pin 42RH 24 Remove front band lever Fig 17 Fig 17 Removing Installing Front Band Lever 42RH 25 Slide front band rearward and onto driving shell Band will not be removed until after front rear clutch removal 26 Remove front and rear clutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 18 J9121 124 Fig 18 Removing 42RH Front Rear Cl...

Page 1238: ...AFT HUB INTERMEDIATE SHAFT THRUST PLATE J9121 215 Fig 21 Removing Intermediate Shaft Thrust Plate 42RH 30 Slide front band off driving shell Fig 22 and remove band from case 31 Remove planetary geartrain as assembly Fig 23 Support geartrain with both hands during re J9121 217 Fig 23 Removing Planetary Geartrain And Intermediate Shaft Assembly 42RH 32 Loosen rear band adjusting screw 4 5 turns 33 R...

Page 1239: ...attaching overrunning clutch cam to case Fig 28 39 Remove overrunning clutch cam and roller clutch assembly as a unit Fig 29 Turn cam back and forth and tilt it inward to remove it from case Fig 26 Rear Band Pivot And Reaction Pin Location 42RH Fig 27 Low Reverse Drum And Rear Band Removal 42RH Fig 28 Overrunning Clutch Cam Bolt Locations 42RH 40 Compress front servo rod guide about 1 8 inch with ...

Page 1240: ... not replcae bushings as a matter of course Replace bush ings only when they are actually worn or scored Use recommended tools to replace bushings The tools are sized and designed to remove install and seat bushings correctly The bushing replacement tools are included in Bushing Tool Set C 3887 B Pre sized service bushings are available for re placement purposes Only the sun gear bushings are not ...

Page 1241: ...tainer if worn or damaged OVERRUNNING CLUTCH ASSEMBLY 1 Install clutch rollers in spring retainer Fig 33 Be sure springs are seated squarely against roll ers Ru Glyde Door Eze or similar products to prelubri cate seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush...

Page 1242: ...sing and support assembly for alignment reference 3 Loosen bolts that attach pump body to support Fig 37 4 Remove pump to support bolts and separate support from pump housing Fig 38 5 Remove inner and outer gears from reaction shaft support Fig 39 6 If pump seal was not removed during transmis Fig 36 Removing Pump Housing Seal Fig 37 Loosening Pump Support Bolts J9321 213 Fig 38 Separating Pump Ho...

Page 1243: ...in 1993 42RH oil pumps has a new design drive lug The new design incorpo rates drive flats instead of the square lug used previously The 1993 torque converter hub has also been redesigned to accept the new drive If pump gear replacement is necessary be very sure to order and install the new style gears Inspect the pump and reaction shaft support bush ings Minor bushing wear is acceptable Replace t...

Page 1244: ...s with knife blade afterward RH282 Fig 45 Staking Oil Pump Bushing All REPLACING REACTION SHAFT SUPPORT BUSHING 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 46 Do not clamp any part of reaction shaft or support in vise 2 Hold Cup Tool SP 3633 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns ...

Page 1245: ... jelly after installation Squeeze each ring until ring ends are securely hooked together CAUTION Th reaction shaft support seal rings will break if overspread or twisted If new rings are be ing installed spread them only enough for installa tion Also be very sure the ring ends are securely hooked together after installation Otherwise the rings will either prevent pump installation or break during ...

Page 1246: ...ve pressure plate clutch plates and clutch discs Fig 52 2 Compress clutch piston spring with Compressor Tool C 3575 A Fig 53 Be sure legs of tool are seated squarely on spring retainer before compress ing spring 3 Remove retainer snap ring and remove com pressor tool Fig 53 Compressing Front Clutch Piston Spring 42RH 4 Remove spring retainer and clutch spring Note position of retainer on spring fo...

Page 1247: ...ner are for positioning retainer in spring 8 Compress piston spring and retainer with Com pressor Tool C 3575 A Fig 53 Then install new snap ring to secure spring retainer and spring 9 Install clutch plates and discs Fig 52 Install steel plate then disc until all plates and discs are in stalled 10 Install pressure plate and waved snap ring Fig 52 FRONT CLUTCH INSPECTION Clean the front clutch comp...

Page 1248: ...l adhere to component surfaces and could restrict or block fluid passages after assembly Replace the clutch discs if warped worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs on the pressure and clutch plates are also in good condition The lugs must not be bent cracked or ...

Page 1249: ...ar or damage Replace the shaft if worn scored or damaged in any way REAR CLUTCH ASSEMBLY 1 Soak clutch discs in transmission fluid 2 Install new seal rings on clutch retainer hub and input shaft Figs 63 and 64 J912M50 Fig 62 Removing Input Shaft From Rear Clutch Retainer 42RH a Be sure clutch hub retainer seal ring is fully seated in groove Fig 63 Ring must not be twisted or distorted b Note that ...

Page 1250: ...or petroleum jelly Then lubricate retainer hub and bore with transmission fluid Fig 65 Pressing Input Shaft Into Rear Clutch Retainer 42RH 7 Install clutch piston in retainer Use twisting motion to seat piston in bottom of retainer Do not attempt to push the piston straight in This could fold the seals over causing leakage and clutch slip 8 Install piston spring in retainer and on top of piston Fi...

Page 1251: ...k sun gear and driving shell condition Re place the gear if damaged or if the bushings are scored or worn The bushings are not serviceable Re place the driving shell if worn cracked or damaged Replace planetary gear sets if gears pinion pins or carrier are damaged in any way Replace the annu lus gears and supports if either component is worn or damaged Inspect the geartrain spacers thrust plates s...

Page 1252: ...arward 3 Install rear thrust washer on rear planetary gear Fig 70 Use enough petroleum jelly to hold washer in place Also be sure washer tabs are prop erly engaged in gear slots 4 Install rear annulus over and onto rear plane tary gear Fig 70 5 Install assembled rear planetary and annulus gear on intermediate shaft Fig 71 Verify that as sembly is fully seated on shaft 6 Install front thrust washer...

Page 1253: ...J912M59 Fig 73 Installing Sun Gear Spacer 42RH 11 Position wood block on bench and support sun gear on block Fig 76 This makes it easier to align THRUST PLATE Fig 74 Installing Spacer And Thrust Plate On Sun Gear 42RH SUN DRIVING GEAR SHELL REAR THRUST PLATE J9121 162 Fig 75 Installing Sun Gear And Rear Thrust Plate In Driving Shell 42RH and install sun gear lock ring Keep wood block handy as it w...

Page 1254: ... washer on gear and be sure washer tabs are all prop erly seated 15 Assemble front annulus gear and support if necessary 16 Position thrust plate on front 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 washer on front planetary gear Fig 81 Use enough...

Page 1255: ...ng workbench Then support geartrain on wood block positioned under forward end of output shaft This is necessary so geartrain components will move forward for accurate end play check 24 Check planetary geartrain end play with feeler gauge Fig 85 Gauge goes between shoulder on intermediate shaft and end of rear annulus sup port SELECTIVE Fig 84 Installing Planetary Selective Snap Ring 42RH 25 Geart...

Page 1256: ...ston servo springs and snap ring Fig 86 REAR SER 0 AND BAND OVERHAUL REAR SERVO PISTON DISASSEMBLY 1 Remove seal from servo piston Note which way seal lip faces for assembly reference 2 Compress cushion spring in vise only enough to allow piston plug snap ring removal Fig 87 Use wood block between vise jaws and end of piston plug to keep plug aligned and in position 3 Remove snap ring from end of ...

Page 1257: ...the com ponent resulting in unsatisfactory operation after assembly and installation Remove valves plugs and springs with a pencil magnet Do not use pliers to remove any of the valves plugs or springs and do not force any of the components out or into place The valves and valve body housings will be damaged if force is used Tag or mark the valve body springs for reference a s they are removed D o ...

Page 1258: ...manual lever Fig 97 MANUAL LEVER PARK ROD J9121 81 Fig 97 Park Rod Removal 42RH 10 Remove screws attaching pressure adjusting screw 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 spring and switch valve spring Fig 98 Do not remove throttle pressure adjus...

Page 1259: ...3 4 ACCUMULATOR HOUSING HOUSING ATTACHING SCREWS Fig 102 Removing 3 4 Accumulator Housing 42RH 16 Remove following parts from valve body lower housing 3 4 shift valve and spring pressure regula tor valve spring clutch valve clutch valve spring and clutch valve plug Fig 103 17 Remove boost valve connecting tube Fig 104 Disengage tube from upper housing port first Then rock opposite end of tube back...

Page 1260: ...er plate from upper housing Fig 107 22 Turn transfer plate over so upper housing sep arator plate is facing upward Fig 108 23 Remove brace plate from lower housing sepa rator plate and transfer plate Fig 108 24 Remove upper housing separator plate from transfer plate Fig 109 Note position of filter in separator plate for assembly reference LOWER HOUSING VALVE BODY SCREWS 13 S c TUBE BRACE J9321 14...

Page 1261: ...111 Then remove one large and six smaller diameter check balls with magnet total of 7 check balls are used SMALL DIAMETER CHECK BALLS 6 LARGE DIAMETER CHECK BALL 1 J9321 154 Fig 111 Valve Body Check Ball Locations 42RH 2 Remove E clip that secure shuttle valve second ary spring on valve stem Fig 112 E CLIP SECONDARY SHUTTLE VALVE J9121 179 Fig 112 Shuttle Valve E Clip And Secondary Spring Location...

Page 1262: ...switch 8 Remove throttle plug and 1 2 and 2 3 governor valve regulator valve and spring and manual valve plugs Fig 114 Also remove shuttle valve primary Fig 114 spring if not removed in prior step 7 Remove kickdown detent kickdown valve and throttle valve and spring Fig 114 Fig 114 Control Valve Locations 42RH Upper Housing ...

Page 1263: ...e E clip and remove shuttle 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 ACCUMULATOR HOUSING DISASSEMBLY FIG 117 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston seals VALWE 10DY CLEANING AND INSPECTION The only serviceabl...

Page 1264: ... the throttle and manual valve levers and shafts Do not attempt to straighten a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straight edge to check surface flatness Minor scratches may be removed with crocus cloth using only very light pressure Minor ...

Page 1265: ...lves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Re place the valve body if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Check the two separator plates for distortion or damage of any kind Inspect the upper housing lower housing 3 4 a...

Page 1266: ...EVE REGULATOR VALVE THROTTLE PRESSURE PLUG RETAINER VALVE SPRING 2 3 SHIFT VALVE GOVERNOR PLUG LINE PRESSURE ADJUSTING SCREW ADJUSTING SCREW BRACKET PRESSURE SWITCH REGULATOR VALVE VALVE AND AND SPRING SPRING SHUTTLE VALVE PLUG ALUM GOVERNOR VALVE END PLATE MANUAL LEVER DETENT BALL AND SPRING J9221 21 Fig 119 Upper Housing Components 42RH Valve Body Alum Indicates Aluminum Part ...

Page 1267: ...10 2 Install filter screen in upper housing separator plate Fig 109 3 Align and position upper housing separator 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 remaing separator plate attaching screws Tighten screws to 4 Nrn 35 in lbs torque Assembling Upper And Lower Housings 1 Position upper housing so internal pa...

Page 1268: ...e into upper housing port Fig 122 Seat both ends of tube once in position TUBE BRACE UPPER LOWER HOUSING PORT J932M62 Fig 122 Boost Vaive Tube Installation 42RH 3 4 Accumulator Installation 1 Position converter clutch valve and 3 4 shift valve springs in housing Fig 123 2 Loosely attach accumulator housing with right side screw Fig 123 Install only one screw at this time as accumulator must be fre...

Page 1269: ...nts are properly aligned Then tighten all three bracket screws to 4 N m 35 in lbs torque 6 Install throttle lever in upper housing Then in stall manual lever over throttle lever and start man ual lever into housing 7 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Re tainer Tool 6583 Fig 93 8 Align manual lever with detent ball and man ual valve Hold t...

Page 1270: ...e sure the tools and workbench area used for assembly operations are equally clean Shop towels used for wiping off tools and hands must be made from lint free material Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages Lubricate the transmission components with Mopar transmission fluid during reassembly Use petroleum jelly Door Eze or Ru ...

Page 1271: ...B ROD QUIDE SNAP RING J9121 136 Fig 132 Compressing Front Rear Servo Springs Fig 133 Location Of Non Threaded Hole In Clutch Cam 42RH S OVERRUNNING CLUTCH CAM SEAT IN CASE 40N THREADED HOLE IN CLUTCH CAM ALIGNS HERE BLANK AREA OF SEAT i J9121 541 Fig 134 Location Of Blank Area In Clutch Cam Bolt Circle 42RH 5 Mark location of non threaded hole in clutch cam and blank area in bolt circle with greas...

Page 1272: ...te freely in clockwise direction and lock in counterclockwise direction as viewed from front of case 13 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be TRANSMISSION 0VERHAUL 42RH 21 271 Fig 137 Rear Band Installation 42RH Fig 138 Installing Low Reverse Drum 42RH sure to align governor feed holes in gasket with feed passages in case Fig 139 Also instal...

Page 1273: ...taining Snap Ring Fig 142 Rear Band Lever And Pivot Pin Installation hooked together Also verify that shaft seal rings are installed in sequence shown 20 Check rear clutch fiber thrust washer Fig 146 Use additional petroleum jelly to hold washer in place if necessary 21 Align clutch discs in front clutch and install front clutch on rear clutch Fig 147 Rotate front clutch retainer back and forth un...

Page 1274: ...stall if transmission is as close to upright position as possible 25 Install front and rear clutch units as assembly Fig 150 Align rear clutch with front annulus gear and install assembly in driving shell Re sure out put shaft thrust washer and thrust plate are not displaced during installation INPUT SHAFT TEFLON SEAL RING METAL SEAL RING Fig 145 Input Shaft Seal Ring Location 42RH REAR CLU1CH ETA...

Page 1275: ...d adjusting screw Fig 152 30 Push front band reaction pin completely into place Then tighten band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still seated before continuing 31 Coat band reaction pin access plug with sealer and install plug in converter housing Fig 151 Installing Front Band And Reaction Pin 42RH 32 Check seal rings on reaction shaft sup...

Page 1276: ...r Align lo cating lugs on piston in locating bores in re tainer Fig 157 Use thin plastic strip or feeler gauge to help guide piston outer seal into retainer 41 Install spacer on intermediate shaft if not previously installed TRANSMISSION 0VERHAUL 42RH 21 275 Fig 154 Installing Pilot Studs And Oil Pump Gasket 42RH Fig 155 Installing Oil Pump Assembly In Case 42RH 42 Install overdrive piston thrust ...

Page 1277: ...nit cannot be fully installed on intermediate shaft Overdrive unit will have to be disassembled in order to re align splines 46 Carefully withdraw alignment tool from over drive unit OVERDRIVE PISTON THRUST PLATE J9121 354 Fig 158 Installing Overdrive Piston Thrust Plate 42RH BE SURE THIS SHOULDER OVERDRIVE PISTON THRUST IARINC Fig 159 Installing Overdrive Piston Thrust Bearing 42RH SPECIAL TOOL 6...

Page 1278: ...nd rear bands as follows a Loosen band adjusting screw locknuts b Tighten each band adjusting screw to 5 Nnn 72 in lbs with torque wrench c Back off front band adjusting screw 2 1 2 turns d Back off rear band screw 4 turns e Tighten each adjusting screw locknut Hold adjusting screws with wrench to prevent turning when tightening locknut 55 Install seal on park neutral position switch Fig 162 Then ...

Page 1279: ...nd transmission rear servo boss Fig 2 6 Work overdrive unit rearward and off transmis sion intermediate shaft Fig 3 a If overdrive unit does not require service in sert Alignment Tool 6227 2 in overdrive unit over running clutch and planetary gear to maintain spline alignment Fig 4 If clutch and gear splines rotate out of alignment overdrive unit will have to be disassembled in order to re align s...

Page 1280: ...hrust Bearing 11 Remove pump oil seal with Special Tool C 3861 Fig 8 Be sure to tighten tool threads completely into seal before using puller bolt to withdraw seal J9321 182 s Fig 8 Removing Pump Oil Seal 46RH 12 Remove oil pan bolts and remove pan Fig 9 and gasket Fig 10 Oil pan magnet can be removed or left in pan as needed Fig 11 Exercise care when removing pan to avoid distorting or bending pa...

Page 1281: ...onger than valve body screws 15 Remove hex head valve body attaching bolts Fig 14 A total of 10 hex head bolts are used to se cure valve body to case 16 Lift valve body upward Push solenoid connec tor and manual lever shaft out of case Then raise valve body guide park rod out of case and remove valve body Fig 15 Do not use boost valve tube to lift valve body Set valve body aside for disas sembly c...

Page 1282: ...g 46RH 19 Remove oil pump and reaction shaft support assembly as follows a Tighten front band adjusting screw until band is tight around front clutch retainer Fig 18 This will prevent retainer from coming out with pump and possibly damaging clutch or pump com ponents b Remove oil pump bolts c Thread Slide Hammer Tools C 3752 into threaded holes in flange of oil pump housing Fig 19 d Remove oil pum...

Page 1283: ...ge 46RH 23 Squeeze front band together slightly and slide band over front clutch retainer and out of case Fig 23 24 Remove front and rear clutch assemblies as a unit Fig 24 Set assemblies aside for disassembly and inspection after removal 25 Remove front band reaction pin and lever Start pin through lever and out of case bore with drift or punch Then use pencil magnet to withdraw pin completely Fi...

Page 1284: ...rns 30 Remove snap ring that retains low reverse drum on overdrive piston retainer hub Fig 29 31 Slide low reverse drum off piston retainer hub and out of rear band Fig 30 32 Note that overrunning clutch race will remain on splines of low reverse drum after removal Fig 31 The race is a permanent press fit on the hub splines Do not attempt to remove the race 33 Remove overrunning clutch assembly Fi...

Page 1285: ...in for cleaning inspection and assembly reference 36 Remove rear band and link Fig 34 37 Compress front servo rod guide with C clamp and Tool C 4470 or Valve Spring Compressor C 3422 B Fig 35 Compress guide only enough to permit snap ring removal about 1 8 in 38 Remove servo piston snap ring Fig 35 Un seat one end of ring Then carefully work removal tool around back of ring until free of ring groo...

Page 1286: ...cement purposes Only the sun gear bushings are not serviced Low cost of the sun gear assembly makes it easier to simply replace the gear and bush ings as an assembly Fig 37 Removing Overdrive Piston Retainer 46RH Heli Coil inserts are recommended for repairing damaged stripped or worn threads in aluminum parts These inserts are available from most automo tive jobbers Stainless steel inserts are pr...

Page 1287: ...NG CLUTCH OVERHAUL Inspect condition of the clutch cam cage type re tainer rollers springs and clutch race Replace the clutch cam if worn or damaged Also check fit of the cam in the transmission case If the cam is loose the case may be worn or cracked The clutch race is permanently pressed onto the low reverse drum hub If either the drum or race are worn or damaged replace the drum and race as an ...

Page 1288: ...e cam is drawn into case evenly and does not become cocked 12 Install clutch cam setscrew Fig 39 13 Remove clutch cam installer tools and piston retainer 14 Stake case in 12 places around clutch cam to help secure cam in case Use blunt punch or chisel to stake case TRANSMISSION 0WERHAUL 48RH 21 287 Fig 43 Assembling Clutch Cam Puller Bolt And Press Plate 15 Clean case and cam thoroughly Be sure an...

Page 1289: ...drum Tilt drum slightly and carefully engage clutch race on drum hub in overrunning clutch rollers Raise drum to level posi tion Then rotate the drum in clockwise direction un til fully seated Fig 47 Overrunning Clutch Seated In Cam 5 Check overrunning clutch operation Low re verse drum should rotate freely in clockwise direc tion and lock in counterclockwise direction 6 Align and reinstall overdr...

Page 1290: ...ervo compo nents Replace the spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap ring if distorted or warped Check rear band condition Replace the band if dis torted the lining is burned or flaking off or the lin ing is worn grooves no longer visible at any point on PISTON RINGS 2 SERVO PISTON O RING PISTON ROD SPRING WASHER SNAP RING ...

Page 1291: ...ck condition of the seal rings and thrust washer on the reaction shaft support The seal rings do not need to be replaced unless cracked severely worn or no longer hooked together PUMP BODY INNER GEAR OUTER GEAR J932M77 Fig 52 Pump Gear Removal 46RH Inspect the pump and support components Replace the pump or support if the seal ring grooves or ma chined surfaces are worn scored pitted or damaged Re...

Page 1292: ...ed during installation 6 Stake pump bushing in two places with blunt punch Remove burrs from stake points with knife blade Fig 58 Check the pump vent Fig 54 The vent must be secure Replace the pump body if the vent is cracked broken or loose Inspect the pump bushing Fig 54 Then check the reaction shaft support bushing Replace either bush ing only if heavily worn scored or damaged It is not necessa...

Page 1293: ... 5302 BUSHING BUSHING X REACTION SHAFT BUSHING REMOVAL BUSHING INSTALLATION J9221 245 Fig 59 Reaction Shaft Bushing Replacement 46RH ASSEMBLING OIL PUMP AND REACTION SHAFT SUPPORT 1 Lubricate pump gears with transmission fluid and install them in pump body 2 Install thrust washer on reaction shaft support hub Lubricate washer with petroleum jelly or trans mission fluid before installation 3 If rea...

Page 1294: ... the piston retainer The ball must move freely and not stick Replace the retainer bushing if worn scored or there is any doubt about bushing condition Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check the clutch piston check ball The ball sh...

Page 1295: ...er and outer seals on clutch pis ton Be sure seal lips face interior of retainer 3 Lubricate new inner and outer piston seals with Ru Glyde or Door Eze 4 Install clutch piston in retainer Use twisting motion to seat piston in retainer Do not force pis ton straight in This could fold seals over caus ing leakage and clutch slip 5 Install and position clutch piston springs as shown in Figure 64 6 Ins...

Page 1296: ...achined surfaces are se verely scored Replace the clutch discs if warped worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the steel plates and the pressure plate if heavily scored warped or broken Be sure the driv ing lugs on the discs and plates are also in good con dition The lugs must not be bent cracked or damaged in any way Replace the piston spring and...

Page 1297: ... piston Convex side faces downward toward piston 7 Install spacer ring on top of piston spring 8 Install wave spring on top of spacer ring Then seat wave spring in retainer groove If wave spring will not seat properly spacer ring has probably shifted over and into wave spring groove in re tainer Use small screwdriver to realign spacer ring if necessary 9 Install inner pressure plate in clutch reta...

Page 1298: ...her position on gear for assembly reference 7 Remove rear planetary gear and rear annulus gear from intermediate shaft Fig 75 8 Remove thrust plate from rear annulus gear Fig 76 TRANSMISSION 0VERHAUL 46RH 21 297 Fig 71 Disassembling Front Planetary And Annulus Gears 46RH Intermediate Shaft And Geartrain Inspection Clean the intermediate shaft and planetary compo nents Fig 77 in parts cleaning solv...

Page 1299: ... remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then replace the necessary component Replace the sun gear as an assembly if the gear teeth are chipped or worn Also replace the gear as an assembly if the bushings are scored or worn The sun gear bushings are not serviceable Replace the thrust plate if worn or severely scored Replace the driv...

Page 1300: ...jelly to hold washer in place if desired 7 Lubricate sun gear bushings with petroleum jelly or transmission fluid Fig 79 Installing Rear Annulus Gear On Intermediate Shaft 46RH 8 Install sun gear and driving shell on output shaft Fig 83 Seat shell against rear planetary gear Verify that thrust washer on planetary gear was not displaced during installation 9 Install tabbed thrust washer in driving ...

Page 1301: ...lide them TABBED THRUST WASHER J9121 73 Fig 84 Installing Driving Shell Thrust Washer 46RH onto shaft Be sure planetary pinions are seated on sun gear and that planetary carrier is seated on out put shaft 13 Place geartrain in upright position Rotate gears to be sure all components are seated and prop erly assembled Snap ring groove at forward end of output shaft will be completely exposed when co...

Page 1302: ...tary geartrain end play with feeler gauge Fig 89 Insert gauge between rear an nulus gear and shoulder on output shaft as shown End play should be 0 15 to 1 22 mm 0 006 to 0 048 in 17 If end play is incorrect install thinner thicker planetary snap ring as needed Fig 87 Installing Front Planetary And Annulus Gear Assembly 46RH Fig 88 Installing Planetary Snap Ring 46RH ...

Page 1303: ...e valves and valve body housings will be damaged if force is used Tag or mark the valve body springs for refer ence a s they are removed D o not allow them to be come intermixed 1 Remove boost valve cover Fig 90 2 Remove boost valve retainer valve spring and boost valve Fig 91 HOUSING J932M26 Fig 91 Boost Valve Components 46RH DETENT BALL AND SPRING HOUSING J9321 121 Fig 92 Securing Detent Ball An...

Page 1304: ...Rod Removal 46RH 10 Remove screws attaching pressure adjusting screw 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 spring and switch valve spring Fig 98 Do not remove throttle pressure adjusting screw from bracket and do not disturb adjusting screw sett...

Page 1305: ...UMULATOR HOUSING HOUSING ATTACHING SCREWS Fig 102 Removing 3 4 Accumulator Housing 16 Remove following parts from valve body lower housing 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 CLUTCH VALVE PLUG PRESSURE REGULATOR VALVE SPRING J9321 146 Fig 103 Clutc...

Page 1306: ...lower housing and overdrive separa tor plate from transfer plate Fig 106 21 Remove transfer plate from upper housing Fig 107 22 Turn transfer plate over so upper housing sep arator plate is facing upward Fig 108 23 Remove brace plate from lower housing sepa rator plate and transfer plate Fig 108 24 Remove upper housing separator plate from transfer plate Fig 109 Note position of filter in separato...

Page 1307: ... and remove switch valve regulator valve and spring and manual valve Fig 114 7 Remove kickdown detent kickdown valve and throttle valve and spring Fig 114 8 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 114 Also remove shuttle valve primary spring if not removed in prior step SMALL DIAMETER CHECK BALLS 6 LARGE DIAMETER CHECK BALL 1 J932M54 Fig 112 Shuttle Valve E Clip And Secondary Sprin...

Page 1308: ...TRANSMISSION OVERHAUL 46RH 21 307 156 Fig 113 Shuttle And Boost Valve Components 46RH Fig 114 Control Valve Locations 46RH Upper Housing ...

Page 1309: ...The remaining valve body components are serviced only as part of a complete valve body assembly Clean the valve body components with a standard parts cleaning solution only Do not use gasoline kerosene or any type of caustic solution Dry the parts with compressed air Make sure all passages are clean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components ...

Page 1310: ...ating and cause the valves and plugs to stick and bind PISTON SEAL RING PISTON SPRING END PLATE J9121 277 Fig 117 3 4 Accumulator Housing Components 46RH Inspect the valves and plugs for scratches burrs nicks or scores Minor surface scratches on steel valves or plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands Maintaining sharpness of these edges is v...

Page 1311: ...s to recom mended torque only Lower Housing Assembly Fig 116 1 Lubricate valves springs and the housing valve and plug bores with Mopar ATF Plus or Dexron II transmission fluid 2 Install 3 4 timing valve spring and valve in lower housing 3 Install 3 4 shuttle valve in lower housing Press valve inward and install E clip on end of valve to secure it in housing 4 Install 3 4 shuttle valve spring and ...

Page 1312: ...UTTLE VALVE COVER SLEEVE REGULATOR VALVE THROTTLE PRESSURE PLUG RETAINER VALVE SPRING 2 3 SHIFT VALVE GOVERNOR PLUG LINE PRESSURE ADJUSTING SCREW ADJUSTING SCREW BRACKET SHUTTLE VALVE PLUG ALUM GOVERNOR VALVE END PLATE AAANUAL LEVER DETENT BALL AND SPRING J9221 21 E w 00 o z m 30 Fig 118 Upper Housing Components 46RH Valve Body Alum Indicates Aluminum Part ...

Page 1313: ...d ary spring and install spring on end of valve b Hold shuttle valve in place c Compress secondary spring and install 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 8 Install 1 2 and 2 3 valve governor plugs in valve body 9 Install shuttle valve p...

Page 1314: ... 3 4 accumula tor with shoulder type screw Connector has small lo cating tang that fits in dimple at top of accumulator housing Fig 124 Seat tang in dimple before tight ening connector screw 7 Install solenoid assembly and gasket Tighten solenoid attaching screws to 8 N m 72 in lbs torque SOLENOID CASE CONNECTOR Fig 124 Solenoid Connector Installation 46RH 8 Verify that solenoid wires are properly...

Page 1315: ...ousing Then in stall manual lever over throttle lever and start man ual lever into housing 7 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Re tainer Tool 6583 Fig 92 8 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove de tent ball retainer fool after lever is sea...

Page 1316: ...d sub assemblies are easily installed by hand when properly aligned If a part seems diffi cult to install it is either misaligned or incorrectly assembled Verify that thrust washers thrust plates and seal rings are correctly positioned These parts will prevent proper assembly is mispositioned or left out by accident The planetary geartrain front rear clutch assem blies and oil pump are all much ea...

Page 1317: ... m 13 ft lbs torque 7 Install overrunning clutch components if not yet installed Refer to Overrunning Clutch Overhaul in this section if necessary 8 Position rear band and link in case Fig 134 Be sure notched side of link faces away from band Fig 133 Installing Overdrive Piston Retainer 46RH Fig 134 Installing Rear Band And Link 46RH 9 Install low reverse drum Fig 135 Slide drum through rear band ...

Page 1318: ... Bottom front servo piston in bore and install servo spring 16 Install front servo piston rod guide as follows TRANSMISSION 0VERHAUL 4SRH 21 317 Fig 137 Installing Rear Band Reaction Pin 46RH A D J U S T I N G A D J U S T I N G J 9 1 2 1 9 2 Fig 138 Rear Band Levers And Strut 46RH a Place Tool SP 5560 or similar size tool on guide and position C clamp on tool and case Fig 140 b Slowly compress rod...

Page 1319: ...front clutch ASSEMBLY J9121 508 Fig 141 Installing Intermediate Shaft And Planetary Geartrain 46RH Fig 142 Installing Intermediate Shaft Thrust Plate 46RH on rear clutch Turn front clutch retainer back and forth until front clutch discs are fully seated on rear clutch splined hub 24 Install intermediate shaft thrust washer in hub of rear clutch retainer Fig 145 Use petroleum jelly to hold washer i...

Page 1320: ...and 29 Install oil pump Pilot Studs C 3288 B in case Fig 148 Fig 145 Installing intermediate Shaft Thrust Washer 46RH Fig 146 Installing Front Rear Clutch Assemblies 46RH 30 Install new oil pump gasket on pilot studs and seat it in case Be sure gasket is properly aligned with fluid passages in case Fig 148 31 Check seal rings on reaction shaft support Be sure rings are hooked together correctly Al...

Page 1321: ...ely and evenly to fully seat pump in case Then final tighten pump bolts to 20 N m 15 ft lbs torque 35 Verify correct assembly Rotate input and out put shafts and check for bind If bind exists compo nents are either misassembled or not seated Disassemble and correct as necessary before proceed ing Fig 149 Reaction Shaft Seal Ring And Thrust Washer installation 46RH Fig 150 Oil Pump installation 46R...

Page 1322: ...elly to hold thrust plate in position on piston 41 Install overdrive piston thrust bearing in di rect clutch hub Fig 154 Use liberal quantity of pe troleum jelly to hold thrust bearing in place Note that one side of bearing has dark coated sur face This surface faces overdrive piston Also be sure raised shoulder on inside diameter of bearing faces forward as well Fig 153 Installing Overdrive Pisto...

Page 1323: ... bolts by hand Then tighten bolts evenly in a di agonal pattern to 12 Nnn 105 in lbs torque Do not overtighten valve body bolts This could result in distortion and cross leakage after in stallation 51 Install new filter on valve body Tighten filter screws to 4 Nnn 35 in lbs 52 Install seal on park neutral position switch Fig 157 Then install and tighten switch to 34 Nnn 25 ft lbs Fig 157 Park Neut...

Page 1324: ...rated sludge metal particles or clutch friction material The torque converter should also be replaced if contaminated by the same mal function Debris and residue not flushed from the cooler and lines will flow back into the transmission and converter The result could be a repeat failure and shop comeback Fig 158 Installing Manual Lever Shaft Seal ...

Page 1325: ... overdrive clutch pack retaining ring Fig 5 page Overdrive Unit Cleaning and Inspection 330 Overdrive Unit Disassembly 324 Fig 3 Removing Overdrive Piston Fig 4 Removing Overdrive Piston Thrust Bearing 6 Remove overdrive clutch pack Fig 6 Note that thickest plate is positioned at rear of clutch pack 7 Remove overdrive clutch wave spring Fig 7 8 Remove overdrive clutch reaction snap ring Fig 8 Note...

Page 1326: ... Clutch Pack Retaining Ring Fig 6 Overdrive Clutch Pack Removal Fig 7 Removing installing Overdrive Clutch Wave Spring Fig 8 Removing Overdrive Clutch Reaction Snap Ring Fig 9 Removing Installing Locating Ring Access Cover Fig 10 Releasing Shaft Front Bearing From Locating Ring ...

Page 1327: ...awl spring and reaction plug 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 ring with long flat blade screwdriver 17 Remove rear bearing by tapping overdrive case on wood block to dislodge bearing Fig 13 Removing Governor Support And Tube Assembly Fi...

Page 1328: ... E CLIP Fig 16 Governor Valve And Shaft Removal Installation GOVERNOR ASSEMBLY GOVERNOR SNAP RING j m r r j9121 303 Fig 17 Removing Installing Governor Snap Ring GOVERNOR BODY AND DRIVE ASSEMBLY J9221 39 Fig 18 Removing Installing Governor Body And Drive Assembly OUTPUT SHAFT GOVERNOR DRIVE KEY J9221 43 Fig 19 Removing Governor Drive Key FRONT BEARING SNAP RING Fig 20 Removing Installing Front Bea...

Page 1329: ... top of Tool 6227 1 to help distribute load and provide needed extra press length 10 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 22 11 Remove direct clutch pack snap ring first Fig 22 12 Remove direct clutch hub retaining ring Fig 23 13 Release press load on clutch spring slowly and comp...

Page 1330: ... OVERDRIVE UNIT OVERHAUL 42RH 46RH 21 321 Fig 24 Direct Clutch Pack Removal Fig 27 Removing Overrunning Clutch Assembly J9121 312 Fig 26 Removing Sun Gear Thrust Bearing Planetary Gear ...

Page 1331: ...ing ring Fig 31 23 Mark annulus gear and output shaft for as sembly alignment reference Fig 32 24 Remove annulus gear from output shaft Fig 33 Use rawhide or plastic mallet to tap gear off shaft 25 Remove output shaft front bearing if not pre viously removed OVERDRIVE UNIT CLEANING AND INSPECTION Clean the geartrain Fig 34 and case components Fig 35 with solvent Dry all parts except the bear ings ...

Page 1332: ...STON PISTON THRUST PLATE SELECTIVE CLUTCH HUB SNAP RING PISTON THRUST BEARING CLUTCH PACK RETAINING RING OVERDRIVE CLUTCH PACK REACTION PLATE REACTION SNAP RING J9J21 289 SEAL Fig 34 Overdrive Geartrain Components 42RH Shown ACCESS PLATE AND GASKET CASE GASKET PLATE SPACER INSULATOR DAMPER WEIGHT SHAFT RETAINING BOLT PARK PAWL SPRING REACTION PLUG AND SNAP RING PARK LOCK ROD J9121 290 Fig 35 Overd...

Page 1333: ...Check the lugs on the clutch plates for wear The plates should slide freely in the drum Re place the plates or drum if binding occurs Governor Components Check condition of the annulus gear direct clutch hub clutch drum and clutch spring Fig 34 Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or cracked Be sure the splines and lugs on the gear drum and hub...

Page 1334: ...any snap ring if its condition is doubtful Inspect the output shaft bushings Fig 37 The small bushing is the intermediate shaft pilot bush ing The large bushing is the overrunning clutch hub bushing Replace either bushing if scored pitted cracked or worn The bushings can be removed with blind hole puller tools such as Snap On set CG40CB for small bushings and set CG46 for large bushings New bushin...

Page 1335: ...12 Install overrunning clutch Fig 42 Insert snap r i n g pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion CLUTCH DRUM OVERRUNNING CLUTCH ASSEMBLY EXPAN DING TYPE SNAP RING PLIERS OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT CLUTCH DRUM ANNULUS GEAR J9121 314 Fig 42 Installing Overrunning Clutch 13 Install planetary gear in annulus ge...

Page 1336: ...st bearing are fully seated before proceeding 18 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 47 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated be fore proceeding Fig 46 Sun Gear Installation 19 Install direct clutch spring Be sure spring is properly seated on spring plate Fig 47 Fig 47 Installing D...

Page 1337: ... shop press Fig 52 WARNING THE NEXT STEP IN GEARTRAIN AS SEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IM PORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 800 POUNDS USE SPRING COM PRESSOR TOOL C 6227 1 AND A HYDRAULIC TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUST...

Page 1338: ...dge of hub and compressor tool as shown in Figure 52 S P E C I A L T O O L M B 9 9 0 8 9 1 S P E C I A L T O O L 6 2 2 7 2 C L U T C H H U B S P E C I A L T O O L 6 2 2 7 1 D I R E C T C L U T C H P A C K C L U T C H D R U M J 9 2 2 1 2 Fig 52 Mounting Geartrain Assembly In Shop Press 28 Slowly compress clutch hub and spring Fig 53 Compress spring and hub only enough to expose ring grooves for clu...

Page 1339: ...nd snap ring on output shaft Fig 56 Be sure locating ring groove in bearing is toward rear of shaft 2 Install governor drive key in output shaft Fig 56 3 Install new seal rings on governor drive Be sure ring ends are securely interlocked before pro ceeding Fig 57 4 Assemble governor drive and body Be sure fil ter is properly seated and positioned in governor body before tightening attaching bolts ...

Page 1340: ... pawl shaft Fig 14 Verify that spring end is hooked to pawl and straight end of spring 11 Install pawl shaft retaining bolt Tighten bolt to 27 Nnn 20 ft lbs torque 12 Install park lock reaction plug Note that plug has locating pin at rear Fig 60 Be sure pin is seated in hole in case before installing snap ring REACTION Fig 60 Reaction Plug Locating Pin And Snap Ring 13 Install reaction plug snap r...

Page 1341: ... spring on top of reaction ring Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring se curely in groove c Install reaction plate Fig 68 d Install first clutch disc followed by first clutch plate SPECIAL TOOL 6227 2 CASE GEARTRAIN SPECIAL TOOL 6227 1 J9221 6 Fig 66 Installing Overdrive Case On Geartrain e Install remaining clutch discs and plates in same order...

Page 1342: ...on Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 71 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and dividing by 4 End Play Measurement Inches Spacer Thickness Inches 7336 7505 158 159 7506 7675 175 176 7676 7855 193 194 7856 8011 211 212 J9121 341 Fig 70 Intermediate Sh...

Page 1343: ...lation 345 Transfer Case Removal 345 SAE multi purpose gear lubricants with an API grade rating of GL 5 are recommended for severe duty operation SAE grades 80 75W 90 90 80W 90 140 and 80W 140 are all acceptable Use SAE 80 or 75W 90 when ambient tempera tures are below 23 C 10 F Use SAE 90 or 80W 90 when ambient temperature is above the stated range SAE 140 or 80W 140 can be used when severe ser v...

Page 1344: ...mpo nents may be worn or damaged Low lubricant levels are a frequent cause of noisy operation Insufficient lubricant will lead to over heating subsequent damage to bearing and gear sur faces and hard shifting Transfer case bearing noise is higher in pitch than gear noise If the unit is noisy in 4WD range only the front shaft bearings are probably at fault If the unit is noisy in all ranges an over...

Page 1345: ...e helper start engine and shift transmis sion into gear If transmission output shaft rotates problem is with transfer case If transmission shaft does not rotate problem is with transmission or re lated component SHIFT LINKAGE ADJUSTMENT 1 Shift transfer case into neutral 2 Remove screws attaching shift lever boot and seal to floor pan Fig 2 3 Slide shift lever boot and seal upward for vi sual acce...

Page 1346: ...cure them to frame rails with wire 6 Disconnect transfer case shift lever from range lever on transfer case 7 Support transfer case with transmission jack Secure transfer case to jack with safety chains 8 Remove nuts attaching transfer case to trans mission adapter 9 Slide transfer case rearward until it is clear of transmission output shaft DISTANCE SENSOR ADAPTER DRIVEN GEAR J9021 151 Fig 4 Spee...

Page 1347: ......

Page 1348: ...AIL LINK RETAINING CLIP 21 LINK TO RAIL RETAINING PIN 3 HIFT FORK A N D RAIL FRONT WHEEL INTERLOCK HOLE PLUGS 4 FRONT OUTPUT SHAFT BEARING BEARING S N A P RING INPUT SHAFT SNAP RING ADAPTER OIL SEAL 2 GASKET TRANSFER CASE ADAPTER ADAPTER SLEEVE SLEEVE RETAINING RING GASKET TRANSMISSION ADAPTER J9021 149 5 Remove rear retainer rear output shaft and gears as assembly 6 Remove rear seal retainer from...

Page 1349: ...gear oil during assembly Use petroleum jelly to pre lubricate and hold bearings in place during installa tion Use new gaskets and seals throughout Do not re use these components Replace snap rings if distorted or damaged and use new yoke locknuts to secure the yoke and flange 1 Install bearing cups in idler gear with shop press Fig 10 2 Assemble idler gear gear bearing cones bear ing spacer and sh...

Page 1350: ...r seals gasket and adapter on input shaft Fig 5 19 Install shift link and link retaining pins clips 20 Assemble rear output shaft Install gears bearings and spacers Fig 5 21 Install new snap ring Tap ring to seat it and check end play End play should be 0 05 to 0 68 mm 0 002 to 0 027 in 22 Install pilot bearing rollers in rear output shaft Use as much petroleum jelly as needed to hold bearing roll...

Page 1351: ...ff road operation or when the vehicle is driven on paved road surfaces covered by snow ice or similar low traction elements TRANSFER CASE IDENTIFICATION An identification tag Fig 1 is attached to the rear case of each NP241 transfer case The tag provides the transfer case model number assembly number serial number and low range ratio The transfer case serial number also represents the date of buil...

Page 1352: ...le with MOPAR ATF PLUS Type 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 II Automatic Transmission Fluid Check for leaks and repair if necessary If unit is still noisy after drain and refill disassembly and inspection may be required to locate sou...

Page 1353: ...ehicle 2 Remove fill and drain plugs and drain oil from transfer case 3 Mark propeller shaft and transfer case yoke for alignment reference 4 Disconnect propeller shaft Secure shaft to un derside of vehicle 5 Remove transfer case yoke retaining nut and seal washer Use Special Tool C 3281 to hold yoke while removing nut 6 Remove transfer case yoke 7 Remove retainer seal if seal or bushing is to be ...

Page 1354: ...apter in housing 6 Rotate adapter until required range numbers are at six o clock position Fig 6 Be sure adapter range numbers correspond to number of teeth on pin ion 7 Seat adapter in housing 8 Install adapter retainer Tighten retainer bolt to 11 N m 100 in lbs torque 9 Install vehicle speed sensor Tighten sensor coupling nut to 17 N m 150 in lbs torque and in stall sensor wires 10 Check and cor...

Page 1355: ...position Be sure lever is against 4H position in gate 3 Raise vehicle 4 Loosen lock bolt in shift rod adjusting swivel Fig 8 5 Check shift rod fit in swivel Be sure rod does not bind in swivel 6 Verify that transfer case range lever is in 4H position vertical Move lever if necessary 7 Tighten shift rod lock bolt to 90 in lbs torque 8 Lower vehicle 9 Check shift linkage operation Fig 7 Shift Lever ...

Page 1356: ......

Page 1357: ...t yoke if neces sary Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission 3 Install and tighten transfer case attaching nuts to 47 N m 35 ft lbs 4 Install rear crossmember 5 Remove jack stand from under transmission 6 Align and connect propeller shafts 7 Connect speed sensor wires and vacuum switch hoses 8 Connect transfer case shift...

Page 1358: ...ning Rear Case Fig 5 Removing Installing Mode Spring 4 Remove mainshaft mode fork and shift rail as assembly 5 Remove front output shaft Fig 8 NP241 TRANSFER CASE 21 3i7 Fig 8 Removing Installing Front Output Shaft ...

Page 1359: ... Input Shaft FRONT SNAP RING LOW RANGE GEAR RR21F44 Fig 13 Removing Installing Low Range Gear Snap Ring 3 Remove low range gear and input gear as as sembly Fig 12 4 Remove low range gear snap ring Fig 13 5 Remove input gear and thrust washer from low range gear 6 Remove shift detent plug and O ring seal Then remove the detent spring and plunger Fig 14 Re place O ring seal on plug if seal is worn o...

Page 1360: ...d stop ring If there is evidence of chipping or excessive wear install new parts at reassembly Be sure the clutch sleeve slides easily on the clutch hub Synchronizer springs should be in place with the tang inside the cavity of one strut The rings should not exhibit any evidence of interference with the pol ished gear cone or inside diameters of the clutch hub SNAP RING SNAP RING PLIERS RR21F45 Fi...

Page 1361: ...ARING REPLACEMENT 1 Remove both drive sprocket bearings simulta neously using a shop press Tool Handle C 4171 and Remover Installer Tool C 4697 1 Fig 19 2 Clean sprocket bearing bore after removing old bearings 3 Before proceeding note that sprocket bearings are positioned differently Fig 20 Front bearing is installed flush with end of bore However rear bear ing is recessed slightly Be sure to ins...

Page 1362: ...from rear case bore with Re mover Tools L 4518 1 and L 4454 1 Fig 28 2 Clean bearing bore thoroughly Fig 23 Removing Rear Retainer Seal Fig 24 Removing Mainshaft Rear Output Bearing 3 Install new bearing with Handle C 4171 and Installer C 4608 Fig 29 TRANSFER CASE ASSEMBLY 1 Lubricate transfer case components with auto matic transmission fluid during assembly 2 If transfer case bearings were repla...

Page 1363: ...and fork as assembly Be sure shift rail is aligned in range fork and is seated in case bore 10 Install drive chain and front shaft sprocket Fig 7 11 Install snap ring that secures driven sprocket to front output shaft Fig 6 12 Install detent plunger spring and plug Fig 14 Replace O ring on plug if necessary Do not re use old O ring if damaged Tighten plug to 21 N m 16 ft lbs torque 13 Install mode...

Page 1364: ...in retainers if necessary 20 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker silicone adhesive sealer Loctite 518 or Loctite 573 to sealing surface of rear retainer Then install retainer and tighten retainer bolts to 31 Nnn 23 ft lbs 21 Install yokes seal washers and retaining nuts Tighten yoke nuts to 176 271 Nnn 130 200 ft lbs torque 22 Install vacuum switch Tighten switch to 27 Nnn 20 ft lbs...

Page 1365: ...H Clutch Disc Usage Front Clutch Rear Clutch Overdrive Clutch Gas Overdrive Clutch Diesel Direct Clutch 4 4 4 4 4 6 3 4 4 3 4 4 4 5 8 Front Clutch Spring Usage 1 1 9 9 11 Band Adjustments backed off from 72 in lbs Front Band Rear Band 2Vi 4 2Yi 4 214 2 Th 2 Recommended Fluid all MOPAR ATF Plus Type 7176 Automatic Transmission Fluid J9321 210 32RH 36RH 37RH SPACER THRUST PLATE SNAP RING SPECIFICATI...

Page 1366: ...ust plate and spacer are select fit components Refer to size charts and selection procedures in Overdrive Unit Assembly and Adjustment J9221 143 AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS 32RH 36RH 37RH Overdrive Clutch Fourth Gear Only Pressure should be within 21 kPa 3 psi of line pressure Line Pressure at accumulator Closed Throttle 1000 rpm and above 372 414 kPa 54 60 psi 648 kPa 94 p...

Page 1367: ... converter 31 N m 270 in lbs Crossmember Bolts Nuts 68 N m 50 ft lbs Driveplate Bolts 75 N m 55 ft lbs Extension Housing Bolts 43 N m 32 ft lbs Front Band Reaction Pin Access Plug 17 N m 13 ft lbs Front Band Adjusting Screw Locknut 34 N m 25 ft lbs Governor Body to Park Gear Bolts 11 N m 8 ft lbs Lockup Module Screws 4 N m 35 in lbs Neutral Switch 34 N m 25 ft lbs Oil Filter Screws 4 N m 35 in lbs...

Page 1368: ...4 N m 40 ft lbs J9221 250 G360 SET TO TORQUE SPECIFICATIONS NP241 TORQUE SPECIFICATIONS Clutch Housing Bolts 47 N m 35 ft lbs Drain Fill Plugs 47 Nm 35 ft lbs Front Rear Bearing Retainer Bolts 22 30 N m 16 22 ft lbs Rear Crossmember Bolts Nuts 68 N m 50 ft lbs Shift Cover Bolts 22 30 N m 16 22 ft lbs Skid Plate And Crossmember Bolts Nuts 41 N m 30 ft lbs Transfer Case Attaching Nuts 47 Nm 35 ft lb...

Page 1369: ......

Page 1370: ...speed rating are encoded in the letters and numbers imprinted on the side wall of the tire Refer to the chart to decipher the tire identification code Fig 1 Performance tires will have a speed rating letter after the aspect ratio number The speed rating is page Rotation 3 Tire Inflation Pressures 2 Tire Noise or Vibration 4 Tire Wear Patterns 4 Tread Wear Indicators 3 not always printed on the tir...

Page 1371: ... drift Refer to the Owner s Manual for information re garding proper tire inflation pressure This pressure has been carefully selected to provide for safe vehicle operation Tire pressure should be Fig 2 Under infiation Wear Fig 3 Over Infiation Wear checked cold once per month Tire pressure de creases when the outside temperature drops Inflation pressures specified on the placards are al ways cold...

Page 1372: ...e benefits of rotation are especially worth while Rotation will Increase tread life Help to maintain mud snow and wet traction lev els Contribute to a smooth quiet ride The suggested method of tire rotation is the same side front to rear pattern Fig 4 Other rotation methods can be used but they will not provide all the tire longevity benefits Dual wheel vehicles require a different tire rota tion ...

Page 1373: ...tensity as speed varies Tire noise will usually remain constant TIRE WEAR PATTERNS Under inflation results in faster wear on shoulders of tire Over inflation causes faster wear at center of tread Excessive camber causes the tire to run at an angle to the road One side of tread is worn more than the other Excessive toe in or toe out causes wear on the tread edges of the tire from dragging of tire T...

Page 1374: ...M E N T TOE CASTER CAMBER I ALIGNMENT NOT OK ADJUST ALIGNMENT TO PREFERRED SETTINGS O K 1 CAR LEADS OPPOSITE DIRECTION PROBABLE CAUSE TIRES SWITCH TIRES FRONT TO REAR LEFT FRONT TO LEFT REAR LEFT REAR TO LEFT FRONT RIGHT FRONT TO RIGHT REAR RIGHT REAR TO RIGHT FRONT R O A D TEST O K CAR STILL LEADS CROSS SWITCH FRONT TIRES R O A D TEST A CAR STILL LEADS SWITCH RIGHT FRONT 1 R O A D TEST CAR S T I ...

Page 1375: ...rrectly aligning the inner and outer wheels WHEEL INSTALLATION The wheel studs and nuts are designed for specific applications They must be replaced with equivalent parts Do not use replacement parts of lesser quality or a substitute design All aluminum and some steel wheels have wheel stud nuts which feature an en larged nose This enlarged nose is necessary to en sure proper retention of the alum...

Page 1376: ...is not recommended Their service history may have included severe treat ment Refer to the Specifications Chart for informa tion regarding above requirements WHEEL ORNAMENTATION W A R N I N G H A N D L E A L L W H E E L O R N A M E N T A T I O N WITH E X T R E M E C A R E DURING R E M O V A L A N D IN S T A L L A T I O N S H A R P E D G E S ON T H E C O V E R S O R C A P S C A N C A U S E P E R S O...

Page 1377: ...he high spot is within 101 6 mm 4 0 in of the first spot and is still excessive replace the tire If the high spot is within 101 6 mm 4 0 in of the first spot on the wheel the wheel may be out of spec ifications Refer to Wheel and Tire Runout If the high spot is NOT within 101 6 mm 4 0 in of either high spot draw an arrow on the tread from second high spot to first Break down the tire and re mount ...

Page 1378: ...d 2 2ND HIGH SPOT O N TIRE SPOT O N TIRE J9322 5 Fig 10 Remount Tire 90 Degrees In Direction of Arrow J9022 4 Fig 11 Checking Tire Runout 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 spotting from a parked position Make sure all wheel nuts are properly torqued Relocate wheel on the mounting ...

Page 1379: ... is runout in both tire and wheel Remove tire from wheel and re mount wheel on hub in former position Check wheel radial runout Fig 12 STEEL WHEELS Radial runout 0 040 in Lateral runout 0 045 in ALUMINUM WHEELS Radial runout 0 030 in Lateral runout 0 035 in If point of greatest runout is near original chalk mark remount tire 180 degrees Recheck runout ...

Page 1380: ...ne 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 to the vibration condition Refer to the following cause codes and descriptions for explanations when referring to the chart TRR Tire and Wheel Radial Runout Vehicle speed sensitive mechanical vibration The run...

Page 1381: ...hicle 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 differ ential gears and bearings will cause noise Replace the defective component s as necessary SSC Suspension and Steering Components Vehicle speed sensitive mechanical vibration Worn suspension steering components can cause mechani c...

Page 1382: ... 90 Cone 16 Inch Single Wheel 5 8x18 with 90 Cone 16 Inch Single Wheel 5 8x18 with Flanged Nut 16 Inch Dual Wheel TORQUE 109 to 150 N m 80 to 110 ft lbs 115 to 155 N m 85 to 115 ft lbs 240 to 305 N m 175 to 225 ft lbs 410 to 475 N m 300 to 350 ft lbs J9322 9 T O R Q U E S P E C I F I C A T I O N S ...

Page 1383: ......

Page 1384: ...ide Mirrors 13 Roof Vent Ramcharger 20 Splash Shields Front Fender 9 Sport Bar 18 Tailgate 14 LABELS DECALS PLATES GENERAL INFORMATION The labels decals and plates that are attached to Ram Van and Wagon vehicles contain safety or oth erwise essential information Figs 1 2 3 and 4 INSTALLATION Follow the instructions included with each replace ment label decal or plate to affix it to a panel or comp...

Page 1385: ...rews Fig 6 2 Tighten the extension panel screws to 2 N m 17 in lbs torque Tighten the radiator support panel screws to 3 Nnn 21 in lbs torque 3 Install the headlamp bezels and the screws Fig 5 Tighten the screws to 2 Nnn 17 in lbs torque 4 Remove the support and lower the hood GRILLE EMTENSION PANEL REMOVAL 1 Raise and support the hood 2 Remove the grille If necessary refer to the re moval procedu...

Page 1386: ...rille Extension Panel Support Bracket Diesel Engine only GRILLE OPENING PANEL GOP AND RADIATOR SUPPORT PANEL REMOVAL 1 Raise and support the hood Remove the bat tery 2 Remove the grille 3 Remove the extension panel 4 If equipped remove the extension panel sup port bracket 5 Remove the headlamps from the headlamp re ceptacles in the GOP 6 Drain the engine coolant from the radiator in a clean contai...

Page 1387: ...support panel Install the screws Tighten the screws to 23 Nnn 200 in lbs torque 13 Test the hood latch and the release cable for proper operation 14 Install the headlamps in the headlamp recep tacles 15 Install the extension panel support bracket if equipped Install the grille extension panel and the grille 16 Install the battery and the holddown bracket Tighten the holddown rod nuts to 2 Nnn 20 i...

Page 1388: ...s torque 3 Install the cable grommet in the dash panel hole Fig 12 4 Attach the cable to the rear clip in the engine compartment 5 Route the cable under the radiator support panel flange Attach it to the clip and then connect it to the hood latch 6 Adjust the latch cable 7 Test the hood latch release cable for proper op eration RELEASE CABLE HANDLE BRACKET HOOD LATCH RADIATOR BAFFLE PANEL J9123 37...

Page 1389: ... full open po sition 2 Mark the position of the hinge bolts Loosen the bolts Fig 15 3 Support the hood at the side being removed Remove the bolts and hinge from the hood and fender panel INSTALLATION 1 Position the replacement hinge against the fender panel Install and finger tighten the bolts 2 Align the hood bolt holes with the marks 3 Tighten the hinge bolts to 23 N m 200 in lbs torque LATCH ST...

Page 1390: ...o cated at the rear of the cowl grille under the seal 4 Disengage the rear of the grille from the wind shield weatherstrip seal 5 Detach windshield washer hoses from the noz zles and the clips 6 Separate the grille from the cowl Remove it from the cowl upper panel DASH TAB ENGINE SCREW J9123 385 Fig 18 Blower Motor Housing Insulation Panel INSTALLATION 1 Position the grille on the cowl upper panel...

Page 1391: ...ttery H O L D D O W N S T R A P R E A R B R A C E N U T S U P P O R T B R A C K E T B A T T E R Y S C R E W U N U T S U P P O R T B R A C K E T N U T J9123 355 W A S H E R B O L T F W D U N U T L E F T F R O N T F E N D E R N U T B O L T R A D I A T O R B A F F L E P A N E L Fig 20 Battery Tray Removal Installation FRONT FENDERS 3 Remove the grille extension panel 4 Remove the battery and tray for...

Page 1392: ... the splash shield from the frame rail and the fender inner panel INSTALLATION 1 Position the splash shield on the frame rail and the fender inner panel 2 Install the retainers to attach the shield to the fender inner panel and to the frame rail 3 Install the frame rail to shield screws and pushnuts RIGHT FRONT FENDER CLIP RETAINER CLIP RETAINER FRAME LEFT FRONT FENDER SPLASH SHIELD FRAME RAIL RIG...

Page 1393: ... 27 with a heat gun 2 Lift one edge of the nameplate with a putty knife or a similar thin blade tool Peel the mould ing and tape from the panel Apply additional heat to any location where the tape remains 3 Remove the residual tape adhesive from the panel with 3M All Purpose Cleaner or an equivalent INSTALLATION 1 Clean the painted panel surface with a com mercial wax and silicone removal solution...

Page 1394: ...tailgate hatch gate INSTALLATION 1 Position the applique on the tailgate hatchgate with the corner studs mated with the retainers 2 Install the applique screws in the tailgate hatchgate Figs 29 and 30 Tighten the screws to 2 N m 20 in lbs torque 3 If applicable install the hatchgate trim panel 4 Close the tailgate hatchgate ROOF MOULDING REMOVAL 1 Remove the moulding end caps 2 Pry the moulding fr...

Page 1395: ... ing of stripe 7 Apply soap solution to body panel surface 8 Place stripe into position on body panel Smooth out wrinkles by pulling lightly on edges of tape stripe until it lays flat on panel surface 9 Push air pockets from under tape stripe to the perimeter of the panel from the center of the tape stripe out 10 Remove air bubbles from under tape stripe us ing a body putty squeegee Fig 34 CAUTION...

Page 1396: ... t e t h e r is a l s o a t t a c h e d to the c a r g o box panel w i t h o n e of t h e s c r e w s 5 Remove the housing and nozzle tube from the cargo box panel INSTALLATION 1 Position the fuel filler housing and nozzle tube and the fuel cap tether at the opening in the cargo box panel 2 Install the housing nozzle and tether screws in the panel Tighten the screws to 2 N m 20 in lbs torque 3 Att...

Page 1397: ...es 3 Install the mirror base nuts Tighten the nuts to 11 N m 95 in lbs torque 4 Position the cover over the mirror base 5 Install the cover screw Tighten the screw to 2 N m 17 in lbs torque LOW PROFILE OUTSIDE MIRROR REMOVAL 1 Remove the bolts that attach the support braces to the door outer panel 2 Remove the mirror and braces from the door outer panel INSTALLATION 1 Position the mirror and brace...

Page 1398: ...DOWN HOLD CAB REAR D O W N HOLD J9113 18 Fig 41 Cab Holddowns Typical Single rear wheel On the left side insert the tail gate hinge half into the cargo box hinge half Move the tailgate to the left On the right side insert the tailgate hinge half into the slot in cargo box hinge half Dual rear wheel On the left side connect the tail gate clearance ID lamp wire harness connectors In sert the wire ha...

Page 1399: ...eparate the clip and rod from each latch TAILGATE ASSEMBLY 1 Lubricate the latches the handle and lock and the rod ends before assembly 2 Install the rod and clip on each latch 3 At each end of the tailgate insert the rod into the opening Position the latch on the end of the tail gate Install the bolts Tighten them to 23 N m 200 in lbs torque 4 Connect the lock latch rods to the lock arms Retain t...

Page 1400: ...oof panel screws Tighten the screws to 23 N m 200 in lbs torque 5 Test the hatchgate and hinge operation If nec essary add spacer s for hinge adjustment AUXILIARY RETAINER SCREW NUT HATCHGATE J9123 387 Fig 46 Hatchgate Support Rod Hinge Removal Installation HATCHGATE REMOVAL 1 Open and support the hatchgate 2 Remove the hinge roof panel screws WARNING D O NOT DISCONNECT T H E S U P P O R T R O D S...

Page 1401: ...ainers from the inner panel Remove the trim panel from the hatchgate 3 Remove the screws and the latch cover Fig 48 4 Remove the screws at each side of the hatch gate Disengage both lock tubes from the latch 5 Remove both lock tubes from the hatchgate 6 Disconnect the hatchgate ajar switch and ground wire from the latch Fig 49 7 Remove the screws and the latch from the hatchgate inner panel 8 Remo...

Page 1402: ...cle rear frame structure with bolts Fig 51 If necessary the box can be removed for repair service access or replacement Refer to the procedure within Group 13 Frame Fig 50 Sport Bar CARGO CARGO BOX SIDE PANEL BRACES DUAL REAR WHEELS REMOVAL 1 Remove the brace side panel screw and U nut 2 Remove the floor cross sill screw 3 Remove the brace from the cargo box INSTALLATION 1 Position the brace at th...

Page 1403: ... and the frame 4 Install the hinge on the cover with the screws Tighten the screws to 11 N m 95 in lbs torque 5 Water test the roof vent FRAME REMOVAL 1 Remove the screws and the inner trim ring from the headliner and roof panel Fig 53 Roof Vent 2 Separate the seal between the frame and the roof panel 3 Remove the vent cover and frame from the roof panel as a unit INSTALLATION 1 Clean frame and ro...

Page 1404: ...ge Hinge Replacement 21 Key Lock Cylinder 25 Power Door Lock Motor 26 Service Information 21 Vent Window and Channel 23 Window Glass and Door Weatherstrip Seals 27 Window Glass Channels Regulators 23 7 Remove the floor jack from the door 8 If necessary adjust the door Refer to the ad justment procedure s DOOR ADJUSTMENT The door position is adjusted at the hinge locations at either the cowl or the...

Page 1405: ...removal procedure 2 Disconnect the component wire harness from the main wire harness Remove the main wire har ness retainer from the door panel Remove the main wire harness from the door 3 Support the door with a padded floor jack 4 Remove the door hinge bolts from the cowl Re move the floor jack and the door from the vehicle 5 If equipped retain the door hinge shims for proper installation INSTAL...

Page 1406: ...glass channel 6 Install the beltline weatherstrip seal 7 Raise or lower the vent window to provide a 1 6 mm 0 06 in fore aft glass freeplay Then raise the window to the closed position Tighten the upper screw to 2 N m 18 in lbs torque 8 Lower the window glass completely Position the front channel tightly against the glass Tighten the front channel lower bracket screw to 11 N m 95 in lbs torque 9 T...

Page 1407: ...rom the window regulator arm roller 4 Lower the glass and channel to the bottom of the door 5 Remove the center of the regulator rivets with a drift punch Fig 6 Drill them out with a 6 mm 1 4 in diameter drill bit 6 Remove the regulator from the door INSTALLATION 1 Position the regulator in the door Fig 6 Re tain it on the inner door panel with 1 4 20 x 1 2 bolts and nuts Tighten the nuts to 10 N ...

Page 1408: ...m panel and the waterdam DETERMINING KEY LOCK CODE When the door key or the key code is not available the following procedure can be used to determine the key code 1 Remove the lock cylinder from the door 2 Remove the tumbler cover from the lock cylin der housing and discard it Fig 9 3 Individually remove each spring driver and tumbler set from the lock cylinder housing DOOR KEY Fig 8 Key Lock Cyl...

Page 1409: ... waterdam and the trim panel If necessary refer to the installation procedure DOOR INSIDE HANDLE REMOVAL 1 Raise the window glass to the closed position 2 Remove the door trim panel and the waterdam 3 Remove the handle latch rod from the inside handle actuator Fig 10 4 Remove the screws from the reinforcement plate Remove inside handle and seal from the door inner panel INSTALLATION 1 Position the...

Page 1410: ...or latch rod 4 Remove the door latch screws from the door in ner panel face 5 Remove the door latch from the door INSTALLATION 1 Install the latch striker if removed 2 Insert the door latch Position it at the door in ner panel face and connect the rods to it 3 Install the latch screws in the door panel face Fig 12 Tighten the screws to 9 Nnn 7 ft lbs torque 4 Test and verify that the latch operate...

Page 1411: ...at the corners is critical The seal must be seated at each corner Avoid puck ering and stretching the seal at the corners 3 When correctly installed the seal ends will meet at the door lower centerline 4 Inspect the fit of the door in the door opening If not correct adjust the door fit so the seal is not damaged when the door is closed Refer to the door adjustment procedure BUTYL DOOR Fig 14 Cab B...

Page 1412: ...rip seal Fig 2 4 Position an assistant outside the vehicle to re ceive the windshield glass 5 Starting at either inside upper corner gently push the glass outward Separate it from the weath erstrip seal Continue until the glass is completely separated from the seal Fig 3 6 The assistant now can remove the glass from outside the vehicle 7 Remove the weatherstrip seal from the wind shield opening 8 ...

Page 1413: ...nuts to 3 N m 24 in lbs torque 3 Attach the latch to the quarter panel Tighten the screws to 3 N m 24 in lbs torque 4 Test the vent window for water leaks WEATHERSTRIP SEAL REMOVAL 1 Remove the vent window If necessary refer to the removal procedure 2 Pull the seal away from the flange 3 Clean the flange as necessary INSTALLATION 1 Position the seal at the window opening 2 Mate the seal with the f...

Page 1414: ...e window and seal in the opening with the free ends of the cord inside the vehicle Pull on the cord ends Pull the seal channel lip over the window flange 5 Test the window for water leaks 6 As applicable install the window reveal moul ding or retainer 7 Clean the vehicle as necessary SLIDING WENT GLASS REMOVAL 1 Remove the complete rear window from the cab opening If necessary refer to the removal...

Page 1415: ...n the weatherstrip seal 3 Install the retainer strip in the seal channel 4 Install the hatchgate window glass according to the following instructions Moisten a length of 6 mm 1 4 in diameter cord with a soap and water solution Verify that the cord is long enough to go all the way around the edge of the weatherstrip seal Insert the cord into the window flange in the seal Position the glass in the w...

Page 1416: ...ect installation Fig 13 4 Apply butyl tape to the entire edge of the win dow flange Fig 14 SECTION A A SECTION B B Fig 14 Butyl Tape Installation 5 Remove excess tape and butt the tape ends firmly together 6 Install the quarter window glass on the butyl tape Fig 15 7 Force the glass against the butyl tape to obtain a good seal Fig 15 8 Test the quarter window glass for water leaks 9 If leakage occ...

Page 1417: ......

Page 1418: ...luster or component Refer to Group 8 Elec trical for additional information 4 If applicable disconnect the shift position indi cator from the steering column Fig 3 5 Remove the IP cluster or component from the instrument panel INSTALLATION 1 Position the IP cluster or component at the in strument panel Connect the wire harness connec tors 2 Install the cluster or component in the instru ment panel...

Page 1419: ...lbs torque 3 Position the ash receiver tray in the housing Connect the wire harness connector to the cigarette lighter GLOVE BOX REMOVAL 1 Remove the glove box door hinge screws from the instrument panel Fig 5 2 Remove the glove box from the instrument panel INSTRUMENT PANEL SCREW LAMP HOOD PANEL ASH TRAY HOUSING LIGHTER ELEMENT SCREW LIGHTER CLAMP ASH TRAY HOUSING LIGHTER SHELL ASH RECEIVER TRAY ...

Page 1420: ...reinforcement bracket I P screws to 3 N m 24 in lbs torque 2 Position the I P at the dash panel 3 Connect the Wire harness connectors Window defog tubes Speedometer cable Heat vent tube PRNDL cable Temperature control cable to the I P Refer to the applicable service informa tion groups for additional information 4 Install the I P screws Tighten the IP cowl screws to 23 N m 200 in lbs torque Tighte...

Page 1421: ...to 2 N m 20 in lbs torque 4 Install the instrument panel on the dash panel If necessary refer to the installation procedure G L O V E B O X O P E N I N G S C R E W I N S T R U M E N T P A N E L I N S T R U M E N T C L U S T E R O P E N I N G l P T P L E N U M P A N E L R E I N F O R C E M E N T B R A C K E T 7 L O W E R R I G H T S C R E W R E I N F O R C E M E N T R E I N F O R C E M E N T B R A ...

Page 1422: ... nuts to 26 Nnn 230 in lbs torque 8923 56 Fig 14 Left Side Bucket Seat REMOVAL RIGHT SEAT The right side bucket seat is equipped with a tilt able platform This is to provide entry to the rear seating area Fig 15 When tilted a gas operated rod supports the seat The tilt latch release levers are located on the side and on the rear of the seat 1 Remove the bolts that attach the seat platform tilt hin...

Page 1423: ...minate all vertical freeplay at rear of the seat platform TILT LATCH STRIKER R E M O V A L R I G H T SEAT 1 Remove the striker bolts from the reinforce ment panel and the floor panel 2 Remove the striker from the panels TILT LATCH STRIKER INSTALLATION RIGHT SEAT The latch striker can be adjusted via the slotted holes in the striker base 1 Position the striker on the reinforcement panel 2 Install t...

Page 1424: ...de of the cab 4 Remove the support Lower the vehicle Re move the jump seat cushion from the cab INSTALLATION 1 Position the backrest at the cab side panel In stall the nuts Tighten them to 4 N m 35 in lbs torque 2 Install the cab side trim panel 3 Position the seat cushion in the cab 4 Raise and support the vehicle Install the nuts on the hinge studs Tighten the nuts to 23 N m 200 in lbs torque 5 ...

Page 1425: ...panels are comprised of the Windshield header trim panel Door header trim panels A pillar trim panels Cowl side trim panels Rear corner trim panels Quarter window trim panels Rear window upper trim panel RD156 Fig 21 Folded Seatback V l t w I I N DIRECTION OF ARROW D DIRECTION OF ARROW C SEAT CUSHION Fig 22 Folding Seat Cushion Hinges Torsion Bar Rear window lower trim panel Rear header hatchgate ...

Page 1426: ...trim panel to avoid possible damage to both trim panels Fig 25 ROOF INNER PANEL REAR TRIM PANEL WEATHERSTRIP SEAL A PILLAR A PILLAR TRIM PANEL DOOR HEADER TRIM PANEL DOOR HEADER A N D REAR TRIM PANEL JUNCTION ROOF INNER PANEL WINDSHIELD GLASS DOOR HEADER TRIM PANEL D O O R HEADER TRIM PANEL WINDSHIELD HEADER TRIM PANEL WINDSHIELD GLASS D O O R HEADER A N D A PILLAR TRIM PANEL JUNCTION DOOR HEADER ...

Page 1427: ...OOK REAR WINDOW LOWER TRIM PANEL J9023 58 Fig 28 Club Cab Quarter Window Rear Window Upper Lower Trim Panels SCREW COAT HANGER HOOK REAR UPPER TRIM PANEL J9123 381 Fig 29 Coat Hanger Hook QUARTER WINDOW UPPER AND HATCHGATE HEADER TRIM PANELS REMOVAL 1 For convenience fold forward the rear passen ger seat If necessary refer to the removal procedure 2 Remove the spare tire 3 Remove the trim panel sc...

Page 1428: ...orque 5 Install the spare tire SPARE TIRE CARRIER RETAINER ROD AND STAND OFF 2 Remove the quarter window trim panel and the quarter panel lower trim panels If necessary refer to the removal procedures 3 Remove the rod retainer from the quarter panel support bracket 4 Remove the tire stand off cap nut bolt and spacer from the quarter window lower panel INSTALLATION 1 Install the tire stand off bolt...

Page 1429: ...r anchor bolts in the side panels Tighten the anchor bolts to 40 N m 350 in lbs torque Ram Trucks and Chassis Cabs Install the cover to conceal the shoulder belt upper anchor bolt Ramchargers Install the quarter window trim panel If necessary refer to the installation proce dure 3 Position the belt buckles on the floor panel 4 Install the shoulder belt buckles Install the lap belt and buckle ancho...

Page 1430: ...in the floor panel Tighten the anchor bolts to 40 Nnn 350 in lbs torque 3 Position the shoulder belt upper anchor plate at the roof inner liner Install the upper anchor bolts in the roof inner liner Tighten the anchor bolts to 40 Nnn 350 in lbs torque 4 Position the covers over the upper anchor bolts 5 Install the quarter panel lower trim panel If necessary refer to the installation procedure 6 In...

Page 1431: ...val installation Permanent damage possibly will result 1 Remove the sunvisors and clips If necessary refer to the removal procedure 2 As applicable remove the dome cargo lamp and or the dome reading lamp 3 Ram Trucks and Chassis Cabs remove the Windshield header trim moulding Door header trim moulding Rear corner trim panel or quarter window trim panel club cab Rear window upper trim moulding If n...

Page 1432: ...NER SCREW RETAINER SNAP ON TRIM MOULDING ENDCAP CENTER OF VEHICLE FRONT HEADLINER REAR HEADLINER ROOF INNER PANEL WINDSHIELD HEADER TRIM MOULDING FRONT OF VEHICLE SCREW SCREW SUN VISOR SCREW REAR TRIM ARM MOULDING REAR OF VEHICLE J9123 359 Fig 43 Ramcharger Sunvisor Headliner Trim Moulding ROOF INNER PANEL BRACKET BULB HOLDER DOME LAMP BRACKET HEADLINER LENSE DOME LAMP WITH HEADLINER SCREW DOME LA...

Page 1433: ...port bracket to the roof inner panel Figs 42 and 43 2 Detach the sunvisor from the clip 3 Remove the sunvisor from the roof inner panel 4 Remove the screw and the clip from the roof in ner panel INSTALLATION 1 Install the sunvisor clip with the screw Tighten the screw to 4 N m 35 in lbs torque 2 Position the sunvisor in the clip Align the arm support bracket holes with the headliner holes 3 Instal...

Page 1434: ...retainers sill well covers and scuff plates 4 Remove the carpet mat from the floor panel and the vehicle INSTALLATION 1 Position the carpet mat on the floor panel 2 Install seat s and all other necessary compo nents If necessary refer to the applicable installa tion procedure s 3 Install the trim panels retainers sill well cov ers and scuff plates 4 Place the floor mats if equipped on the carpet m...

Page 1435: ...T E S C U T C H E O N 1 5 I N A D H E S I V E N O I S E N D I N S U L A T O R nj F R O N T R E T A I N E R S F R O N T F L O O R C A R P E T N O I S E I N S U L A T O R D A S H C A R P E T S C U F F P A N E L X A R P E T P L A T E P A N E L S C U F F P L A T E R E A R F L O O R C A R P E T S D O O R S I L L P A N E L J 9 1 2 3 4 1 3 Fig 54 Carpet Scuff Plate Rear Seat Striker Escutcheon Retainers ...

Page 1436: ... C A R P E T O R M A T QR t H O L E F O R T R A N S F E R C A S E H O L E F O R A 8 3 3 O V E R D R I V E S C R E W P L A T E S C R E W S C R E W F L O O R 1 I N S U L A T I O N P A N E L P A D S H I F T L E V E R C O V E R W A S H E R S C R E W C A R P E T F L O O R O R M A T P A N E L B O O T S E A L I N S U L A T I O N P A D 4 S P E E D T R A N S M I S S I O N ANb TRANSFER C A S E A 8 3 3 O V E...

Page 1437: ...Remover and allow to dry 3 Fill the inside of the scratch or chip with a coat of filler primer Do not overlap primer onto good sur face finish The applicator should be wet enough to puddle fill the defect without running Do not stroke brush applicator on body surface Allow the filler primer to dry hard 4 Cover the filler primer with color touch up paint Do not overlap color touch up onto the origi...

Page 1438: ...OMPRESSOR The seven piston SD 709 com pressor is used on all vehicles This compressor com presses the low pressure refrigerant vapor into a high pressure high temperature vapor CLUTCH PULLEY AND COIL These are mounted on the compressor providing a convenient way to drive it and disengage it in accordance to the cooling needs CONDENSER The condenser is located in front of the radiator Its function ...

Page 1439: ...rator core Having given up its heat to boil the refrigerant the air is cooled and passes into the passenger compartment of the vehi cle From the evaporator the vaporized refrigerant is drawn back to the compressor to repeat the cycle RADIATOR CAP Air conditioned vehicles must be equipped with a radiator cap having a holding pressure of 98 122 kPag 14 18 psig Replace the radiator cap that does not ...

Page 1440: ...ngine coolant is provided to the heater system by 2 heater hoses With engine idling at normal operat ing temperature set the heater control to maximum heat defrost and high blower setting Using a test thermometer check the air temperature coming from the defroster outlets refer to Temperature Reference Chart Should the temperature not meet the minimum values shown refer to Heater Diagnosis Mechani...

Page 1441: ...g d Blower motor defective HEATER DIAGNOSIS MECHANICAL INSUFFICIENT HEAT OBSTRUCTED HEATER OUTLETS TEMPERATURE DOOR MISDIRECTED OR BINDING KINKED OR UNATTACHED CONTROL CABLE SEE CONTROL CABLE SECTION MODE DOOR IMPROPERLY ADJUSTED OR BINDING UNATTACHED CONTROL CABLE OBSTRUCTED HEATER HOSE KINKED HEATER HOSE SEE ROUTING AIR IN HEATER CORE LOW COOLANT FLOW INSUFFICIENT COOLANT IN SYSTEM DEFECTIVE THE...

Page 1442: ... MOTOR WIRE CONNECTOR MAKE SURE FEED WIRE TERMINALS ARE NOT BACKED OUT OF INSULATOR OR OFF CENTER CHECK RESISTOR CONTINUITY AND RESISTOR CONNECTIONS VOLTAGE AT BATTERY LEAD CONNECTOR REMOVE WIRING CONNECTORS FROM RESISTOR TERMINALS MAKE SURE THAT TERMINALS ARE NOT BACKED OUT OF INSULATOR CHECK FOR BATTERY VOLTAGE IN EACH FAN SWITCH POSITION REPLACE SLOWER SWITCH VOLTAGE IN ALL SWITCH POSITIONS CHE...

Page 1443: ...ISE STILL PRESENT LO DSE TIGHTEN RE CHECK MOUNTING OK OK NOISE GONE PROBLEM NOT IN BLOWER SYSTEM VIBRATION STILL PRESENT CHECK BLOWER SCROLL AREA FOREIGN MATERIAL IN FAN OR SCROLL YES REMOVE FOREIGN MATERIAL FAN RUBBING HOUSING NO REPLACE MOTOR RE CHECK VIBRATION GONE YES A TO C DJUST ZORRECT RE CHECK REMOVE BLOWER WHEEL AND OPERATE BLOWER MOTOR AT LOW SPEED REPLACE BLOWER WHEEL RE CHECK NOISE STI...

Page 1444: ...m will not be low on charge un less there is a leak Find and repair the leak If the leak can be repaired without discharging the system the low refrigerant charge level can be corrected as follows Maintaining the discharge pressure of 1 550 1 720 kPag 225 250 psig add refrigerant gas through compressor suction line until foam is cleared from sight glass Then add 13 oz 368 g or 1 can of refrigerant...

Page 1445: ...e of the instrument panel COMPRESSOR OIL LEVEL It is important to have the correct amount of oil in the A C system to ensure proper lubrication of the compressor Too little oil will result in damage to the compressor Too much oil will reduce the cooling ca pacity of the system and consequently result in higher discharge air temperatures To provide the desired balance for adequate lubri cation and ...

Page 1446: ... 60 ML 2 FL OZ CONDENSER 30 ML 1 FL OZ FILTER DRIER 30 ML 1 FL OZ REPLACE COMPONENT COMPRESSOR DRAIN OIL REMOVE FILTER DRIER AND COMPRESSOR CHECK FOR LEAKS REMOVE VISUALLY INSPECT FOR CONTAMINATION AND CLEAN H VALVE 1 1 DISCHARGE SYSTEM AND CORRECT LEAKS 1f REPLACE FILTER DRIER INSTALL NEW FILTER DRIER COMPRESSOR DRAIN OIL INSTALL REPLACEMENT COMPRESSOR OIL REQUIRED IN COMPRESSORS 136 ml 4 6 oz CO...

Page 1447: ...ause of trouble To perform the test the air temperature in the test room must be 21 C 70 F minimum 1 Connect a tachometer and manifold gauge set Fig 5 2 Set A C controls to MAX A C temperature le ver on full cool and blower on HIGH 3 Start engine and adjust rpm to 1 000 RPM with A C clutch engaged 4 Engine should be warmed up with doors win dows and hood closed 5 Insert a thermometer in the left c...

Page 1448: ...MPRESSOR DISCHARGE GAUGE PSIG kPag 2 m POSSIBLE I CAUSE I 20 35 PSIG 140 240 PSIG 1000 HI 140 TO 240 kPag 966 TO 1656 kPag i NORMAL C r a FREEZE H VALVE 15 INCHES OF VACUUM THAW H VALVE 38 PSIG 262 kPag OR MORE THEN DROPS TO 25 TO 35 PSIG 172 TO 240 kPag RETURN RECIRC DOOR VACUUM LINES TO NORMAL a 1000 HI 20 30 PSIG 140 TO 207 kPag H240 PSIG OR HIGHER 1656 kPag 20 30 PSIG 140 207 kPag 140 PSIG 966...

Page 1449: ...MENTS AND TESTS To keep the vacuum harness in place common vi nyl tape sometimes called plastic tape of electri cian s tape cannot be used It will cause the tube to deteriorate directly under the tape when high under hood temperatures are involved A compatible nylon type of tape such as MS CH69 281 or an equiva lent must be used The test of the push button switch operation deter mines whether or n...

Page 1450: ... exactly 27 kPag 8 inches If correct inspect the fit of the 7 port hose connector plug on the push button switch This plug must be positioned all the way onto the 7 ports on the push button switch CAUTION Do not use lubricant on the switch ports or in the holes in the plug a s lubricant will damage the vacuum valve in the switch If it is difficult to properly position connector plug on the switch ...

Page 1451: ...defective or missing 4 Test the vehicle If noise persists continue trouble shooting system for source of noise Refer to A C Compressor and Clutch Diagnosis Charts CLUTCH COIL TEST 1 Verify battery state of charge test indicator should be green 2 Connect an ammeter 0 10 ampere scale in se ries with the clutch coil terminal Use a voltmeter 0 20 volt scale with clip leads measuring voltage across the...

Page 1452: ... REPLACE COMPRESSOR FRONT COVER COMPRESSOR WONT TURN PROPERLY CLUTCH ENGAGES BUT SLIPS OR SMOKES CLUTCH SLIPPING LOW VOLTAGE AT CLUTCH CHECK WIRING SWITCHES CLUTCH AMPERAGE AND GROUND I AMPERAGE GREATER THAN 5 AMPS CLUTCH COIL PARTIALLY SHORTED REPLACE COIL OIL GREASE ON FRICTION SURFACES CHECK SHAFT SEAL FELT COIL SNAP RING NOT PROPERLY INSTALLED IF BEARING DEFECTIVE REPLACE PULLEY AND ARMATURE N...

Page 1453: ... f CHECK WIRING AND SWITCHES f CHECK VOLTAGE DROPS FROM CLUTCH TOWARD BATTERY CYCLING SWITCH IF CONTACT OPEN CHECK REFRIGERANT CHARGE IF CHARGE OK REPLACE SWITCH COMPRESSOR LEAKS OIL OR REFRIGERANT DEFECTIVE CRANKSHAFT SEAL CARTRIDGE DEFECTIVE CRANKSHAFT SEAL PLATE DEFECTIVE SEAL O RING FRONT COVER REAR COVER DEFECTIVE COMPRESSOR THRU BOLT READ COMPRESSOR SERVICE SECTION FOR REPAIR DEFECTIVE COMPR...

Page 1454: ... The discharge of R 12 gas near an open flame page Pressure Gauge and Manifold Assembly 18 Refrigerant 17 Refrigerant Leak Repair Procedure 20 Service Precautions 17 can produce a very poisonous gas called phosgene Phosgene is generated when a flame type leak detec tor is used CAUTION When charging an A C system always keep the tank in an upright position If the tank is on its side or upside down ...

Page 1455: ... and Manifold Assembly Tool C 3740 A is the most important tool used to service the air conditioning system Fig 1 COMPONENTS E AP0RAT0R SUCTiOl GAUiE The left side of the manifold set is calibrated to register 0 to 100 kPag 0 to 30 inches of vacuum The gauge will also register 0 to 1 000 kPag 0 to 150 psig This gauge is connected to the suction ser vice port of the compressor A special service por...

Page 1456: ...cessary to adhere to the fol lowing procedure to keep air and moisture out of the system 1 Connect the manifold gauge set to the compres sor and long test hose from manifold gauge set center connection to Vacuum Pump Tool C 4289 2 Open both manifold gauge set valves 3 Start the vacuum pump and operate until the evaporator suction gauge registers at least 88 kPag 26 inches of vacuum If at least 88 ...

Page 1457: ...se of an especially low charge add 230 g 1 2 lb of refrigerant If there has been a significant oil loss check the system oil level If leak repair was possible without discharging system and an oil level check was not necessary use procedure for correcting low refrigerant level CORRECTING LOW REFRIGERANT LEVEL Since the refrigeration system is completely sealed the refrigerant level will not be low...

Page 1458: ...sor and install protective caps at service ports R V I C E S D 7 0 9 INDEX page Compressor 21 Compressor Shaft Seal 25 The A C system uses a 7 piston design Sanden SD 709 compressor Designated the SD 709 the compres sor is mounted on the front right side of the engine and is driven by a serpentine belt System lubrication is provided by 135cc 15cc 4 6 cu in 0 5 cu in of 500 viscosity refrigerant oi...

Page 1459: ...hen the compressor is not in operation the pul ley free wheels on the clutch hub bearing When the coil is energized the plate is magnetically engaged with the pulley and turns the compressor shaft J8924 18 Fig 3 Clutch Front Plate REMOVAL 1 Insert the 2 pins of the front plate spanner into any 2 threaded holes of the clutch front plate Fig 2 Hold clutch plate stationary Remove hex nut 2 Remove clu...

Page 1460: ...rotor puller shaft protector over the ex posed shaft 8 Install the puller plate and bolt Fig 7 2 bolts go through the plate and into the jaws Finger tighten bolts 9 Turn puller center bolt clockwise using 3 4 inch socket until rotor pulley is free J8924 23 Fig 8 Loosen Coil Lead Wire FIELD COIL SNAP RING J8924 22 J8924 24 Fig 9 Snap Ring and Field Coil INSTALLATION 1 Install the field coil with th...

Page 1461: ...ck that original clutch shims are in place on compressor shaft b Replace compressor shaft key c Align front plate keyway to compressor shaft key 9 Install front plate assembly 10 Using shaft protector gently tap front plate to shaft until it has bottomed to the clutch shims Fig 12 Listen for a distinct change of sound during the tapping process J8924 27 Fig 12 Front Plate to Shaft Installation 11 ...

Page 1462: ... into the threaded holes 3 Turn center bolt clockwise until front plate is loosened Shaft seal replacement should be done on the bench Never use any old parts of the shaft seal assembly Rebuild the complete assembly 4 Insert the snap ring tool points into the 2 holes of the felt ring metal retainer and remove felt ring Fig 14 5 Remove the clutch shim Use O ring hook and a small screwdriver to prev...

Page 1463: ...t free or synthetic cloth and clean refrigerant oil Then blow out with dry pressurized vapor 2 Make sure all foreign substances are thor oughly removed 3 Insert Seal Sleeve Protector over compressor shaft Fig 19 J8924 34 Fig 19 Insert Seal Sleeve Protector 4 Do not touch the new seal lapping surfaces Dip the mating surfaces in clean refrigerant oil before proceeding 5 Engage slots of Seal Remover ...

Page 1464: ...s 12 Replace shaft hex nut Tighten the hex nut to 37 N m 27 ft lbs torque 13 Check air gap with feeler gauge The specifi cation is 0 406 0 787 mm 0 016 0 031 inch If air gap is not consistent around the circumference lightly pry up at the minimum variations Lightly tap down at points of maximum variation The air gap is determined by the spacer shims When installing the original or a new clutch ass...

Page 1465: ...nstalling the cylinder head valve plate use the new gaskets in the parts kit 1 Coat new valve plate gasket with clean refrig erant oil 2 Install valve plate gasket by aligning valve plate gasket to locating pin holes and oil orifice in cylinder block For easy reference the gaskets have a notch at the bottom outside edge 3 Install valve plate by aligning valve plate lo cating pins to the pin holes ...

Page 1466: ...ating system is dependent upon correct opera tion and adjustment of all operating controls The in spections tests and adjustments should be used to locate the cause of a malfunction The tests in this page Evaporator Heater Assembly 36 Expansion H Valve 37 Faceplate 32 General Information 29 Heater Assembly 33 Heater Control 32 Louver Assemblies 39 Operation of All Controls 29 Resistor Block 33 Tem...

Page 1467: ...outside air door is open same as A C mode Vacuum is applied to the top side of the air condi tioning door actuator This will close off the passage to the air conditioning distribution duct and open the passage to the heater defroster duct Since the heat er defroster door is in the heat position the full flow of heated air goes through the heater outlets A small amount of heated air will bleed thro...

Page 1468: ...CUUM VIOLET RED I CHECK VALVE I DEFROSTER H 5 W N RESTRICTOR DARK GREEN AIR COND t ACTUATOR I HEATING WATER VALVE ACTUATOR ON OFF YELLOW HEAT ACTUATOR LIGHT GREEN RECIRCULATING GRAY ACTUATOR OUTSIDE AIR SOLID LINE INDICATES ENGINE VACUUM VIOLET ACTUATOR HEAT PUSH BUTTON CONTROL VACUUM SWITCH RESTRICTOR IS PART OF VACUUM CONNECTOR AND NOT VISIBLE ACTUATOR OUTSIDE RN1001 Fig 1 Vacuum Circuits Air Co...

Page 1469: ...TION 1 Engage attaching clips around bottom of face plate 2 Connect 4 WD drive indicator wiring if equipped 3 Roll faceplate into position and install mount ing screws Fig 2 4 Install map lamp HEATER CONTROL REMOVAL 1 Remove faceplate 2 Remove attaching screws Fig 3 3 Pull control outward TAB FLAG FLAG RETAINER J9124 118 MOUNTING SCREW 2 HEATER CONTROL UNIT RB459 Fig 3 Heater Control 4 Disconnect ...

Page 1470: ...on control unit 5 Install control unit into instrument panel 6 Install faceplate 7 Move levers to extreme right to adjust clips RESISTOR BLOCK REMOVAL 1 Remove connector from resistor block 2 Remove mounting screws 3 Remove resistor block from plenum INSTALLATION 1 Place resistor block on plenum 2 Install mounting screws 3 Connect wiring connector HEATER ASSEMBLY REMOVAL 1 Disconnect the negative ...

Page 1471: ... the cover that retains instrument panel wiring Let wiring hang free 16 Remove mounting screw and slide left air duct out through instrument cluster opening if equipped Fig 9 17 Remove screws attaching defroster duct to dash panel Fig 9 18 Reach in through instrument panel opening and disengage snaps to separate defroster duct into 2 pieces 19 Remove defroster duct halves through instru ment clust...

Page 1472: ...ASSEMBLIES HEAT DEFROST DOOR ACTUATOR DEFROSTER DUCT MOUNTING SCREW TEMPERATURE CONTROL CABLE RED FLAG MOUNTING HARNESS TAB VACUUM HARNESS MOUNTING NUT BLOWER MOTOR RECEIVER TEMPERATURE CONTROL LEVER HEATER A C CONTROL ASSEMBLY MOUNTING NUT BLOWER MOTOR FEED WIRES VACUUM LINES i DRAIN TUBE RB4 B Fig 9 Heater and Evaporator Assembly ...

Page 1473: ...e cowl side trim panel 11 Detach radio ground strap 12 Remove center distribution duct 13 Remove floor air distribution duct 14 Disconnect temperature control cable from unit through glove box and tape out of way 15 Disconnect vacuum lines from extension on control unit and detach vacuum lines from defroster duct Fig 10 16 Remove wiring connector from resistor block 17 Remove blower motor connecto...

Page 1474: ...heater hoses and unit In stall condensate tube Fig 9 19 Connect refrigerant and heater lines to unit on engine side 20 Connect the negative cable to the battery 21 Fill the cooling system refer to Group 7 Cool ing System 22 Evacuate and charge the system 23 Check operation of all controls and perfor mance of the A C system HEATING AND AIR CONDITIONING 24 37 H VALVE Fig 13 Expansion H Valve Assembl...

Page 1475: ...ument panel cluster 8 Install right instrument panel pivot bolt 9 Install right kick pad 10 Install instrument panel center brace 11 Position the duct in through glove box open ing Fig 9 Install mounting screw 12 Close glove box 13 Connect the negative cable to the battery AIR CONDITIONER DISTRIBUTION AND SPOT COOLER DUCTS RIGHT BI LEVEL REMOVAL 1 Disconnect the negative cable from the battery 2 O...

Page 1476: ...in carefully swing the assembly into housing so the felt pads are not damaged Ensure top and bot tom pivot pins are properly engaged 3 Install faceplate TORQUE SPECIFICATIONS DESCRIPTION f O R Q U E DESCRIPTION Compressor SD 709 Cylinder Head Bolts 32 N m 24 ft lbs Magnetic Clutch Hex Nut 37 N m 27 ft lbs Mounting Bolts 27 N m 20 ft lbs Oil Filter Plug 10 N m 7 ft lbs Service Valve to Compressor F...

Page 1477: ......

Page 1478: ...rred to as the engine controller or SBEC The PCM records the vehicles mileage and stores it into memory every 8 miles At that time the PCM checks for the 60 000 and 82 500 mileage trip points When the current mileage matches one of the above men tioned trip points the SRI light is activated The following parts are to be replaced at either the indicated mileage or when the SRI light remains on when...

Page 1479: ...ed without defacing information and destroying it The following VECI label illustrations are used as examples only If there are any differences be tween these illustrations and the VECI label those shown on vehicle label should be used FEDERAL VEHICLE EMISSION CONTROL INFORMATION LABEL TYPICAL IMPORTANT VEHICLE INFORMATION THIS VEHICLE C O N F O R M S T O U S E P A R E G U L A T I O N S A P P L I ...

Page 1480: ... F U E L INJECTION M I X T U R E H A V E B E E N P R E S E T AT T H E FACTORY ADJUSTMENTS SHOULD NOT BE M A D E DURING ROUTINE SERVICE CAUTION A P P L Y PARKING B R A K E W H E N SERVICING V E H I C L E 5 2 LITRES SPARK PLUGS 0 9 mm GAP RC12YC RENSEIGNEMENTS RELATIFS A U SYSTEME ANTIPOLLUTION L E P R E S E N T V E H I C U L E A E T E FABRIQUE P O U R E T R E VENDU AU CANADA E T I L A E T E CONCU D...

Page 1481: ...label should be used ENGINE VACUUM SCHEMATIC 3 9U5 2L 5 9L LDC ENGINES TO ATMOSPHERE i TRANSDUCER FUEL TANK PRESSURE RELIEF ROLLOVER VALVE W ORIFICE EVAP CANISTER TO CLIMATE CONTROL CRUISE CONTROL 4WD AXLE WHEN EQUIPPED INTAKE MANIFOLD ORIFICE ENGINE VALVE COVER FUEL PRESSURE REGULATOR M P MANIFOLD VACUUM PORTED VACUUM 8 EGR VALVE EVAP PURGE SOLENOID MAP SENSOR CHECK VALVE W ORIFICE CRANKCASE BREA...

Page 1482: ... ENGINE M MANIFOLD VACUUM P PORTED VACUUM EVAP CANISTER ROLLOVER VALVE W ORIFICE CRANKCASE BREATHER DOWNSTREAM AIR t t TO CLIAAATE CONTROL VEHICLE SPEED CONTROL 4X4 AXLE WHEN EQUIPPED TO BRAKE BOOSTER AIR PUMP INTAKE MANIFOLD ORIFICE CHECK VALVE W ORIFICE J9325 34 ...

Page 1483: ...led maintenance free EVAP canister is used on all vehicles The canister is mounted in the en gine compartment on the right side wheel well Fig 1 The EVAP canister is filled with granules of an activated carbon mixture Fuel vapors entering the EVAP canister are absorbed by the charcoal gran ules Fuel tank pressure vents into the EVAP canister Fuel vapors are temporarily held in the canister un til ...

Page 1484: ...g 5 Filtered air is routed into the crankcase through the air filter hose and crankcase breather filter This forces crankcase vapors through the PCV valve It is then drawn into a passage in the intake manifold Here it becomes part of the cali brated air fuel mixture to be consumed in the com bustion chamber The PCV system constantly ventilates the crankcase to help prevent sludge for mation and va...

Page 1485: ... valve cover If the valve is not plugged a hissing noise will be heard as air passes through the valve Also a strong vacuum should be felt at the valve inlet Fig 9 Fig 9 Check Vacuum at PCV Valve Typical 2 Install the PCV valve Remove the crankcase breather filter Hold a piece of stiff paper such as a parts tag loosely over the opening of crankcase breather filter at the cylinder head valve cover ...

Page 1486: ... to dislodge any solid particles Blow out the fitting with shop air If necessary use a smaller drill to avoid remov ing any metal from the fitting CRANKCASE BREATHER FILTER GAS POWERED ENGINES The crankcase breather filter Fig 12 is located on the cylinder head valve cover It must be kept clean and lubricated At the recommended interval remove the filter and wash it thoroughly in kerosene or sim i...

Page 1487: ...ure trans page Heated Inlet Air System 10 Oxygen 02 Sensor 13 ELECTRICAL VACUUM CONNECTION SUPPLY 9125 34 Fig 2 Electric EGR Transducer EET Gas Powered Engines ducer measures the amount of exhaust gas back pressure on the exhaust side of the EGR valve It then varies the strength of the vacuum signal ap plied to the EGR valve The transducer uses this back pressure signal to provide the correct amou...

Page 1488: ... check the system using the DRB II scan tool For use of the DRB II refer to the appropriate Powertrain Diagnostics Pro cedure service manual EGR SYSTEM SERVICE A malfunctioning EGR system can cause engine spark knock sags or hesitation rough idle engine stalling and poor driveability To be sure of proper operation of the EGR system inspect all passages for blockage Check moving parts for binding I...

Page 1489: ...ducer assy If valve is satisfac tory check control system Remove throttle body and inspect port slot type in throttle bore and associated passage in throttle body Use suitable sol vent to remove deposits and check for flow with light air pressure Normal operation should be restored to EGR system Refer to Group 14 General Diagnosis On Board Diagnostics to check solenoid If removal of vacuum hose fr...

Page 1490: ... Air flows from the turbocharger into the inter cooler Fig 5 Air leaves the intercooler passes through the air intake heaters and enters the intake manifold TURBOCHARGER TURBOCHARGER TO INTERCOOLER INTERCOOLER J9114 238 Fig 5 Intercooler Diesel AIR INTAKE HEATER DIESEL ENGINE The air intake heater warms the intake air before it enters the manifold If intake manifold air temper ature is below 16 C ...

Page 1491: ...s Diesel Engine low When the ignition key is turned to the ON po sition the solenoids will make a clicking noise This indicates they are energized Refer to Group 14 Fuel System for air intake heater relay operation WHEEL WELL J9114 67 Fig 7 Air Intake Heater Relays Diesel Engine ...

Page 1492: ...is compressed and ex pelled into the relief valve also refer to Air Injection Pump in this group for additional information Pres sure relief holes in the air relief valve Fig 2 will prevent excess downstream pressure Air is injected at both of the catalytic convertors referred to as downstream All injected air is routed by the air relief valve Figs 1 or 2 Downstream air flow assists the oxidation ...

Page 1493: ...caping through the inlet side of valve it must be replaced Refer to the Component Removal Installation section of this group for check valve replacement procedures AIR PUMP DIAGNOSIS Condition Possible Cause Correction EXCESSIVE BELT NOISE a Loose belt or defective auto belt tensioner a Refer to Group 7 Cooling b Seized pump b Replace pump EXCESSIVE PUMP NOISE CHIRPING a Insufficient break in a Re...

Page 1494: ...tighten to 10 N m 90 in lbs torque In stall housing to engine and tighten wingnut to 1 5 N m 15 in lbs torque AIR FILTER FILTER HOUSING DIESEL ENGINES REMO VAL INSTALLA TION Remove the hose clamp at air filter housing Fig 2 Remove mounting nuts and remove air filter housing from vehicle To replace air filter element only Remove hose clamp and hose at air filter housing inlet tube Remove three wing...

Page 1495: ...PUMP RELIEF VALVE REMOVAL 1 Remove the relief valve hose clamp Fig 4 and remove hose at relief valve 2 Remove relief valve from air pump two bolts Fig 4 Discard old gasket INSTALLATION 1 Clean the gasket mounting area on the pump and valve 2 Install a new gasket Fig 4 relief valve to pump and install relief valve to pump Tighten bolts to 10 N m 95 in lbs torque 3 Install relief valve hose and hose...

Page 1496: ...es at exhaust gas recirculation EGR valve 4 Remove 2 EGR valve mounting bolts Fig 5 and remove EGR valve Discard old gasket 5 Disconnect electrical connector at engine oil pressure sending unit 6 To prevent damage to oil pressure sending unit a special tool such as number C 4597 must be used Fig 6 Remove sending unit from engine 7 Loosen EGR tube mounting nut at intake man ifold Fig 7 Fig 6 Oil Pr...

Page 1497: ...ECTRICAL CONNECTOR TRANSDUCER J9325 15 Fig 8 Electric EGR Transducer EET Typical EVAP CANISTER The EVAP canister is mounted in the engine com partment on the right side wheel well Fig 9 REMOVAL 1 Remove fuel tubes lines at EVAP canister Note location of tubes lines before removal for easier installation 2 Remove mounting bolt at canister mounting strap Fig 9 3 Remove canister and two piece strap f...

Page 1498: ...ith an identical cap to be sure of correct system operation CAUTION Remove the fuel tank filler tube cap to relieve fuel tank pressure The cap must be re moved prior to disconnecting any fuel system com ponent or before draining the fuel tank PLASTIC GASKET RN348 Fig 11 Fuel Tank Filler Tube Cap Typical OXYGEN 02 SENSOR For description operation diagnosis and removal installation procedures of the...

Page 1499: ......

Page 1500: ...SEL ENGINE SERVICE PROCEDURES 9 107 Name Group page 5 9L ENGINE SERVICE PROCEDURES 9 77 ENGINE DIAGNOSIS 9 5 STANDARD SERVICE PROCEDURES 9 1 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 1 EXHAUST SYSTEM DIAGNOSIS 11 3 GENERAL INFORMATION 11 1 SERVICE PROCEDURES DIESEL ENGINES 11 17 SERVICE PROCEDURES GASOLINE ENGINES 11 4 SPECIFICATIONS 11 27 FRAME AND BUMPERS 13 1 ATTACHED COMPONENTS 13 30 B U M P E R S...

Page 1501: ...POWER STEERING PUMP 19 11 POWER STEERING SYSTEM DIAGNOSIS 19 2 RECIRCULATING BALL POWER STEERING GEAR 19 20 STEERING COLUMN 19 35 STEERING LINKAGE 19 17 TORQUE SPECIFICATIONS 19 40 TRANSMISSION AND TRANSFER CASE 21 1 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING 21 85 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION 21 142 AUTOMATIC TRANSMISSION 32RH 36RH 37RH 42RH 46RH 21 73 G360 MANUAL TRANSMISSIO...

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